Raypak 106 Installation & Operating Instructions Manual Download Page 3

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WARNINGS

Pay Attention to These Terms

WATER CHEMISTRY

Automatic Chlorinators &

Chemical Feeders

SAFETY

Water Temperature Safety

INTRODUCTION

Ratings & Certifications

Clearances

Base Installation

Outdoor Installation

Indoor Installation

Combustion & Ventilation Air

Gas Connections

Water Connections

Electrical Connections

OWNER’S OPERATING

INSTRUCTIONS

Control Adjustments—Analog

Control Adjustments—Digital

Thermostat Operation—Advanced Flame

Technology (AFT) Board

Status and Diagnostics

Remote Control Installation

Wiring Diagrams

Post Start-Up Inspection

Cold Weather Operation

MAINTENANCE

SERVICE

Water Pressure Switch

Flame Roll-Out Safety Switch

High Limits

Burner Tray Removal

Gas Valve Removal

Pilot Removal & Cleaning

Heat Exchanger Removal

Tube Cleaning Procedure

De-sooting Procedure

Replacement Parts

TROUBLESHOOTING

Mechanical

Electronic Control Logic Flowchart

Analog Control Logic Flowchart

ILLUSTRATED PARTS LIST

CONTENTS

Summary of Contents for 106

Page 1: ...y or the gas supplier This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference Models 106 156 Atmospheric Above Ground Pool Spa Heater Chauffe Piscine English French AVERTISSEMENT Assurez vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d incendie ou d explosion ou pour éviter...

Page 2: ...2 Rev 2 reflects the following Changes to Fig 3 on page 10 Table F on page 13 Fig 28 on page 29 Additions None Deletions None ...

Page 3: ...TIONS 17 Control Adjustments Analog 17 Control Adjustments Digital 17 Thermostat Operation Advanced Flame Technology AFT Board 19 Status and Diagnostics 21 Remote Control Installation 22 Wiring Diagrams 24 Post Start Up Inspection 25 Cold Weather Operation 25 MAINTENANCE 26 SERVICE 26 Water Pressure Switch 26 Flame Roll Out Safety Switch 27 High Limits 27 Burner Tray Removal 28 Gas Valve Removal 2...

Page 4: ...d service must be performed by a qualified installer service agency or the gas supplier WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the heater free of combustible materials gasoline and other flammable liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the ...

Page 5: ...water Automatic Chlorinators Chemical Feeders All chemicals must be introduced and completely dilut ed into the pool or spa water before being circulated through the heater Do not place sanitizing chemi cals in the skimmer High chemical concentrations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent ...

Page 6: ...l damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 F 2 2 C 5 Persons with a medical histo...

Page 7: ...icated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by consignee Authorization to return goods must be received from the factory prior to shipping Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts specify the model and serial number...

Page 8: ...ARNING This unit contains refractory ceramic fiber RCF insulation in the combustion chamber RCF as manufactured does not contain respirable crystalline silica However following sustained exposure to very high temperatures 2192F the RCF can transform into crystalline silica cristabolite The International Agency for Research on Cancer IARC has classified the inhalation of crystalline silica cristabo...

Page 9: ...s than recommended may require removal of the heater to service either the heat exchanger or the burner tray In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater Base Installation Heater must be mounted on a level base such as cementable slab or cement blocks Heaters may not be installed on carpeting Thi...

Page 10: ...l not be installed with the top of the vent assembly within 10 ft 3m below or to either side of any opening into the building Refer to the latest revisions of CAN CSA B149 The heater must be raised 7 in 0 2m above the surface which could support snow ice or debris Refer to the latest revisions of CAN1 2 21 M85 Outdoor Stack High Wind Conditions Outdoor Units Only In areas where high winds are freq...

Page 11: ...each opening shall have a minimum net free area as noted in Table D Vent Piping Vent piping the same size as the drafthood outlet is recommended however when the total vent height is at least 10 ft 3m drafthood relief opening to vent ter minal the vent pipe size may be reduced as specified in the National Fuel Gas Code ANSI Z223 1 Canada CAN CSA B149 As much as possible avoid long horizontal runs ...

Page 12: ...he heater jacket All gas piping should be tested after installation in accordance with local codes CAUTION Do not use 5 10 or 20 gallon 19 38 or 76 Liter propane tanks like those used with con sumer barbecues to supply gas to this heater CAUTION The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess o...

