Raypak 185A Guide

Page 1
RAYPAK REPLACEMENT INSTRUCTIONS
PC BOARD, TEMPERATURE CONTROL & SENSOR
(KIT #010253F) MODELS 185A, 265A, 335A & 405A
IMPORTA T OTICE
These instructions are intended for use by qualified personnel specifically trained and experienced in the installation of this
type of heating equipment and related system components. Installation and service personnel may be required to be li-
censed in some states. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to
these instructions.
DA GER - SHOCK HAZARD
Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components.
DA GER - PROPA E HAZARD
Make sure to determine if unit is propane and see special instructions on page 5.
SCOPE:
This version of the temperature control board has the capability of an integrated ignition module plus 3-wire temperature sen-
sor. The kit includes a gasket and a plastic shield that is mounted to the back side of the control panel to eliminate moisture
accumulation on the CD display. It is a direct replacement for the following models: 185A, 265A, 335A, and 405A.
P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
This kit includes:
(1) PC control board (1) PC board plastic shield (2) Brackets
(1) Temperature sensor (6) Plastic #8 washers (1) CD gasket
(1) Remote wire harness (1) Hi tension wire extension (4) Screws #6 x 3/8
(6) Screws #8 x 1/2” (2) Screws #10 x 1/2” (1) Instructions
The new
style board
is larger
thanthe old
style board
MODELS
185A, 265A, 335A, 405A
PRODUCED NOV. 1998
THROUGH OCT. 2003
SERIA # 9811 TO # 0310

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Replaces: 09-05-08
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ACCESSI G THE BOARD
1. Turn off the power to the heater.
2. Turn off the gas to the heater.
3. Remove front door.
4. Remove the four screws on the side of the heater
holding the control panel. See Fig. 1 and Fig. 2.
5. ay control panel forward toward you to acces the
back of the control board.
Fig. 1
REMOVE THESE SCREWS
Fig. 2

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REMOVI G THE CIRCUIT BOARD
Make sure the power and gas are off.
1. Unplug all connectors from old circuit board. See
Fig. 3.
2. Unplug keypad ribbon from old circuit board.
3. Remove four screws as shown in Fig. 4.
4. Remove old circuit board.
Fig. 3
2.2
UNPLUG ALL CONNECTORS
REMOVE KEYBOARD
RIBBON
Fig. 4
REMOVE MOUNTING SCREWS

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Replaces: 09-05-08
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DISCO ECTI G IG ITIO CO TROL
Make sure the power and gas are off.
1. Unplug all wires and connectors from ignition module.
(See Fig. 5)
ote: The replacement board has an integrated ignition
module. The old ignition module can be left installed,
but will not be used.
Fig. 5
UNPLUG ALL WIRES

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Effective: 10-01-10
Replaces: 09-05-08
Page 5
PROPA E HEATERS O LY:
PREPARE EW REPLACEME T CO TROL PCB FOR I STALLATIO
1. ocate the proper propane tab on the board as shown in Fig. 6.
2. Break off tab with pliers as shown in Fig. 7 &Fig. 8.
ote:
Requirements for Propane safety time vary by
area. Check your local and state code regula-
tions to determine whether your required
Propane safety time is 15 seconds or 90 sec-
onds.
Fig. 6
PROPANE
TABS
15-Second
Safety Time
90-Second
Safety Time
Fig. 7
(90-Second
Safety Time Shown)
Fig. 8
(90-Second Safety Time Shown)
BROKEN TAB

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Replaces: 09-05-08
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Low Ox O LY:
PREPARE EW REPLACEME T CO TROL PCB FOR I STALLATIO
1. DO NOT break tab See Fig. 9 and Fig. 10.
2. No additional wiring or connections are necessary for ow NOx oper-
ation.
Fig. 9
DO NOT
break
tab.
Fig. 10
DO NOT
break
tab.

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Effective: 10-01-10
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EW CIRCUIT BOARD & GASKET I STALLATIO USI G OLD BEZEL
ote: Disregard window gasket installation if already present.
1. Remove backing on gasket and install adhesive side on the control
panel bezel as shown in Fig. 11.
2. Re-assemble with new board to plastic bezel using the included three
mounting screws (#6 X 3/8”) as shown in Fig. 12 &Fig. 13.
REMOVE BACKING
Fig. 11
LAY BOARD
DOWN
Fig. 12
CLEAR
WINDOW
GASKET
STICKY SIDE TO
PLASTIC BEZEL
RE-ASSEMBLE WITH NEW BOARD
MOUNTING SCREWS
Fig. 13

