Raypak P-R185B To P-R405B, C-R185B To User manual

Part No. 240612
CATALOG NO. 6000.52-AH
Effective: 11-01-03
Replaces: 09-01-03
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models
P-R185B to P-R405B
C-R185B to P-R405B
Low NOx
P-R185BL to P-R405BL
C-R185BL to C-R405BL
RP2100
SWIMMING POOL
and
SPA HEATER
This manual should be maintained in legible condition and kept adjacent to the
heater or kept in a safe place for future reference.
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
—WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
—Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
Fig.# 9478

CONTENTS
3
4 PART ONE
OWNER'S OPERATING INSTRUCTIONS
4 SECTION 1
START-UPPROCEDURES
4 Before Start-Up
5 Lighting Instructions & Shut-Off Procedure
(Manually Lighted Pilot MV)
6 Operating Instruction & Shut-Off Procedures
(Automatically Lighted Pilot IID)
7 After Start-Up
7 SECTION 2
CAUTION
7 SECTION 3
MAINTENANCE& CARE PROCEDURE
8 Pool & Spa Water Chemistry
8 Cold Weather Operation
9 Winterizing the Pool & Spa Heater
10 PART TWO
INSTALLATION/SERVICE INSTRUCTIONS
10 SECTION 1
RECEIVING EQUIPMENT
10 SECTION 2
GENERAL SPECIFICATIONS
11 SECTION 3
INSTALLATION INSTRUCTIONS
11 Clearances
12 Outdoor Installation
12 Indoor Installation
12 Specifications and Dimensions
16 Combustion Air
17 Vent Piping
17 Gas Supply Connections
18 Gas Line Sizing Chart
19 Plumbing For Water Connections
23 RP2100 Heat Exchanger Reversal Procedure
24 Electrical Wiring
25 Transformer Wiring
26 Wiring Diagram-Millivolt (Mechanical Therm.)
27 Wiring Diagram-Atmospheric
28 Wiring Diagram- Low NOx
29 SECTION 4
SERVICING INSTRUCTIONS
29 General Location of Controls
29 Control Adjustments
30 Digital Thermostat Controls
31 Digital Diagnostics and Faults
32 Remote Control Operation and Installation
34 Pressure Switch Adjustment
34 Flame Roll-Out Safety Switch
34 High Limit Removal
34 Pilot Safety Millivolt and IID
35 Burner Drawer Removal
35 Gas Valve Removal
35 Main Burner and Orifice Removal
35 Pilot Removal and Cleaning
35 Heat Exchanger Removal
36 Tube Cleaning Procedure
36 Desooting Procedure
36 Immersion Well replacement
36 Unitherm Governor (U.G.) Replacement
37 Low Nox
39 SECTION 5
TROUBLE SHOOTING GUIDE
39 Mechanical
40 Electrical MV Units
41 Electrical IID Units
42 Digital Control Logic
40 SECTION 6
REPLACEMENTPARTS
41 IPL Drawing
43 Part Numbers

4
BEFORE START-UP
BURNERS
Clean main burners, combustion fan and air louvers of
dust, lint and debris. Keep heater area clear and free from
combustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
RP2100 DIGITAL IID POLYMER
SECTION 1 - START-UP PROCEDURES
Your Raypak Pool/Spa heater has been designed for years of safe and reliable pool/spa water heating. It is available
in millivolt or electronic control options. ASME certified units, typical used in commercial applications, are also
available. This manual provides operation, installation, maintenance, and service information for these heaters.
If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater
contains the control center that allows you to turn the heater on or off and adjust the temperature settings for the pool
or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). The heater is also equipped with a
toggle switch to turn the heater on and off, see fig. # 9472 above for location. Section 4 of this manual contains more
details about the use of the controls in the Controls Adjustments subsection.
WATER
Water must be flowing through the heater during opera-
tion. Insure that system is filled with water and have pump
operating.
Fig.# 9472
ON
OFF
Fig.# 9478
PART ONE - OWNER'S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
TO TURN OFF GAS TO APPLIANCE
A. This appliance has a pilot that must be lighted
by hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call
the fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. Force or
attempted repair may result in a fire or explo-
sion.
D. Do not use this appliance if any part has been
underwater. Immediately call a qualified serv-
ice technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been underwater.
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
MILLIVOLT SYSTEM
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On/Off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn
clockwise to "Off".
NOTE:Knob cannot be turned from "Pilot" to Off"
unless knob is pushed in slightly. Do not
force.
6. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go
to the next step.
7. Locate pilot mounted on the right side panel of
the burner drawer. For burner drawer location,
see location of control section, page 20.
HONEYWELL PILOT ROBERTSHAW PILOT
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
8. Turn knob on gas control counter-clockwise
to "Pilot"
9. Place flame to end of pilot tube. Push in
control knob all the way and hold to light pilot.
Continue to hold control knob in for about one
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
*If knob does not pop up when released, stop
and immediately call your service technician
or gas supplier.
10. Stand to the side of the heater and turn the gas
control knob counter clockwise to "On".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
Fig. # 8083.0 Fig. # 8084.1
GAS CONTROL KNOB SHOWN IN OFF POSITION
HONEYWELL
GAS VALVE
MILLIVOLT
ROBERTSHAW
GAS VALVE
MILLIVOLT
Fig. # 8081.0
Fig. # 8079.0
5

