Raypak RP-045 User manual

Raypak
Indirect
Pool
Heaters
INSTALLATION AND
OPERATION MANUAL
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance.
To do so may result in an explosion or fire.
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.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place
for future reference.
P/N 241399 Rev. 5
Effective: 04-30-21
Replaces: 12-15-20
Model Series RP-045 through
RP-995 and B Ti-180 through
B Ti-500

2
Rev. 5 reects the following: Table A: Added "Model Number column". Changed row heading from "CR24" to "Ti".
Table C: Added information rows for: RP-185, RP-305 & RP-495.

3
TABLE OF CONTENTS
1. WARNINGS ............................................................. 4
Pay Attention to These Terms ................................. 4
Caution.................................................................... 4
2. WATER CHEMISTRY ............................................. 5
3. INSTALLATION GUIDELINES.............................. 7
Plumbing ................................................................. 7
Flow......................................................................... 7
Controls................................................................... 8
Chemical feeders or salt water generators ............. 8

4
ADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death
or substantial property damage if ignored.
AWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal
injury, death or substantial property damage if ignored.
ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury
or product or property damage if ignored.
CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition
which could cause minor personal injury or product or property damage if ignored.
NOTE Indicates special instructions on installation, operation, or maintenance which are important but
not related to personal injury hazards.
1. WARNINGS
Pay Attention to These Terms
NOTE: Minimum 18 AWG, 105°C, stranded wire must
be used for all low voltage (less than 30 volts) external
connections to the unit. Solid conductors should not
be used because they can cause excessive tension on
contact points. Install conduit as appropriate. All high
voltage wires must be the same size (105°C, stranded
wire) as the ones on the unit or larger.
NOTE: The instructions in this manual are for the
use of qualied individuals specially trained and
experienced in the installation and maintenance of this
type of equipment and related system components.
Installation and service personnel are required by
some states to be licensed. Persons not qualied
shall not attempt to install, service, or maintain this
equipment.
Elevated water temperature can be hazardous. The
U.S. Consumer Product Safety Commission has these
guidelines:
1. Spa 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
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 history of heart disease,
circulatory problems, diabetes, or blood pressure
problems should seek a physician’s advice before
using pools or hot tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihistamines,
or anticoagulants, should not use spas or hot tubs.
CAUTION: Operating control and high limit are NOT
part of the Indirect Pool Heater. These items must be
supplied separately.
CAUTION

5
2. WATER CHEMISTRY
(Corrosive water causes damage that will not be covered under warranty.)
For your health and the protection of your pool equipment, it is essential that your water be chemically balanced.
The following levels must be used as a guide for balanced water.
Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool & Spa Types
Water Temp. °F (°C) 68 to 88 (20-31) 89 to 104 (32-40) 68 to 104 (20-40)
pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8
Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120
Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400
Salt (PPM)
RP 316L SS 1000 MAXIMUM 1000 MAXIMUM 1000 MAXIMUM
Titanium 6000 MAXIMUM** 6000 MAXIMUM** 6000 MAXIMUM**
Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3
Total Dissolved
Solids (PPM)
RP 316L SS 1000 MAXIMUM 1000 MAXIMUM 1000 MAXIMUM
Titanium 3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM
Metals (PPM) 0 0 0
*Free Chlorine MUST NOT EXCEED 5 PPM!
• Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water
is balanced.
• Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water. Unless
controlled, they can lead to excessive chlorine levels, which can damage your heater.
• Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier
for the correct levels for your water.
** Titanium is immune to saline and seawater.

