Raypak | 131 | Operating instructions | Raypak 131 Operating instructions

Version 9D 10/1/07
Raypak Pool & Spa Heaters
Residential & Premium Range
Installation and Operating Instructions - Version 2
Residential Models: P0131, P200, P0280, P0350, P0430
Premium Models: PC0127, PC0167, PC0280, PC0430
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.
Effective 01/12/06
TABLE OF CONTENTS
SAFETY .........................................................................................................................................................3
WATER TREATMENT ...................................................................................................................................3
INSTALLATION INSTRUCTIONS .................................................................................................................4
OPERATING INSTRUCTIONS ......................................................................................................................9
PROGRAMMING OF HEATER CONTROLLER..........................................................................................12
ELECTRICAL CONNECTIONS OF POOL/SPA MOTORISED VALVES ...................................................13
WIRING DIAGRAMS....................................................................................................................................16
PRODUCT SPECIFICATIONS.....................................................................................................................20
POOL HEATER OPERATION FLOW CHART ............................................................................................21
TYPICAL POOL/SPA SYSTEM DIAGRAM.................................................................................................22
WARRANTY (AUSTRALIA ONLY) .............................................................................................................23
SERVICE......................................................................................................................................................24
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.
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 enter water heated by this appliance without testing temperature first. Temperatures above 45oC can
cause severe burns. Prolonged exposure to elevated water temperatures may be hazardous to your health.
DO NOT use this appliance to heat water for drinking.
DO NOT place articles on or against this appliance.
DO NOT store chemicals or flammable materials in the same room as this appliance.
DO NOT spray aerosols near this appliance.
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 whilst cleaning you pool.
WHAT TO DO IF YOU SMELL GAS!
¾ DO NOT try to light this appliance.
¾ DO NOT touch any electrical switch.
¾ 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.
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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 can not 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
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one at floor level. Minimum vent area must be at least 630cm2 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.
The following table details minimum acceptable clearances (mm) for indoor installations on non-combustible
floors only:
Rear Front LH
RH Above
Side Side
Non-Combustible Surfaces
150
750
600
150
1200
Combustible Surfaces
500
750
600
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.
Where standard flueing options can not 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.
AGA Approved Cowl
Dist. above roof as
stated in AS5601
Self supporting flue
Min. Flue
Length 3m
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.
Indoor Hood Conversion
To convert the heater from outdoor configuration to indoor:
1. Remove all screws form the appliance top panel and discard sheet
metal.
Raypak Draft Hood
Heater
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.
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
Dataplate - 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
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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.
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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.
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.
Caution! Ensure that all water valves are correctly positioned to allow flow through the pool heater. If the water
flow valves are not correctly positioned the heater may ignite without flow through the heater. This will damage
the pool heater and/or the system and will void warranty.
Pressure Switch Adjustment
Models: Spartan, 200, 280, 340, 430.
1. Remove the In/Out access cover 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 5, turn the Pressure Switch knurled adjustment wheel located on the
pressure switch, clockwise until the heater ignites, then continue a further ¼ of a turn.
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 and Raypak should be contacted.
9. The pump should be cycled on and off several times to ensure that the adjustment is correct.
Pressure Switch Adjustment
Models: 127, 167.
1. Remove cover 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, using an Allen key, turn the adjustment screw anti-clockwise until the
heater fires and then continue one quarter turn.
8. The pump should be cycled on and off several times to ensure that the adjustment is correct.
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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 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
Spartan
127
167
200
280
350
430
Part No: 96209131
Min. l/s
1.3
1.0
1.0
1.3
1.6
2.3
2.5
8
Max. l/s
6.9
3.7
3.9
6.9
6.9
6.6
6.9
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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.
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. PO – No mains power to the unit
2. o – Insufficient water pressure
3. F1 – Water temperature
exceeds maximum permitted
4. F2 – Main sensor open circuit
5. F3 – Main sensor short circuit
6. F4 – Secondary sensor short circuit
When the mains power supply is interrupted, the unit will revert to a standby mode utilising the back-up battery
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 battery 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.
There is a high limit temperature safety device built into the heat exchanger header. In the event of a system
fault resulting in water temperature exceeding the maximum limit of this device, the controller will display F1.