A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
ELECTRONIC IGNITIONS SYSTEMS
to "Off". Make sure knob rest against stop.
For Robertshaw 7200 gas valve.
Push in and move gas control lever counter-
clockwise to "Off" position.
5. Replace heater door panel.
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
*If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, don't try to repair
it; call a qualified service technician. Force or
attempted repair may result in fire or explo-
sion.
D. Do not use this appliance if any part has been
underwater. Immediately call a qualified serv-
ice technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been underwater.
OPERATING INSTRUCTIONS
1.STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.
5. Remove heater door panel.
6. For Honeywell Valve: Turn gas control
knob clockwise to "Off".
For Robertshaw valve: Turn gas control
knob clockwise to "Off".(Models
265-405) Push in and move gas control
lever counter-clockwise to "Off"
position. (Model 185)
7. Wait 5 minutes to clear out any gas. If you
then smell gas STOP! Follow "B" in the
safety information previously stated. If you
don't smell gas, go to the next step.
8. Turn gas control knob counter-clockwise
to "On". (Honeywell VR 8300 and
Robertshaw 7000)
9. Replace heater door panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier. TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat at the lowest setting.
2. Turn off all the electric power to the appliance
if service is to be performed.
3. Remove heater door panel.
4. For Honeywell VR 8300 and Robertshaw
7000 gas valve.
Turn gas control knob clockwise
GAS CONTROL KNOB SHOWN IN "ON" POSITION
GAS
INLET
HONEYWELL
VR 8300 GAS
VALVE IID
ROBERTSHAW
7200 GAS VALVE
IID MODEL 185
GAS CONTROL
LEVER SHOWN
IN "OFF"
POSITION
GAS
INLET
ROBERTSHAW 7000
GAS VALVE IID
MODEL 265-405
Fig. # 8080.0
6
Fig. # 8934.1

AFTER START-UP
Feel the inlet and outlet pipes. Outlet pipe should be only
slightly warmer than the inlet. It should not be hot.
VISUAL INSPECTION
With the heater on, remove the door and make a visual
check of the pilot and burner. The flame should be blue
with a well-defined pattern.
4" MAX
Fig. # 8205.2
MAIN BURNER FLAME
Fig. # 8964.1
PILOT BURNER FLAME
A yellow or "floating" flame indicates restricted air open-
ings or incorrect orifice size. Should this occur, shut the
heater off and contact your installer or gas supplier.
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to shut
off the burners in the event that water supply to the heater
is interrupted. It is very important to verify that the switch
electrically opens and shuts off the gas valve when water
flow to the heater is interrupted. Otherwise, rapid and
severe damage will likely occur to the heater. (The water
pressure switch should be checked and adjusted for
proper operation by a qualified service person at the time
of installation and periodically checked thereafter. Refer
to pressure switch servicing instruction in Section 4 of
this manual).
SECTION 2 - CAUTION
Elevated water temperature can be hazardous, and the U.
S. Consumer Product Safety Commission recommends
the following guidelines:
1. Spa or hot tub water temperatures should never
exceed 104°F (40°C). A temperature of 100°F (38°C)
is considered safe for a healthy adult. Special
caution is suggested for young children.
2. Drinking of alcoholic beverages before or during spa
or hot tub use can cause drowsiness which could
lead to unconsciousness and subsequently result in
drowning.
3. Pregnant Women Beware! Soaking in water over
102°F (39°C) can cause fetal 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 ther-
mometer; 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 history of heart disease,
circulatory problems, diabetes, or blood pressure
problems should obtain a physician's advice before
using pools or hot tubs.
6. Persons taking medications which induce drowsi-
ness, such as tranquilizers, antihistamines, or anti-
coagulant, should not use spas or hot tubs.
SECTION 3 - MAINTENANCE AND
CARE PROCEDURES
To be followed one month after start-up and then semi-
annually.
1. Inspect top of heater and drafthood for soot, a sticky
black substance around finned tubes and "V"
baffles), and open flue gas passage ways. Any visible
soot should be cleaned for proper operation.
7
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use steel
wire brush.
2. Clean main burners and pilot burner of dust and lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.