6
* Nominal values are based on 140°F (60°C) temperature differential between incoming heating and heated water.
** Titanium - widely used in industrial salt water environments. Due to its unsurpassed corrosion resistance, this unique super alloy option
is a ‘true’ salt water product, now available from Raypak for the most demanding of applications, from high chlorination to high salt
content.
HEAT SOURCE
WATER IN
POOL WATER OUT
HEAT SOURCE
WATER OUT
POOL WATER IN
Figure 1. Dimensions
Table A. Specifications
Part Number
Model
Number
Nominal
Capacity*
BTU/hr (Kwh)
Dimensions Inches (mm)
SS316L Ti** A B C
Pool Conn.
NPT
F
Boiler Conn.
NPT
G
Length
L
Diameter
ØD
Heat
Transfer
Area
ft² (m²)
013476 RP-045 45,000 (13,188) 4-3/16
(106)
4-3/8
(111)
2-15/16
(75)
1
(25)
3/4
(19)
10-1/4
(260)
3-1/8
(79)
1.62
(0.15)
013477 RP-075 75,000 (21,980) 4-3/16
(106)
6-7/8
(175)
3-1/4
(83)
1-1/2
(38)
3/4
(19)
13-1/2
(343)
3-1/8
(79)
2.64
(0.25)
013478 RP-125 125,000 (36,634) 4-3/16
(106)
8-7/8
(225)
3-1/4
(83)
1-1/2
(38)
3/4
(19)
15-3/8
(391)
3-1/8
(79)
3.64
(0.34)
013479 RP-185 185,000 (54,218) 5-1/8
(130)
7-5/8
(194)
3-3/8
(86)
1-1/2
(38)
1
(25)
14-3/8
(365)
4-1/16
(103)
4.70
(0.44)
013480 RP-245 245000 (71,802) 5-1/8
(130)
12-11/16
(322)
3-3/8
(86)
1-1/2
(38)
1
(25)
19-1/2
(495)
4-1/16
(103)
6.80
(0.63)
013481 RP-305 305,000 (89,387) 5-1/8
(130)
17-3/8
(441)
3-3/8
(86)
1-1/2
(38)
1
(25)
24-3/16
(614)
4-1/16
(103)
9.00
(1)
013482 RP-495 495,000 (145,070) 5-3/16
(132)
34-13/16
(884)
3-5/8
(92)
2
(51)
1
(25)
42-1/16
(1068)
4-1/16
(103)
16.8
(2)
013483 RP-995 995,000 (291,606) 6-9/16
(167)
26-5/8
(676)
4-5/16
(110)
2
(51)
2
(51)
35-3/16
(894)
5-1/2
(132)
21.5
(2)
018306 Ti-180 185,000 (54,218) 5-5/8
(143)
7-11/16
(195)
4-1/4
(107)
1-1/2
(38)
1-1/4
(31)
16-1/8
(409)
4-1/16
(103)
4.70
(0)
018307 Ti-305 305,000 (89,387) 5-5/8
(143)
17-1/2
(444)
4-1/4
(107)
1-1/2
(38)
1-1/4
(31)
25-15/16
(635)
4-1/16
(103)
9.00
(1)
018308 Ti-495 495,000 (145,070) 5-5/8
(143)
35-5/16
(889)
4-1/4
(107)
1-1/2
(38)
1-1/4
(31)
43-3/4
(1092)
4-1/16
(103)
16.80
(2)

7
Table C. Flow & Pressure Drop
Pressure Temperature
°F (°C)
SS316L* B Ti Titanium
Tubeside 190 PSI 150 PSI 406 (208)
Shellside 190 PSI 150 PSI 406 (208)
Model Boiler
Flow
Boiler
Head Loss
Pool
Flow
Pool
Head Loss
Heating
Surface
SS316L Titanium GPM (L/min) Feet (m) GPM (L/min) Feet (m) Ft² (m²)
Min. Max. Min. Max. Min. Max. Min. Max.
RP-045 5
(19)
15
(57)
0.5
(0.2)
1.0
(0.3)
20
(76)
40
(152)
1.5
(0.5)
6.0
(1.8)
2.0
(0.19)
RP-075 10
(38)
20
(76)
1.0
(0.3)
2.5
(0.8)
20
(76)
50
(190)
1.5
(0.5)
7.0
(2.1)
2.8
(0.26)
RP-125 10
(38)
20
(76)
1.0
(0.3)
2.5
(0.8)
20
(76)
50
(190)
2
(0.6)
10
(3)
3.3
(0.31)
Ti-180 20
(76)
30
(114)
1.0
(0.3)
2.0
(0.6)
20
(76)
50
(190)
1.5
(0.5)
9.5
(2.9)
4.7
(0.43)
RP-185 20
(76)
30
(114)
1.0
(0.3)
2.0
(0.6)
20
(76)
50
(189)
1.5
(0.45)
9.5
(2.9)
4.9
(0.45)
RP-245 20
(76)
30
(114)
1.0
(0.3)
2.5
(0.8)
30
(114)
60
(227)
2.5
(0.8)
9.0
(2.7)
7.3
(0.68)
Ti-300 20
(76)
35
(133)
1.5
(0.5)
4.0
(1.2)
30
(114)
60
(227)
1.5
(0.5)
6.0
(1.8)
9.0
(0.83)
RP-305 20
(76)
35
(132)
1.5
(0.45)
4.0
(1.2)
30
(114)
60
(227)
1.5
(0.45)
6.0
(1.8)
9.4
(0.87)
RP-495 25
(95)
35
(132)
3.5
(1.0)
6.5
(2.0)
40
(151)
80
(303)
3.0
(0.91)
12.0
(3.6)
17.3
(1.6)
Ti-500 25
(95)
35
(133)
3.5
(1.1)
6.5
(2)
40
(152)
80
(303)
3.0
(0.9)
12
(3.7)
16.8
(1.56)
RP-995 50
(190)
100
(379)
4.0
(1.2)
13
(4)
70
(265)
120
(455)
5.5
(1.7)
15
(4.6)
23.7
(2)
*Designed and fabricated to the ASME B31.3 Process Piping Code.
3. INSTALLATION
GUIDELINES
Plumbing
Connections to the Indirect Pool Heater must be made
with materials that have similar galvanic properties
to the passivated 316 stainless steel or Titanium of
the heat exchanger. Connections to the heat source
plumbing should be made with 300-series stainless
steel nipples. Dielectric unions are recommended if
dissimilar plumbing is used. Connections to the pool
system should be made with CPVC or PVC adapters or
300-series stainless steel nipples. Dielectric unions are
recommended if dissimilar plumbing is used.
The connection diagram, Figure 2, is shown for reference
only. The system must be designed and installed by
a qualied installer and all local, state, provincial and
national codes, laws, regulations and ordinances must
be followed.
Flow
For optimal heat transfer, use counter-ow; the supply
water from the heat source should ow in the opposite
direction of the return water from the pool/spa, as shown
in Figure 2. Systems must be designed to provide ow
rates within the range provided in Table 3. Do not
exceed the published maximum ow rates. On the
heating side, desired ow rates can be accomplished
with pump sizing and/or the use of balancing valves.
Table B. Design Ratings