In the event F1 is displayed, the unit must be allowed to cool and the controller MUST be switched OFF and
then ON again before the unit will resume normal operation. (This is a safety requirement of the Australian
Standard).
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.
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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. 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.
6. 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.
7. 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.
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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.
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.
PUMP CONNECTION TO HEATER
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
Period
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
3 mins
5 mins
3 mins
Continuous
Continuous
Continuous
Continuous
Program
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.
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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.
Timer Period
1
2
3
4
Start Time
6:00am
10:00am
2:00pm
6:30pm
Temp ° C
24
OFF
24
OFF
Mode
Pool
Pool
Pool
Pool
Auxiliary Outputs
All Off
All Off
All Off
All Off
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
Part No: 96209131
If these time periods are set
the operation sequence will be
as follows:
Period1>Period2> Period4
Period 3 will be ignored
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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.
ELECTRICAL CONNECTIONS OF POOL/SPA MOTORISED VALVES
(Models, 200, 280, 350,430 Only)
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.
Part No: 96209131
13
Rev: 9 - 1
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, 340, 430 Only
A 240VAC system pump can be connected to both the heater and the filtration system to enable heater control
or programmed operation via the heater controller or a RAYPAK remote. Electrical connection should be made
as shown.
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 if it is required.
Note: For models, Spartan 131, 127 and 167 (spa heaters) a 240VAC relay can be added to enable operation
of the pump as previously described. This component must be installed and connected by a licensed electrician.
240VAC 50 Hz
Heater Supply
240VAC 50 Hz
Pump Supply
Heater
Filtration
Controller
Pump
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).
Part No: 96209131
14
Rev: 9 - 1
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.
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.
Part No: 96209131
15
Rev: 9 - 1
WIRING DIAGRAMS
240V AC 50 HZ
Filtration Timeclock
POLYMER HEADER
Hi-Limit
Pressure Switch
(Normally Closed)
(Normally Open)
40C Probe
240V AC 50 HZ
Main Heater Supply
Green/Yellow-300
J4
J2
N Filtration
N MAIN HS
J6
J1
A MAIN HS
Black-300
N PUMP
Pump Socket
240V AC 50 HZ
J3
240V AC 50 Hz
Orange - 900
A Filtration
A PUMP
Red-300
J10
J13
J14
Yellow-300
PUMP
J7
Transformer
Orange-250
J12
24VAC
J11
GAS VALVE
J8
POOL/SPA
24VAC
J16
24VAC
GND
Fuse - 3 Amp
Yellow - 900
Purple - 900
850mm
ACTIVE
240VAC
NEUTRAL
Earth (240VAC)
Screwed To Body
96PE5003
Actuator Connection
Terminal Strip
24V AC
(See Below)
Blue-300
White-300
Blue-700
J15
P-SW
J14
O-T
VALVE
J2
RAYPAK
24V AC
J15
40C
Sensor
GND
Remote
E.I.B.
Purple - 500
96PE5001
96PE5002
SOLAR
J5
POOL/SPA
PUMP
J4
Connection Points For
Raypak Accessories
POOL HEATER PCB
ValveBody
Terminal
Green/Yellow-120
CONTROL
Normally Closed
Neutral
Switched Closed
Connects directly
to Pilot using Pilot
lead and plug.
Neutral
Normally Closed
INGNITER
Switched Closed
24V AC
Actuator Connection
Terminal Strip
Violet-80
GAS VALVE
(Honeywell SV9605H)
Pool Heater 2006/07
200 to 430
1
ISSUE
31/10/06
SER
DATE
APPR
Part No: 96209131
DRG No: 159423
RAYPAK AUSTRALIA Pty.Ltd
NEW RELEASE
E.O.
DESCRIPTION
16
Rev: 9 - 1
Fuse - 3 Amp
IN/OUT HEADER
RETURN HEADER
40C Probe
Hi-Limit
Pressure Switch
(Normally Closed)
(Normally Open)
Transformer
240V AC - 24V AC
2A (50VA)
240VAC
Terminal Block
240V AC 50 Hz
N
Earth Dish (24VAC)
Orange -1200
850mm
Purple - 1200
Yellow - 1200
A
Blue - 500
24V AC
GND
SOLAR
Purple 700
VALVE
E.I.B.
