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

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 2
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

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 3
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

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 4
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

P/ 241169 Rev 4
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

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 6
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.

P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 7
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
Page 8
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
P/ 241169 Rev 4
Effective: 10-01-10
Replaces: 09-05-08
Page 9
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

P/ 241169 Rev 4
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