8
Sample Installation Diagram
NOTE:
- Damage to the Indirect Pool Heater due to improper water chemistry is not covered under the warranty
- Chlorine feeder must be installed after (downstream of) the Indirect Pool Heater and be installed with an
anti-siphoning valve to prevent pool chemicals from backing up into the Indirect Pool Heater.
- This is only a conceptual drawing. A qualified installer must determine whether this system setup
will work in each application. Installer must also ensure compliance with code requirements.
1.
2.
Indirect Pool Heater
3.
4.
5.
6.
Gate valve
7.
Check valve
8.
9.
10.
Flow switch
11.
Thermometer
Drain valve
Filter
Pool/Spa Pump
Bypass valve
POOL WATER FLOW
POOL WATER FLOW
BOILER WATER FLOW
BOILER WATER FLOW
6
Thermostat or Aquastat
3
1
46
2
2
9
8
5
7
10
2
2
11
11
Union
TO BOILER CONTROL
12.Boiler Pump
11
11
3
12
On the pool-side, the ow may be variable either due to
variable-speed pumps or changes in the pressure drop
through the ltration system. These variances can be
accommodated by installing a 2 lb. spring-loaded check
valve in the bypass line along with a manual valve (see
Figure 2 for details).
On model sizes 045 to 495, the check valve will control
bypass ow by directing all ow through the exchanger
under low-ow conditions, and avoiding excessive ow
through the heat exchanger under high-ow conditions.
On 995 models the 2 lb. check valve does not provide
enough resistance to direct adequate ow through the
heat exchanger, and must be augmented by using the
manual valve to throttle ow to provide approximately 6
to 15 ft. of head across the 995 exchanger.
Controls
The Indirect Pool Heater must be installed with
temperature and ow controls to protect the heat
exchanger and control water temperature supplied to
the pool or spa. The return from the pool/spa must
be controlled at the inlet to the Indirect Pool Heater
by a thermostat set to the desired temperature for the
pool/spa, with the maximum recommended operating
temperature of 104°F (40°C) . A second temperature
control must be installed in the outlet piping of the Indirect
Pool Heater to limit pool/spa supply temperatures to
140°F (60°C) maximum. In addition to the temperature
controls, a ow switch should be installed in the pool/
spa supply line to prove adequate ow through the heat
exchanger. All three of these controls must be satised
to provide a call for heat to the heat source.
Chemical feeders or salt
water generators
The pool chemical feeder or salt water generator
(with Titanium exchangers only) must be installed
after (downstream of) the Indirect Pool Heater and
be installed with an anti-siphoning valve to prevent
chemicals from backing up into the Indirect Pool Heater.
During periods of high or uctuating chemical levels, the
Indirect Pool Heater must be isolated from the system
by closing the isolation valves, protecting the unit from
chemical damage.
CAUTION: Operating control, high limit and flow
switch are NOT part of the Indirect Pool Heater.
These items must be supplied separately.
Figure 2. Connection Diagram