RAYPAK
40C
Sensor
96PE5001
96PE5002
Remote
P-SW
CONTROL
Ignitor wires directly
to Pilot using Pilot
lead and plug.
INGNITER
O-T
POOL/SPA
PUMP
Connection Points For
Raypak Accessories
POOL HEATER PCB
Valve
Body
Terminal
Gn/Yw - 120
GAS VALVE
(Honeywell SV9605H)
3
9/11/06
S.R.
Introduction of new PCB
2
10/10/05
A.R.
Amended Hi-Limit Position to after PCB
1
20/06/05
A.R.
ISSUE
DATE
Part No: 96209131
APPR
POOL HEATER PCB WIRING DIAGRAM
MODEL: 167
New Release
E.O.
DRG No: 159299
DESCRIPTION
17
Rev: 9 - 1
Fuse - 3 Amp
POLYMER HEADER
Hi-Limits
Pressure Switch
(Normally Closed)
(Normally Open)
40C Probe
Blue - 900
240VAC
Terminal Block
A
N
240V AC 50 Hz
Yellow - 1200
Purple - 1200
850mm
Orange -900
Transformer
240V AC - 24V AC
2A (50VA)
Earth (240VAC)
Screwed To Body
Blue - 600
24V AC
GND
SOLAR
VALVE
E.I.B.
RAYPAK
40C
Sensor
96PE5001
96PE5002
Remote
P-SW
O-T
Yellow-1200
POOL/SPA
PUMP
Blue - 750
Connection Points For
Raypak Accessories
Blue - 200
Blue - 750
POOL HEATER PCB
Earth Dish (24VAC)
NC
NC
Ignitor
Flame Sense
Valve
Ground
Thermostat
GAS VALVE
WHITE ROGERS
P
Orange - 150
C
M
Pressure Switch
Orange - 750
IGNITION CONTROL
RAM-H4M7-01
Blue - 300
Brown - 150
Grey - 350
4
9/11/06
S.R.
3
10/10/05
A.R.
Amendment of Hi-Limit to after PCB
2
08/08/05
A.R.
Title Change. Addition of extra High Limit
1
20/06/05
A.R.
DATE
APPR
ISSUE
Part No: 96209131
Ignitor
Flame Sense
Introduction of new PCB
POOL HEATER PCB WIRING DIAGRAM
MODELS: Spartan 131
NEW RELEASE
E.O.
DRG No: 159426
DESCRIPTION
18
Rev: 9 - 1
Fuse - 3 Amp
POLYMER HEADER
Hi-Limit
Pressure Switch
(Normally Closed)
(Normally Open)
40C Probe
Blue - 900
240VAC
Terminal Block
A
N
240V AC 50 Hz
Yellow - 1200
Purple - 1200
850mm
Orange -900
Transformer
240V AC - 24V AC
2A (50VA)
Earth (240VAC)
Screwed To Body
Blue - 500
24V AC
GND
SOLAR
VALVE
E.I.B.
P-SW
RAYPAK
40C
Sensor
96PE5001
96PE5002
Remote
O-T
POOL/SPA
Connection Points For
Raypak Accessories
PUMP
Blue - 500
Blue - 500
Blue - 500
POOL HEATER PCB
Earth Dish (24VAC)
NC
NC
Ignitor
Flame Sense
Valve
Ground
P
Thermostat
GAS VALVE
WHITE ROGERS
C
M
Pressure Switch
Orange - 500
IGNITION CONTROL
RAM-H4M7-01
Blue - 500
Ignitor
Brown - 500
Flame Sense
Grey - 500
4
9/11/06
S.R.
3
10/10/05
A.R.
Amendment of Hi-Limit to after PCB
2
8/8/05
A.R.
Modification to Title
1
20/06/05
A.R.
DATE
APPR
ISSUE
Part No: 96209131
Introduction of New PCB
POOL HEATER PCB WIRING DIAGRAM
MODELS: 127
NEW RELEASE
E.O.
DRG No: 159348
DESCRIPTION
19
Rev: 9 - 1
PRODUCT SPECIFICATIONS
BURNER
INJECTOR HEIGHT
PRESSSURE
DIA.