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
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REMOVI G & REPLACI G SE SOR
Make sure the power and gas are off.
1. oosen drain plug to relieve pressure in heat
exchanger. See Fig. 14.
2. Remove five screws and access panel as
shown in Fig. 15.
3. Route the new 3-wire sensor connector to
the board following the existing red sensor
wires.
4. Unscrew compression nut and loosen com-
pression fitting of the old sensor. Remove
the old sensor. See Fig. 16.
5. Install new sensor into the header and
tighten the compression fitting and com-
pression nut.
6. Plug the 3-wire sensor connector into P1, as
shown in Fig. 17 and Fig. 18.
Fig. 14
LOOSEN DRAIN
PLUG TO
RELIEVE
PRESSURE
REMOVE THESE 5
MOUNTING SCREWS
Fig. 15
Fig. 16
UNSCREW
COMPRESSION
NUT
LOOSEN
COMPRESSION
FITTING
Fig. 17
NEW 3-WIRE
SENSOR
LOCATION P1
Fig. 18
P1

Fig. 20
Fig. 21 SIDE VIEW
BRACKETS
2PLACES
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Effective: 10-01-10
Replaces: 09-05-08
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PLASTIC SHIELD &
BRACKET I STALLATIO
Make sure the power and gas are off.
1. Note that the plastic shield is installed under
the front bracket as pictured. Install the
shield brackets and plastic shield using the
existing screws (#8 x ½”) and included
washers on the control panel bracket as
shown in Fig. 19.
2. Connect the wire harnesses to the board.
(Note the location of the clear plastic strip
with the thin connector. This is sometimes
disconnected when there is a remote con-
trol in the system. Refer to the remote wiring
instructions for further details.) Make sure
3-wire sensor P1 is connected.
3. Install the plastic shield over the board and
attach to the brackets using the two black
#10 X ½” screws and washers provided in
the kit. See Fig. 20 and Fig. 21.
4. Go to remote operation instructions.
OR
Return the control panel bracket to the up-
right position and re-attach using the screws
previously removed.
Fig. 19
CLEAR PLASTIC STRIP
WITH THIN CONNECTOR
SHIELD
BRACKETS

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Effective: 10-01-10
Replaces: 09-05-08
Page 10
I STALLI G PILOT HI TE SIO WIRE
EXTE SIO TO 335A:
Make sure the power and gas are off.
1. Connect pilot wire (Side B) to new board
with new extension See Fig. 22 & Fig. 23.
2. Connect Side A to existing pilot wire and
center protective sleeve over connection.
Side
‘A’
Side
‘B’
Fig. 22
CONNECT THIS END
TO NEW PC BOARD
SPARK LUG
CONNECT THIS END
TO EXISTING PILOT
WIRE
Fig. 23
EXISTING PILOT
WIRE

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Effective: 10-01-10
Replaces: 09-05-08
Page 11
DIGITAL THERMOSTAT CO TROLS
Thermostat operation
Your heater is equipped with a microprocessor-controlled thermostat that controls the pool or spa temperature by meas-
uring the temperature of the water entering the heater. It monitors the water temperature and turns the heater on when it
senses that the water temperature is below the set point. It is normal to experience small fluctuations in the return water
temperature during the operation of the heater. The thermostat is calibrated with a very narrow tolerance to ensure accu-
racy of the set temperature. Thus, slight fluctuations in water temperature may cause your heater to cycle on and
off frequently. This is not a problem. It will not harm the heater nor interfere with the thermostatʼs ability to precisely con-
trol the temperature of the pool or spa.
THERMOSTAT CO TROL OPERATIO
The pool heater thermostat, located on the upper front panel
of the heater, controls the pool/spa water temperature. This
control center contains a mode button, up and down tem-
perature adjustment buttons, and an CD display.
Mode Button
The MODE button functions as a means to turn the heater off
or on in either the POO or SPA setting. The CD display in-
dicates the mode the heater is in and the actual water tem-
perature.
Temp Buttons
If the heater is in POO or SPA mode, the desired water tem-
perature (SETPOINT) will also be displayed and may be
changed using the UP or DOWN buttons. A manual toggle
switch is also provided right below the MODE button to allow
the heater to be turned off.
Operation
In the POO or SPA modes, the actual water temperature is
displayed along with the desired water temperature (SET-
POINT). If the heater is firing, a flame icon will be visible.
To adjust the setpoint temperature, make sure the control is
in the appropriate mode (POO or SPA) and push the UP or
DOWN buttons.
Fault History File
To access the Fault History File, press the Mode button until
the display reads OFF. Press both the “UP” and “DOWN”
buttons at the same time (5-7 seconds) until the display
changes and shows a fault code. The latest fault code will
be displayed first. By pressing the “UP” or “DOWN” buttons,
a series of faults will be displayed from the last (highest num-
ber) to the first (lowest number). If the buttons are not
touched after 5-7 seconds, the display will return to its nor-
mal operation.
Actual Water
Temperature
Setpoint Temperature
Flame Icon
Mode
Pool or Spa
Program button
DISP AY CA FOR HEAT
WATER
TEMP SET POINT
MODE
TEMP
LCD Display Temp Buttons Mode Button