Page 13: ...nd turn adjust ment screw clockwise to increase pressure or counter clockwise to decrease pressure Gas Pressure Natural Gas Propane Gas Max Inlet static 10 5 in WC 2 6 kPa 13 in WC 3 2 kPa Min Inlet dynamic 5 in WC 1 2 kPa 11 in WC 2 7 kPa Manifold Gas dynamic 4 in WC 1 0 kPa 10 in WC 2 5 kPa Static means without heater operating dynamic refers to heater operating Table F Gas Pressure Gas Pressure...

Page 14: ...Out header make sure the O rings are properly seated in the grooves Use AquaLube or equivalent non petroleum based lubricant on the O ring Hand tighten the unions Glue PVC or CPVC piping directly to the unions Model No Minimum Maximum 106 156 20 GPM 75 L 70 GPM 265 L When flow rates exceed maximum 70 GPM an external auxiliary bypass valve is required See External Auxiliary Bypass Valve sec tion fo...

Page 15: ...tment To set bypass With clean filter adjustment is made by feeling the inlet and outlet pipes at the heater Outlet pipes should be slightly warmer than inlet and comfort able to the touch If pipe is hot close bypass if cold open bypass Pressure Relief Valve Installation To conform to local building codes it may be neces sary to install a pressure relief valve A 3 4 1 9 cm pressure relief valve ha...

Page 16: ...valent The heater comes standard with a 120 VAC 3 prong power cord For 240 VAC applications see figure 18 Power source must be a wired ground with ground fault circuit interruption circuitry Flow GPM Pressure Drop ft of Head 20 7 6 30 8 2 40 8 7 50 9 3 60 9 8 70 10 4 Table I Pressure Drop The heater must be electrically grounded and bonded in accordance with local codes or in the absence of local ...

Page 17: ...esired location and retightening the set screw 17 HOT COOL Knobstop Ring Knobstop Set Screw Fig 17 Water Temperature Thermostat NOTE Maximum temperature is 104 F 40 C Fig 18 Digital Control Adjustment MENU SET Button The MENU SET button is used to select either POOL or SPA operation It also allows the user to turn the heater off electronically The LCD remains energized and displays OFF while also ...

Page 18: ...18 ...

Page 19: ...en indicates the voltage supplied to the control board Normal readings range from 24 to 29 volts Press the DOWN button The Run Time indicates the total hours of operation for the pool heater as meas ured by the amount of time that the main gas valve has been powered The Cycle count indicates the number of on off cycles of the heater as measured by the number of times the pilot valve has been power...

Page 20: ...ying Celsius as well as Fahrenheit temperatures The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display Choose the desired temperature scale Spa Max Temp Spa Set Point Maximum Adjustment Refer to step one above to access the program screen Press the MENU SET button until Spa Max Temp appears on the digital display Using the UP and DOWN buttons will change the Maximum Te...

Page 21: ...t in com manded state Internal Fault Board fault replace board EEPROM Fault Memory fault reset set points replace board if fault does not clear Clock Fireman Sw Time clock fireman switch circuit is open Low Temp Lockout Water temperature below 36 F 2 C The following heat status messages are displayed in Pool Spa and Remote modes when there are no active fault conditions The following conditions ar...

Page 22: ...he circuit created by the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is supplying its own voltage to the heater it will not work with this heater and may damage the digital circuit board For operation of the heater using the onboard thermo static controls with a time clock see the Time Clock...

Page 23: ... on the control The actual setpoint will be controlled by the remote control 4 Turn the MENU SET button to OFF and remove power from the heater 5 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and con nect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wire to the Remot...

Page 24: ...24 Wiring Diagrams Fig 19 Wiring Diagram Analog Models Fig 20 Wiring Diagram Digital Models ...

Page 25: ...outdoors in freezing climate areas may be shut down for the winter Observe the follow ing procedure for winterizing the heater CAUTION Do not use the heater to maintain water temperatures just above freezing or for freeze protection When heater is used during freezing weather care must be taken to avoid freeze ups Continuous pump operation is a must Additional protection may be required The heater...

Page 26: ... pressure Should these occur shut the heater off and contact your gas supplier or qualified service agency In Out Header Drain Plug Fig 22 In Out Header Drain Plug Location 5 On indoor heaters clean room intake openings to ensure adequate flow of combustion and ventila tion air 6 Keep area around heater clear and free from com bustible materials gasoline and other flammable and corrosive vapors an...

Page 27: ...may be used in place of the factory mounted pressure switch See Illustrated Parts List for 11 psi 76 kPa water pressure switch CAUTION Do not operate the heater without the function of a properly adjusted water pressure switch or flow switch Fig 24 Flame Roll Out Safety Switch High Limits The heater is equipped with two automatic high limits Both are located in the In Out header Both are set to op...