4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is indi-
cated in the previous illustration. Yellow flame
means restriction of the air openings. Lifting or
blowing flame indicates high gas pressure. Low
flame means low gas pressure. Should this occur,
shut the heater off and contact your gas supplier or
qualified service agency.
5. On indoor heaters, clean room intake openings to
assure adequate flow of combustion and ventilation
air.
6. Keep area around heater clear and free from combus-
tible materials, gasoline and other flammable and
corrosive vapors and liquids.
BASIC TIPS IF HEATER WILL NOT FIRE:
1. If you have no electrical power; it may be your "circuit
breakers" have tripped. Try re-setting them.
2 If you have electrical power but the heater will not fire
check the following:
3. The time clock must be moved to the "ON" position.
4. Your pump strainer basket may be full. If so remove
debris.
5. Your filter may be dirty. If so, backwash or clean
filter. (To tell if your filter is dirty, look to see if the
filter pressure will be higher than usual).
6. The pump may have lost it's prime. It may be run-
ning dry, check the pressure on the filter. If there is
no pressure; then you are not moving water (or your
gauge is broken). Try to get the pump to run at it's
normal flow rate.
POOL & SPA WATER CHEMISTRY
Chemical imbalance can cause severe damage to your
heater and associated equipment. Maintain your water
pH between 7.4 and 7.8 and total alkalinity between 100
and 150 p.p.m. If the mineral content and dissolved solids
in the water become too high, scale forms inside the heat
exchanger tubes, reducing heater efficiency and also
damaging the heater. If the pH drops below 7.2, the
heater will be severely damaged. This will result in
corrosion of the heat exchanger. Heat exchanger
damage resulting from chemical imbalance is not
covered by the warranty.
AUTOMATIC CHLORINATORS AND
CHEMICAL FEEDERS
All chemicals must be introduced and completely diluted
into the pool or spa water before being circulated through
the heater. Do not place chlorine tablets or bromine
sticks in the skimmer. High chemical concentrations will
result when the pump is not running (i.e. overnight).
Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical back-
up into the heater when the pump is shut off.
NOTE: High chemical concentrates from feeders and
chlorinators that are out of adjustment will cause very
rapid corrosion to the heat exchanger. Such damage is
not covered under the warranty.
COLD WEATHER OPERATION
8
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
MODERATE CLIMATE: Heater operation can con-
tinue during short term cold spells. When tempera-
tures are below freezing, flow (continuous pump opera-
tion) must be maintained.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze protec-
tion. 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 is not warranted against freeze
ups.
COLD CLIMATE: Prolonged operation with water tem-
peratures below 50°F is not recommended. When
starting the heater with pool temperatures below 50°F
operate the heater continuously until higher tempera-
tures are reached. Operating the heater for prolonged
periods with pool water below 50°F can seriously
damage the heater, and is not covered by the warranty.
For cold climate areas, please follow the winterizing
procedures listed.
IMPORTANT FREEZE INFORMATION

WINTERIZING THE POOL & SPA HEATER
Heaters installed outdoors in freezing climate areas are
subject to be shut down for the winter. Observe the
following step-by-step procedure for winterizing the
heater:
1. Turn off gas valve, manual gas valve, and electrical
supply to the heater.
2. Open drain plug located on the inlet/outlet header,
(under water pipes). Remove the heat exchanger
inspection panel on the side opposite water piping to
gain access to the drain plug on the return header.
Open drain plug on return header.
9
Return Header
Drain Plug
Disconnect compression fittings from the pressure
switch and return header that connects to the 1/4" copper
tube and allow the tube to drain. For ASME Heaters only.