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 12
Resets board to factory default settings.
Resets faults in the History File.
Change from Fahrenheit to Celsius.
SPA setpoint maximum adjustment.
POO setpoint maximum adjustment.
SETdef – Default Settings
Refer to step one above to access the program screen.
SETdef should appear on the screen. If not, press the Mode
button until SETdef appears on the digital display. Press
and hold both “UP” and “DOWN” buttons for 5-7 seconds
until 3 dashes (---) appear. This operation resets the operat-
ing program to its factory default values. Both the POO and
SPA setpoints will revert to 65°F (18.5°C) and both POO
and SPA maximum temperature settings will be 104°F
(40.0°C). Once this is done, reassemble the control panel.
Program Button
1) To access the program screen, press the Mode button
until the display reads OFF. Remove the four screws
holding the control cover on. Swing control panel down
so the back side of the board is visible (see page 30).
ocate the Program Mode button as shown in the figure
on pg. 32. Press the program button (5-7 seconds) until
SETdef appears on the digital display. Release the pro-
gram button.
2) Press the Mode button sequentially until the desired pro-
gram event is reached. There are 5 different events that
can be programmed. They appear in the sequence listed
below:
RESfl – Reset Fault History
Refer to step one above to access the program screen.
Press the Mode button until RESfl appears on the digital dis-
play. Press and hold both “UP” and “DOWN” buttons for 5-7
seconds until 2 dashes (--) appear. This operation resets the
Fault History file to “0” and clears all the stored faults. Once
this is done, reassemble the control panel.
F/Cfff – Fahrenheit to Celsius
Refer to step one above to access the program screen.
Press the Mode button until F/Cfff appears on the digital dis-
play. The digital display is capable of displaying Celsius as
well as Fahrenheit temperatures. The “UP” or “DOWN” but-
tons will select “F” or “C” on the temperature display. Choose
the desired temperature scale. Once this is done, reassem-
ble the control panel.
SETspa 104 – SPA Set Point Maximum Adjustment
Refer to step one above to access the program screen.
Press the Mode button until SETspa 104 appears on the dig-
ital display. Using the “UP” and “DOWN” buttons will change
the Maximum Temperature Setting to your desired value.
The control can be set for a maximum of 107°F. Once this
is done, reassemble the control panel.
SETpool 104 – POOL Set Point Maximum Adjustment
Refer to step one above access into the program screen.
Press the Mode button until SETpool 104 appears on the
digital display. Using the “UP” and “DOWN” buttons will
change the Maximum Temperature Setting to your desired
value. The control can be set for a maximum of 107°F. Once
this is done, reassemble the control panel.

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Effective: 10-01-10
Replaces: 09-05-08
Page 13
If the PRS fault code is displayed, it indicates that there is
insufficient water flow through the heater. Make sure the
pool filter and pump strainer are clean before calling a serv-
ice representative.
DIAG OSTICS
The digital thermostat models are equipped with on-board
diagnostic controls. If there is a safety fault, a fault code will
be displayed along with a service indication.
READI G A FAULT
The word “SERVICE” will flash on and off if the PC board de-
tects a known fault. The fault will be displayed in three big
letters on the lower left of the display.
Service Will
Flash
3 etter
Fault Code
See table
for fault def-
inition
STATUS CODES
Display Definition
CFH Call for heat
C K Time clock
EO End of line test (Factory Use Only)
ON ow NOx Unit
OFF Off mode
PRO Propane gas configured
REM Remote control activated
SPK Spark
SPR Spare fault code indicator
FAULT CODES
Display Definition
BD1 Board failure
EEP Microprocessor error
FAN Blower pressure failure
FF Flame sensing when pilot and gas valves are
closed
GVC Gas valve closed
GVO Gas valve open
H 1 High limit switch #1 open
H 2 High limit switch #2 open
IGN Ignition failure
I O Ignition lockout - Propane units only
PRS Water pressure switch open
RO Heat roll-out safety switch open
SNS Sensor failure, Water temp. below 36°F or
above 110°F
VNT Vent switch open - This is jumped from the fac-
tory.
PROGRAM MODES
Display Definition
CCC Celsius setting
F/C Change from Fahrenheit to Celsius
FFF Fahrenheit setting
RES Reset defaults
SET Set point max adjustment
OTE: The CD temperature display may not agree with the temperature reading of your pool or spa thermometer. The
heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water tem-
perature at the inlet to the heater may differ from that observed at a given location in the pool or spa.