OUTDOOR
WIDTH
DEPTH
WEIGHT
860 mm
440 mm
650 mm
35 kg
1.90 mm
1.10 mm
895 mm
505 mm
280 mm
42 kg
0.77 kPa
2.75 kPa
1.95 mm
1.10 mm
905 mm
365 mm
610 mm
67 kg
44 kW
41 kW
0.77 kPa
2.75 kPa
1.90 mm
1.10 mm
1,085 mm
460 mm
650 mm
70 kg
278 MJ/hr
261 MJ/hr
62 kW
58 kW
0.77 kPa
2.75 kPa
1.90 mm
1.10 mm
1,085 mm
565 mm
650 mm
75 kg
Natural
Propane
343 MJ/hr
323 MJ/hr
76 kW
72 kW
0.77 kPa
2.75 kPa
1.90 mm
1.10 mm
1,085 mm
655 mm
650 mm
85 kg
Natural
Propane
420 MJ/hr
396 MJ/hr
94 kW
88 kW
0.77 kPa
2.75 kPa
1.90 mm
1.10 mm
1,085 mm
740 mm
650 mm
90 kg
MODEL
GAS
INPUT
OUTPUT
Spartan
131
Natural
120 MJ/hr
24 kW
0.85 kPa
1.36 mm
Propane
120 MJ/hr
24 kW
2.64 kPa
0.77 mm
127
Natural
Propane
110 MJ/hr
103 MJ/hr
24 kW
23 kW
0.77 kPa
2.75 kPa
167
Natural
Propane
164 MJ/hr
154 MJ/hr
36 kW
34 kW
200
Natural
Propane
196 MJ/hr
185 MJ/hr
280
Natural
Propane
350
430
Part No: 96209131
20
Rev: 9 - 1
POOL HEATER OPERATION FLOW CHART
NO
Is there any
display on the
LCD?
YES
Check power
point and/or
power supply
YES
Press ON
button
YES
Press the
PROG button
to access
manual mode.
NO
Is controller in
manual mode?
Set
temperature
must be above
pool temp.
NO
Is set
temperature
set above the
pool
?
NO
NO
Is the flame
symbol
displayed?
Is system
pump running?
NO
Is system
pump running?
YES
Switch system
pump on
YES
The pool
heater will light
NO
Part No: 96209131
Press UP button
take set temp
above the pool
temperature.
YES
YES
Switch system
pump on
Press PROG
button to
access manual
mode.
YES
Is the flame
symbol
displayed?
The pool
heater will light
Turn power
point on
YES
Is OFF
displayed on
the LCD?
Is AUTO on
the LCD
display?
NO
Is the power
point switched
on?
NO
YES
Book service
call
21
Rev: 9 - 1
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: 96209131
22
Rev: 9 - 1
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.
Rheem Australia is responsible for all service activities relating to Raypak Australia product.
2.
Rheem Australia reserves the right to transfer fully functional components from a defective heater to a replacement heater if required.
3.
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.
6.
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.
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.
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;
2.
3.
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.
4.
5.
Where there is no flow of water due to faulty plumbing;
Where water leaks are related to plumbing including connections to the heater.
6.
7.
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;
8.
c. Corrosive atmosphere;
d. Incorrect flow rate through the heat exchanger.
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: 96209131
23
Rev: 9 - 1
SERVICE
SERVICE ASSISTANCE
Service must only be undertaken by properly authorised personnel
It is a requirement of all 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.
Australia
Rheem service
13 10 31
www.rheem.com.au
NEW ZEALAND
0800 657 335
NATIONAL
Service:
Spares:
QLD
SYD/CANB
NEWCASTLE
VIC
SA
WA
Phone:
07 3213 0100
029684 9280
02 4961 3515
03 9212 8900
08 8343 0000
08 9351 4238
Fax:
07 3213 0154
02 9684 9188
02 4961 3117
03 9212 8955
08 8359 6002
08 9353 4101
Phone:
07 3213 0102
02 9684 9282
02 4961 3515
03 9212 8911
08 8359 0044
08 9351 4290
Fax:
07 3213 0154
02 9684 9188
02 4961 3117
03 9212 8984
08 8359 6003
08 9356 9914
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: 96209131
24
Rev: 9 - 1
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