SECTION 1 - RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the carton
is damaged, a note should be made on the Bill of Lading when signing for equipment. Remove the heater from the
carton and if it is damaged, report the damage to the carrier immediately. Save the carton.
These items are shipped loose inside the carton with the heater:
STANDARD UNIT ASME UNIT
1. "Pagoda" Top 1. "Pagoda" Top
2. 2" CPVC Union with "O" rings (2) 2. In/Out Flanges (2)
3. Plastic pipe finish flange for gas line 3. 1-1/2" Flange Gaskets (2)
4. Bonding lug with mounting screw 4. 2" Flange Gaskets (2)
(IID units only) 5. Flange Bolts (4)
6. Pressure Relief Valve
7. 2" CPVC Adapters (2)
8. Plastic pipe finish flange for gas line.
9. Bonding lug with mounting screw. (IID units only).
Be sure that you receive the number of packages indicated on the Bill of Lading.
When ordering parts, you must specify model and serial number of heater. When ordering under warranty conditions,
you must also specify date of installation. Raypak recommends that this manual be reviewed thoroughly before
installing your Raypak pool/spa heater. If there are any questions that this manual does not answer, please contact
the factory or your local Raypak representative.
SECTION 2 - GENERAL SPECIFICATIONS
These heaters are design certified and tested under the requirements of ANSI Z21.56 / CSA 4.7 American National
Standard / CSA Standard for Gas-Fired Pool Heaters. All heaters are inter-changeable and can be used either indoor
or outdoors. The appropriate top designated for that type of use is required. If desired, the top can be changed at
a later date to change from outdoor to indoor or vice versa. Millivolt heater contains a self-generating electrical system
operating between .25 and .75 volts.
Ambient Temperature Rating of Heater Components
Millivolt Heater with Honeywell Gas Valve +32°F to +175°F
Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F
Electronic Ignition Heaters* -32°F to + 175°F
*Requires 120V or 240V Power Supply
Atmospheric heaters:
Rated inputs suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000
feet above sea level, as high elevation reduces combustion performance.
Low NOx heaters:
Rated inputs suitable for up to 5000 feet elevation. For elevations above 5000 feet, consult the factory.
10
PART TWO
INSTALLATION AND SERVICE INSTRUCTION

12"
Minimu
m
12"
M
inimum
4"
Minimum
HEATER
Sheet Metal
24 Gauge
11
IMPORTANT NOTICE
These instructions are intended for the use of qualified
personnel only, specifically trained and experienced in
the installation of this type of heating equipment and
related system components. Installation and service
personnel may be required by some states to be li-
censed. If your state is such, be sure your contractor
bears the appropriate license. Persons not qualified shall
not attempt to fix this equipment nor attempt repairs
according to these instructions.
CODE REQUIREMENTS
NOTE: The heater should not be located in an area
where possible water leakage will result in damage to
the area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest edition of the
National Fuel Gas Code, ANSI Z223.1 and National
Electrical Code, ANSI/NFPA 70, and for Canada, the
latest edition of CAN/CGA-B149.1 and B149.2, and
Canadian Electrical Code, CSA C22.1 Part 1 and Part
2.
BASE INSTALLATION
Heater must be mounted on a level base, such as cement
slab, cement blocks or other non-combustible surface.
An optional non-combustible base is available for all
models.
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California
to cause cancer, birth defects or other reproductive harm.
An alternative method for providing a base for combustible
floors is illustrated below. Heaters must not be installed
on carpeting.
CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see the chart
below.
SECTION 3 - INSTALLATION INSTRUCTIONS
WARNING:
Improper installation, adjustment, alteration, service or
maintenance may damage the equipment, create a
hazard resulting in asphyxiation, explosion or fire, and
will void the warranty.
Fig. # 8148.1
Utilize hollow concrete cinder blocks, align holes and
leave ends open.
When installed according to the listed minimum clear-
ances from combustible construction materials, the
Raypak pool heaters can still be serviced without remov-
ing permanent structural construction around the heater.
However for ease of servicing, we recommend a clear-
ance of at least 24" in the front, and at least 18" on the
water connection side. This will enable the heater to be
serviced in its installed location, that is, without move-
ment or removal of the heater.
Clearances less than these (6" minimum), 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.
CLEARANCEFROM
COMBUSTIBLE CONSTRUCTION
INDOOR INSTALLATIONS:
Top*- 30"(Drafthood) Back - 6"
Front - Alcove Right Side- 12" (Water Side)
Vent - 6" Left Side-6"
(Opposite Water side)
OUTDOOR INSTALLATION:
Top* - Unobstructed (Stackless top or outdoor stack)
Back - 6"
Side - 6"
*Clearance from top of vent terminal

Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three (3) sides
must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed
under overhangs with the use of gutters.
For U.S. installations,the point from where the flue products exit the heater must be a minimum of four (4) feet below,
four (4) feet horizontally from, or one (1) foot above any door, window or gravity inlet into any building. The top surface
of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet
horizontally.
VENT TERMINAL (Outdoor) Stackless Top Installation
1. Insert tabs into keyhole (4 places).
Pagoda Top
(Shipped
Loose with
Heater)
2. Snap tabs into keyholes so as not to pull out.
Fig. #RP8280.1
12
Fig. # 8278.2
OUTDOORHEATERS
These heaters are design certified for outdoor installation, when equipped with the approved tops designated for
outdoor use.
HEATER WITH OUTDOOR STACKLESS TOP
Fig# 8245.1
U.S. Installations only
WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause water
to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage some electrical
components, and this would void the warranty.
WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit. Strong air intake from these
equipment can disturb the combustion process and cause damage or personal injury.
For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10 feet
below, or to either side, of any opening into the building.
Refer to the latest revisions of CAN/CGA-B149.1 and
B149.2.

INDOOR HEATER
The design is also certified for indoor installation when equipped with the approved draft hood.
For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate
with occupied area. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific requirements.
Locate heater as close as practical to a chimney or gas vent. Heater must always be vented to the outside. See
Vent Piping Section for venting details. Minimum allowable space is shown on the nameplate.
13
OUTDOOR STACK / INDOOR STACK INSTALLATION
OUTDOOR KIT INCLUDES:
1- Draft hood, painted
1- Adapter plate
3- Mounting brackets (clips)
1- Top panel cover
2- 1 foot sections of metal tape
3- Screws
1- Instructions Clips
Clips
INDOOR KIT INCLUDES:
1- Draft hood, unpainted
1- Adapter plate
3- Mounting brackets (clips)
3- Screws
1- Instructions
ASSEMBLY PROCEDURE
1. Make sure that the gas and electric has been turned
off to the unit.
2. Remove the "pagoda" top from the louvered top and
discard. See Fig. 3.
3. Remove the louvered top and set aside, saving the
four phillips screws for reassembly. See Fig. 3.
4. Remove and discard the rain shield. See Fig. 4.
5 Install adapter plate on top of heater flue collector.
See Fig. 5.
6. Reinstall louvered top on heater and fasten with
Phillips screws set aside in step 3.
WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to the
outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.
NOTE: The outdoor and indoor stack are optional equipment and do not come standard with the heater.
OUTDOOR STACK INDOOR STACK
Model Part No. Part No.
185 006751 006696
265 006752 006697
335 006753 006698
405 006754 006699