9
LIMITED WARRANTY
RAYPAK INDIRECT POOL HEATERS
Models: RP-045, RP-075, RP-125, RP-185, RP-245, RP-305, RP-495, RP-995,
B Ti-180, B Ti-300, B Ti-500
SCOPE OF WARRANTY
EFFECTIVE DATE
APPLICABLE WARRANTY PERIOD
LABOR AND SHIPPING COSTS
WARRANTY EXCLUSIONS
This Limited Warranty doesNOT apply;
1. if the product has been moved from its original place of installation, or if the original
owner no longer owns the property where the original installation was made;
2. if the product is not properly installed with a pool or spa by a qualified licensed installer in
accordance with applicable local codes and ordinances, good trade practices, and the
manufacturer’s installation instructions;
3. if the rating plate(s) or serial number(s) are altered or removed;
4. if the product is modified in any way, or non-factory authorized accessories or other
components are used in conjunction with the product;
Raypak, Inc. (Raypak) warrants to the original owner that the above model HEATER, when
installed in the contiguous 48 states with a pool or spa by a properly licensed installer will be free
from defects in materials and workmanship under normal use and service for the Applicable
Warranty Period. In accordance with the terms of this Limited Warranty, Raypak will, at its option,
repair or furnish a replacement for any defective part of the HEATER if it fails in normal use and
service during the Applicable Warranty Period. The repair or replacement will be warranted for
only the unexpired portion of the original Applicable Warranty Period.
The Effective Date of this Limited Warranty is the date of original installation if properly
documented; if you are not able to provide documentary proof of the date of original installation,
the Effective Date will be the date of manufacture plus 30 days.
If the HEATER is installed with a pool or spa, the Applicable Warranty Period is one (1) year from
the Effective Date, parts and labor, for the HEATER and component parts.
This Limited Warranty covers the normal cost of Raypak authorized labor repairs or replacements
covered by this Limited Warranty which are performed by a Raypak designated service provider
during the Applicable Warranty Period. Do not attempt to repair or replace any in-warranty
product or component part(s) without prior authorization from Raypak. This Limited Warranty
does not cover any travel time or other labor costs. This Limited Warranty does not cover any
shipping costs to and from Raypak's designated service provider or to and from the installation
site. All of the foregoing costs and expenses are your responsibility.
5. to conditions including damage, malfunctions or failures resulting from failure to properly
install, operate or maintain the product in accordance with the manufacturer's
instructions;
6. to conditions including damage, malfunctions or failures from abuse, act of nature,
accident, fire, flood, freeze, lightning or the like;
7. to conditions including damage, malfunctions or failures resulting from or due to
connected system control devices;
8. to conditions including performance problems caused by improper sizing of the heater;
9. to conditions including damage, malfunctions or failures resulting from any alteration,
including the use of any attachment, including any energy saving device, not authorized
by the manufacturer;

10
HOW TO MAKE A WARRANTY CLAIM
EXCLUSIVE WARRANTY-LIMITATION OF LIABILITY
.
DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR POOL HEATER OR
BUSINESS RECORDS.
rellatsnIfoemaNrenwOfoemaN
sserddAsrellatsnIsserddAsrenwO
rellatsnIforebmuNenohpeleTnoitallatsnIretaeHlooPfoetaD
Model Number of Your Pool Heater Serial Number of Your Pool Heater
10. to conditions including damage, malfunctions or failures from misuse or neglect, including
but not limited to, freeze-ups, having flow restrictions or obstructions between the heater
outlet and the pool/spa, or not maintaining a proper chemical balance (PH level must be
between 7.3 and 7.8 and total alkalinity between 80 and 150 PPM. Total dissolved solids (TDS)
must be no greater than 1000 PPM, or 3000 PPM for CR Super Alloy models).
You should immediately notify your dealer and provide proof of purchase, model number, serial
number and date of installation. Your dealer will contact the factory for instructions regarding the
claim and to determine the location of the nearest authorized service center. If the dealer is not
available please contact warranty service at 805-278-5300, supplying model number, serial
number, date of original installation and a description of the problem. Proper authorization
MUST be obtained PRIOR to any repairs for this Limited Warranty to apply. This Limited
Warranty is VOID if the product is repaired or altered in any way by ANY persons or
agencies other than those authorized by Raypak. Raypak reserves the right at all times to
inspect, or require the return of, the defective product or component part and to verify warranty
coverage at its factory.
The Limited Warranty is the only warranty for this product and its component parts given by
Raypak. No one is authorized to make any other warranties on Raypak's behalf. ANY IMPLIED
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS
SPECIFIED IN THIS LIMITED WARRANTY. RAYPAK'S SOLE LIABILITY WITH RESPECT TO
ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. IT IS AGREED
THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS LIMITED WARRANTY
OR IN CONTRACT, TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECIAL,
INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING NO LIABILITY FOR DAMAGE
FROM WATER LEAKAGE) WHICH ARE EXPRESSLY EXCLUDED, NOTWITHSTANDING
ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY. Some states do not
allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
We suggest you immediately record the model and serial number and date of original installation
and retain this Limited Warranty Certificate along with your original proof of purchase and date of
installation/start-up in the event warranty service is needed.
RAYPAK, INC., 2151 Eastman Avenue, Oxnard, CA 93030· [phone] FAX [phone] www.raypak.com

ISO 9001
REGISTERED QUALITY MANAGEMENT SYSTEM
www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]
Litho in U.S.A.