Page 28: ...et aside 6 Remove 4 screws as shown in the image 7 Disconnect wiring from gas valve 8 Remove 2 screws holding the control panel up 9 Flipthe control panel forward 10 Disconnect ignition wire and remove with burner 11 tray Reverse above procedure to reinstall 12 Gas Valve Removal Remove burner tray 1 Disconnect pilot tubing from gas valve 2 Rotate the gas valve counter clockwise to 3 remove valve f...

Page 29: ...alve 2 Remove 2 screws holding pilot bracket in place 3 see image Remove the pilot assembly by pushing the pilot 4 Remove the locating pilot screw from the bracket 5 to release the pilot assembly Reverse above procedure to reinstall 6 Fig 28 Spark to Hood Pilot Fig 29 Pilot Bracket Screws ...

Page 30: ...he tubes as necessary After reaming mount the wire brush in place of the auger and clean out debris remaining in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhib ited de scale solvent for severe scale build up De sooting Procedure Soot will clog areas between fins and cause eventual tube failure Any sign of soot at the base of the burn ers...

Page 31: ... number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty a like part or equal substitution will be returned freight collect Credit will not be issued MANUFACTURER 2151 EASTMAN AVENUE OXNARD CA 93030 NOTE When ordering parts it is important that the heater model number serial number and type of gas are specified ...

Page 32: ...ted dirty pilot Clean pilot and or electrode Weak pilot generator Replace pilot Yellow lazy flame Low gas pressure Adjust gas pressure Insects or debris clogging burner intake ports Clean burners Outer jacket very hot Broken refractory caused by paint blistered shipping damage or improper combustion Replace refractory panels Excessive sooting of heat exchanger Determine cause of sooting correct Ta...

Page 33: ...istance k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor Failure Inspect thermister wires and connector at Terminal P1 Check resistance value of the thermister Reference to chart below Replace thermister if not within 10 of values shown below If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Pressure switch Verify water flow and...

Page 34: ...gh moving water in the system or the gauge is broken Attempt to make the pump run at its normal flow rate Does the pilot spark after performing the above steps 1 The setpoint may be lower than the actual temperature Turn the knob counterclockwise to raise it 2 Check the high limits Both are normally closed 3 Check the rollout switch It must be normally closed 4 Check the wiring in the control box ...

Page 35: ... 2 S 3 S 2 M 3 M 4 M 1 J 2 J 2 J 3 J 4 J 4 J 1 V 2 V 3 V 4 V 11 M 12 M 1 B 10 S 5 S 6 S 7 S 8 S 9 S 9 S 3 B 6 C 8 C 9 C 2 H 3 H 4 H 5 H 6 H 6 H 7 H 7 H 2 C 3 C 10 M 9 M 8 M 5 V 5 C 4 S 7 C 4 C 10 C ILLUSTRATED PARTS LIST ...

Page 36: ...36 1 M 1 C 5 M OPTIONAL 9 C 8 H 10 H 11 H 12 H 13 H 14 H OPTIONAL 15 H 16 H 17 H 9 H 1 P 2 P 3 P 4 P 5 P 1 H ...

Page 37: ...eturn Header Includes 6 H 011596F 011596F 4 H Tube Bundle Copper 014874F 014875F 5 H Baffle Cupro Nickel N A N A 6 H Flange Nut Kit 008259F 008259F 7 H O Ring Gasket 2 011600F 011600F 8 H Sensor Adapter 006714F 006714F 9 H Bypass Kit 014880F 014880F 10 H Bypass Valve 006716F 006716F 11 H Bypass Dam Shaft 006717F 006717F 12 H Bypass Spring 014881F 014881F 13 H Drain Plug 006721F 006721F 14 H Inlet ...

Page 38: ...be 004078F 004078F 5 P Hi Tension Wire w Pilot Electrode 007864F 007864F R REFRACTORY 1 R Refractory Kit 014890F 014891F S SHEETMETAL 1 S Jacket Top 014892F 014893F 2 S Jacket Left 014894F 014895F 3 S Jacket Right 014896F 014897F 4 S Jacket Upper Front 014898F 014898F 5 S Jacket Lower Rear 014899F 014899F 6 S Flue Collector 014900F 014901F 7 S Door Panel Raypak 014902F 014902F Rheem 014903F 014903...

Page 39: ...39 ...

Page 40: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 40 ...

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Raypak 106, Installation & Operating Instructions Manual

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