14
SECURING THE TOP PANEL COVER
INDOOR KIT ONLY
7. Reinstall the louvered top.
8. Mount the draft hood onto the adapter plate lip inside
the heater. See Fig. 6.
9. Proceed to installing the clips, step 14.
SECURING THE TOP PANEL COVER
OUTDOOR KIT ONLY
10. After removing the drafthood from the box, slide the
top panel cover over the draft hood. See Fig. 1.
11. Holding both pieces together, mount the draft hood
on the adapter plate lip inside the heater. See Fig. 6.
12. Take the two pieces of tape and attach to each side
of the drafthood leaving 6" hanging down.
13. Slide the top panel cover up and attach the tape to the
underneath side. This is to temporarily keep the top
panel cover out of the way while you are attaching the
clips as shown in the next steps. See Fig. 7.
INSTALLING THE CLIPS
INDOOR & OUTDOOR KITS
14. Notice that there are three pilot holes above the base
of the drafthood as shown in Fig.8. These are the
locations where the three clips are to be attached.
15. Insert the long edge of one clip between the top panel
cover and the drafthood, see Fig. 9.
16. With a twisting motion, rotate the clip up, see Fig. 10.
17. Pull up on clip, see Fig. 11.
18. Hold the clip up and align the clip hole to the pilot
hole, see Fig. 12.
19. Insert screw into hole and secure using a 5/16" nut
driver.
20. Repeat steps 6-10 using remaining two clips.
21. This completes the indoor drafthood installation. If
installing an outdoor drafthood, proceed to step 13.

15
INSTALLING THE TOP COVER
OUTDOOR KIT ONLY
22. Remove the two pieces ofg metal tape holding the top
panel cover up and discard.
23. Insert the rear two tabs into the slots on the heater top
and slide the top panel cover backwards. See Fig.13.
24. Lower the top panel cover and using your thumbs,
push tabs in and insert the two front tabs into the
slots on the top of the heater. See Fig.14.
25. Lower the top panel cover flush to the top and release
the tabs. They will spring into place as shown in
Fig.15.
26. Turn the gas and electricity to the heater on.

16
SPECIFICATIONS AND DIMENSIONS
*Electrical Connection On Left Side is 19-1/8".
a. All Air From Inside The Building:
Each opening shall have a minimum net free square
inches as noted:
Model Square Inches Model Square Inches
185 181 335 333
265 264 405 399
b. All Air From Outdoors:
When air is supplied directly from outside of building,
each opening shall have a minimum net free square
inches as noted:
Model Square Inches
185 46
265 66
335 84
405 100
COMBUSTION AIR (Indoor Units Only)
Air For Combustion And Ventilation
The heater must have both combustion and ventilation air.
Minimum requirements for net free air supply openings,
one 12 inches from ceiling for ventilation and one 12
inches from the floor for combustion air as outlined in the
latest edition of the National Fuel Gas Code, ANSI
Z2231(Canada-CAN/CGA-B149.1 and B149.2) and any
local codes that may have jurisdiction.
*Designation for Propane is "EP", Natural gas is "EN". Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Polymer)
Headers. Atmospheric heaters: reduce input 4% for each 1000 ft. above sea level when installed above 2000 ft. elevation.
Low NOx heaters: for elevations above 5,000 feet consult factory. For Canada, no de-rate is required for elevations up to
4500 feet. Manufactured under Patent No. 3,623,458. Note: Plastic (Polymer) Headers cannot be used for ASME
installations.
Fig # 9037.2
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B581R181"4/1-81"6"8/5-26"61/1-21"4/3"219127121
B562R462"8/3-22"7"8/7-26"8/1-11"4/3"241259151
B533R433"4/3-52"8"4/3-36"4/3-01"4/3"243251271
B504R993"4/1-92"9"8/3-56"2/1-21"4/3"235243202
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.