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 14
REMOTE CO TROL I STALLATIO A D OPERATIO
CAUTIO : Before installing remote controls to the digital thermostat model heaters read the following:
The digital thermostat model is remote-ready in most cases. The digital liquid crystal display ( CD) shows the actual pool
temperature, operating status, and service codes (See examples below). The touch pad on the control panel allows you
to select the desired pool or spa temperature. It also indicates when a remote system is controlling the heater by display-
ing REM in the display. When connecting the heater to a remote system, identify whether it is a two- or three-wire remote
system. Select the appropriate instruction listed below to properly install the remote to the heater.
REM
OFF Mode Heating in the POO Mode Heating in the SPA Mode Remote Mode
REMOTE OPERATIO
The digital model heaters are equipped with the ability to
work with external remote controls. The supplied 7-pin re-
mote wiring connector supplies power out to either a toggle
switch or the switch contacts of a third party remote. The re-
mote works by either making or breaking the 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 suppling 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 thermostatic
controls with a time clock, see the “Time Clock / Firemanʼs
Switch” section.
ACTIVATING THE REMOTE
The digital thermostat heaters have the ability to discon-
nect from the remote it is wired to. To activate or deactivate
the remote follow these steps:
Note: Electrostatic Discharge (ESD) damage can be caused by direct or
indirect contact with the wiring or circuit board. When one walks to the
heater area, an electrostatic charge accumulates on the body. Contact of
a finger allows the body to discharge, possibly causing device damage.
This damage can be limited if the service person discharges himself, fol-
lowing ESD preventive/removal practices, and holds on to the heater en-
closure for 5 seconds before proceeding.
WATER
TEMP SET POINT
MODE
TEMP
Press and hold all three buttons for 5 to 7 seconds.
The digital display format will change and indicate REMoFF
or REMOn.
OTE: When in remote operation, the keypad mode and
temp buttons are disabled. Remote will flash even when
the unit is off.
REMOn = External remote control ac-
tive (display will flash REM)
REMoFF = Remote disabled (heater
thermostat will control heater - use this
mode to test heater operation)
Pool Common
(BLK/ORN)
Spa Common
(ORN/BLK)
24VAC HOT
(BLU)
7-PIN Remote
Wiring Connector

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Effective: 10-01-10
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Page 15
REMOTE CO TROL WIRI G
Important Installation otes for Remote or External Wiring Configuration
• Remote wiring must be run in a separate conduit.
• Remote wiring must not be run parallel to high voltage lines.
• For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable
twisting 1.5 to 2.5 in. lay and jacketed.
• For runs over 30 feet, the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to 2.5 inch lay that is
shielded and jacketed.
• Maximum cable length is 200 feet.
• For both two- and three-wire remote systems, the provided 7-pin wiring connector must be utilized. Please refer to the
wiring instructions.
OTE: The remote wires must be connected to the 7-pin connector before the connector
is plugged into the board.
2-Wire Remote Control (On-Off)
This application assumes that only one heating function (pool or spa) is required.
1. Turn on power to the heater.
2. For a 2-Wire Remote Control from a remote without its own sen-
sor, push the mode button to the “POO ” or “SPA” mode and set
the desired setpoint (eg. 102 °F for spa).
3. For a 2-Wire Remote Control from a remote with its own sensor,
push the mode button “POO ” or “SPA” mode and set the tem-
perature to the highest setting available on the control. The actual
setpoint will be controlled by the remote control.
4. Turn the mode button to "OFF" and remove power from the heater.
5. On the "Remote Interface Harness", connect the B UE wire to one
side of the "REMOTE" switch and connect the other side to either
the ORANGE/B ACK wire for "SPA" operation or the B ACK/OR-
ANGE wire for "POO " operation.
6. Attach wire nut on unused wire to the "Remote Interface Harness."
7. Install the "7-Pin Remote Interface Harness" to the P8 connector
and turn power “On” to the heater.
See ins ruc ions on previous page o ac iva e he remo e con rol.
3-Wire Remote Control Using Three-Position Switch (Pool-Off-Spa, or Low-Off-High)
This application assumes that both heating functions (pool and spa) are required.
1. Turn on power to the heater.
2. Push the mode button to the "POO " or "SPA" mode and set the
desired temperature for each (eg. 80°F for Pool and 102°F for
Spa).
3. Turn the mode button to "OFF" and remove power from the heater.
4. On the "Remote Interface Harness" connect the B UE wire to one
side of the "REMOTE" switch and connect the ORANGE/B ACK
wire for "SPA" operation and the B ACK/ORANGE wire for the
"POO " operation.
5. Install the "Remote Interface Harness" to the P8 connector and
turn power "ON" to the heater.
See instructions on previous page to activate the remote control.
Wire Nut - BLK/ORN
To Pool (COMM)
ORN/BLK - To Spa (COMM)
BLU - 24VAC
P8 Connector
BLK/ORN - To Pool (COMM)
ORN/BLK - To Spa (COMM)
BLU - 24VAC
P8 Connector

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