VENT PIPING
Vent piping the same size as the draft hood outlet is
recommended, however, when the total vent height is at
least ten (10) feet (draft hood relief opening to vent
terminal), the vent pipe size may be reduced as speci-
fied in Chapter 10 of the National Fuel Gas Code, ANSI
Z 223.1. (Canada-CAN/CGA-B149.1 and B149.2) As
much as possible avoid long horizontal runs of vent pipe
and too many elbows. If installation requires horizontal
non-vertical runs, the vent pipe must have a minimum of
1/4 inch per foot rise and should be supported at not more
than five foot intervals. Plumbers tape, criss-crossed, will
serve to space both horizontal and vertical piping. Gas
vents supported only by the flashing and extending above
the roof more than five feet should be securely guyed or
braced to withstand snow and wind loads. We recom-
mend use of insulated vent pipe spacer through the roofs
and walls. Another option for installation that requires
horizontal runs is using the D-2 powervent kit option.
For more detailed D-2 installation information consult the
D-2 Power Vent manual 6000.57.
The Power Vent Assembly is a fan assisted combustion
system designed for application to Raypak Pool Heater
Models 185-405. The unit, when installed as directed, is
capable of operating in applications such as through the
wall venting and reduced horizontal and vertical vent pipe
sizes in new and current installations. It is certified for
category III venting up to 40 feet equivalent 4" diameter
venting. The unit is factory wired for 240V, with capability
of rewiring for 120V.
For protection against rain or blockage by snow, the vent
pipe must terminate with a vent cap which complies with
the local codes or, in the absence of such codes, to
the latest edition of the National Fuel Gas Code, ANSI
Z223.1. (Canada-CAN/CGA-B149.1 and B149.2)
Fig. #RP 8119.2
17
GAS SUPPLY CONNECTIONS
The discharge opening must be a minimum of two feet
vertically from the roof surface and at least two feet higher
than any part of the building within ten feet. Vent stack
shall be at least five feet in vertical height above the
drafthood outlet. The vent cap location shall have a
minimum clearance of 4 feet horizontally from, and in no
case below, unless a 4-foot horizontal distance is main-
tained, from electric meters, gas meters regulators and
relief equipment.
The weight of the vent stack or chimney must not rest on
heater draft hood. Support must be provided in compli-
ance with applicable codes. The heater top and draft
hood must be readily removable for maintenance and
inspection. Vent pipe should be adequately supported to
maintain proper clearances from combustible construc-
tion.
Type "B" double wall
orequivalentventpipe
is recommended.
However single wall
metal vent pipe may
be used as specified
in the latest edition of
the National Flue Gas
Code ANSI Z 223.1.
(Canada-CAN/CGA-
B149.1 and B149.2)
Gas piping must have a
sediment trap ahead of
the heater gas controls,
and a manual shut-off
valve located outside the
heater jacket. All gas
piping should be tested
after installation in ac-
cordance with local
codes.
Fig. #RP 8090.0
Fig. # 9469
WARNING: Indoor boilers require a drafthood that
must be connected to a vent pipe and properly vented
to the outside. Failure to follow this procedure can
cause fire or fatal carbon monoxide poisoning.
Optional Raypak D-2
Power Vent
Power Vent Kit
Model Part No.
185 008086
265 008086
335 008087
405 008087
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 of 1/2 psig (3.45 KPA). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRESSURED
GAS VALVES ARE NOT COVERED BY
WARRANTY. The heater and its gas connections shall
be leak tested before placing the appliance in
operation. Use soapy water for leak test. DO NOT use
open flame.

Fig. # 8149
NOTE: Do not use Teflon tape on gas line pipe thread.
A flexible sealant is recommended.
A minimum of 7" W.C. and a maximum of 14" W.C.
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 12"
W.C. and a maximum of 14" for propane gas.
GAS PRESSURE REGULATOR
The gas pressure regulator is preset at 4" W. C. for natural
gas, and 11" W. C. for propane gas. The pressure at the
gas valve, taken with a manometer, should be about 3.7"
W. C. natural gas (3.9" W.C. for Low NOx) and 10.5" W.
C. propane gas. If an adjustment is needed, remove seal
and turn adjustment screw clockwise to increase
pressure or counter-clockwise_____to decrease pres-
sure.
18
Gas
Pressure
Adjustment
GAS PRESSURE ADJUSTMENT LOCATIONS
MILLIVOLT GAS VALVES
ELECTRONIC IGNITION GAS VALVES
Robertshaw 7000
Models 185 thru 405
Gas
Pressure
Adjustment
Honeywell VR8304
Models 185 thru 405
Robertshaw 7200
Model 185
ELECTRONIC IGNITION GAS VALVES-CONTINUED
Robertshaw 7000 BDER
Model 265-335
Robertshaw 7000 DERHC
Model 405
Gas
Pressure
Adjustment
Gas
Pressure
Adjustment
Fig # 9263
Fig # 9264
Fig # 9328
Fig # 9327
Fig # 9329
Fig. # 9365
ATMOSPHERIC LOW NOx
PIPE SIZING FOR GAS CONNECTIONS
Low NOx units are not available in propane.

19
High temperature CPVC Header Flanges and header
Flange Nuts are provided. If there is any possibility of
back- siphoning when the pump stops, it is suggested
that a check valve (or valves) also be installed in the
system.
INLET/OUTLET HEADER (Polymer)
CONNECTIONS (POLYMER HEADER)
Before attaching the 2-inch unions to the inlet/outlet
header, make sure the o-rings are properly seated in the
grooves. Use AquaLube or equivalent non-petroleum
based lubricant on the o-ring. Tighten the unions hand
tight. Glue PVC piping directly to the unions.
PLUMBING FOR WATER CONNECTIONS
HEATER LOCATION-Relative to the pump and filter
The RP 2100 heater requires water flow and positive
pressure to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:
1. The inlet side of the filter is plumbed directly to the
discharge side of the filter pump;
2. The outlet side of the filter is then plumbed to the inlet
of the heater; and
3. The outlet of the heater is plumbed to the return line
to the pool or spa. The pump, filter and heater are
thus plumbed in series.
Plumbing from the heater back to the pool must not have
any valves or restriction that could prevent flow when the
pump is operating.
Heater must be located so that any water leaks will not
damage the structure of adjacent area. PVC pipe may
be glued directly into header unions.
FLOW RATES
MODEL PIPE SIZE MIN.GPM *MAX.GPM
185 1-1/4"-1-1/2" - 2 20 125
265 1-1/4"-1-1/2" - 2 25 125
335 1-1/4"-1-1/2" - 2 35 125
405 1-1/4"-1-1/2" - 2 40 125
ASME-Cast Iron
Header Flange Nut
(CPVC)
Inlet
Header Flange
(CPVC)
Flange Gasket
Fig. #2002.1
POLYMER HEADERS
CAUTION: An additional source of heated water, i.e.
a solar system, must be connected to the main line
ahead of the heater inlet pipe in order for it to act as the
primary heat source. If the primary system provides
adequate heat to maintain set-point, the RP2100
heater will not fire. Be advised that the RP2100 control
panel will then display sensed water temperatures
downstream of the primary heating system, rather than
the temperature of the water exiting the pool.
*When flow rates exceed maximum GPM an external
auxiliary bypass valve is required. See external bypass
valve section for details.

20
CONNECTIONS (ASME MODELS)
Heater must be located so that any water leaks will not
damage the structure of adjacent area. High temperature
2" plastic pipe (CPVC) may be threaded directly into the
header flanges. This is not the same as the Schedule 80
PVC pipe which is also colored gray. PVC may be used
immediately after the CPVC adapters.
DO NOT use petroleum base assembly fluids (such as
Petroleum Jelly or lubricating oil). If assembly lube is
required, use a silicon base such as Amoral etc.
There are two sets of flange gaskets supplied with your
heater. Use the appropriate gaskets for all your heater
connections. Discard unused set.
GASKET DESIGN #1: Accepts 1-1/2" copper tube or
1-1/4" galvanized pipe as a slip connection.
GASKET DESIGN #2: Accepts 2" copper tube as a slip
connection. The flange is threaded for 2" screw in pipe
connections. Also used with the 2" CPVC adapters.
#1 #2
Fig. # 8095.1 Fig. # 8097.1
INLET/OUTLET HEADER - ASME
Header Flange
2" CPVC Adapters
PVC Pipe
ASME
Inlet/Outlet Header
Flange Gasket
Fig. # 8093.1
UNITHERM GOVERNOR OPERATION
CAUTION: NEVER install PVC directly into header
flanges. Use the 2" CPVC adapter supplied loose with
the heater.
CAUTION:
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain constant
heater internal temperature between 105° to 115°F
despite continually changing flow rates from the filter
and changing pool temperatures. This narrow range is
needed to prevent damaging condensation on the
burners which will occur if the heater runs for any length
of time below 100°F. It is also needed to inhibit scale
formation in the tubes by maintaining temperatures
well below accelerated scaling temperatures.
GASKET
UNITHERM
GOVERNOR
U.G. PLUG
(Polymer)