Raypak RP-045 User manual

IN TALLATION IN TRUCTION
Catalog No. 6300.50 Effective: 07-28-10 Replaces: NEW P/N 241399 Rev. 1
Model eries
RP-045 through RP-995 and
CR24-185 through CR24-495
Raypak
Indirect
Pool
Heaters
NOTE: The instructions in this manual are for the use of qualified 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 qualified shall not attempt to install,
service, or maintain this equipment.
This manual should be maintained in legible condition and kept adjacent to the heat source or in a safe place
for future use.

Water Chemistry
(Corrosive water voids all warranties)
For your health and the rotection of your ool equi ment, 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 pas Other Pool & pa Types
Water Temp. (Deg. F) 68 to 88 89 to 104 68 to 104
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
alt (PPM)
RP 316L 1000 MAXIMUM 1000 MAXIMUM 1000 MAXIMUM
CR uper
Alloy 6000 MAXIMUM** 6000 MAXIMUM** 6000 MAXIMUM**
Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3
Total
Dissolved
olids (PPM)
RP 316L 1000 MAXIMUM 1000 MAXIMUM 1000 MAXIMUM
CR uper
Alloy 3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM
Metals (PPM) 0 0 0
*Free Chlorine MU T 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 level 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.
2
** CR uperalloy can tolerate higher salt levels, and is even seawater resistant, but salt levels above 6000
PPM may cause damage to other components of the pool system, pool equipment or hardware.

3
Elevated water temperature can be hazardous. The
U. . Consumer Product afety Commission has these
guidelines:
1. pa water temperatures should never exceed
104°F (40°C). A temperature of 100°F (38°C) is
considered safe for a healthy adult. pecial 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! oaking 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.
CAUTION
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, cir-
culatory problems, diabetes, or blood pressure
problems should seek a physician's advice before
using pools or hot tubs.
6. Persons taking medications which induce drowsi-
ness, 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.

4
Model Nominal*
Capacity Diameter Overall Length
Boiler
Connection
Pool
Connection
SS316L CR24**
Super Alloy BTU/hr Inches Inches NPT NPT
RP-045 45,000 3.15 10.5 3/4” 1”
RP-075 75,000 3.15 13.5 3/4” 1-1/2”
RP-125 125,000 3.15 15.5 3/4” 1-1/2”
RP-185 CR24-185 185,000 4.0 15.0 1” 1-1/2”
RP-245 245,000 4.0 20.2 1” 1-1/2”
RP-305 CR24-305 305,000 4.0 25.0 1” 1-1/2”
RP-495 CR24-495 495,000 4.0 43.0 1” 2”
RP-995 995,000 5.5 36.1 2” 2”
* Nominal values are based on 140 °F temperature differential between incoming heating and heated water.
** CR24 uper Alloy - 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 applica-
tions, from high chlorination to high salt content.
HEAT SOURCE
WATE R IN
POOL WATER OUT
HEAT SOURCE
WATER OUT
POOL WATER IN
Figure 1: Dimensions
Table 1: pecifications
SS316L CR24
Super Alloy
L
(in.)
A
(in.)
B
(in.)
C
(in.)
D
(in.)
F
(NPT)
G
(NPT)
RP-045 10.5 4.17 4.39 3.05 3.15 1” 3/4”
RP-075 13.5 4.17 6.89 3.35 3.15 1-1/2” 3/4”
RP-125 15.5 4.17 8.86 3.35 3.15 1-1/2” 3/4”
RP-185 CR24-185 15.0 5.04 7.60 3.74 4.0 1-1/2” 1”
RP-245 20.2 5.04 12.72 3.74 4.0 1-1/2” 1”
RP-305 CR24-305 25.0 5.04 17.40 3.74 4.0 1-1/2” 1”
RP-495 CR24-495 43.0 5.04 34.80 3.96 4.0 2” 1”
RP-995 36.1 6.57 26.63 4.72 5.5 2” 2”
Table 2: Physical Dimensions

5
Table 3: Design Ratings
Pressure Temperature
Tubeside 235 P I 406°F
Shellside 190 P I 406°F
Model Boiler
Flow
Boiler
Head Loss
Pool
Flow
Pool
Head Loss
Heating
urface
SS316L CR24
Super Alloy
GPM Feet GPM Feet Sq. Ft.
Min M x Min M x Min M x Min M x
RP-045 5 15 0.5 1.0 20 40 1.5 6.0 2.0
RP-075 10 20 1.0 2.5 20 50 1.5 7.0 2.8
RP-125 10 20 1.0 2.5 20 50 2.0 10.0 3.3
RP-185 CR24-185 20 30 1.0 2.0 20 50 1.5 9.5 4.9
RP-245 20 30 1.0 2.5 30 60 2.5 9.0 7.3
RP-305 CR24-305 20 35 1.5 4.0 30 60 1.5 6.0 9.4
RP-495 CR24-495 25 35 3.5 6.5 40 80 3.0 12.0 17.3
RP-995 50 100 4.0 13.0 70 120 5.5 15.0 23.7
Designed and fabricated to the
A ME B31.3 Process Piping Code
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 CR24 super alloy
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 refer-
ence only. The system must be designed and installed
by a qualified installer and all local, state, provincial
and national codes, laws, regulations and ordinances
must be followed.
Flow
For optimal heat transfer, counter flow should be uti-
lized, that is the supply water from the heat source
should flow in the opposite direction of the return water
from the pool/spa, as shown in the connection dia-
gram, Figure 2. ystems must be designed to provide
flow rates within the range provided in Table 4. Do not
exceed the published maximum flow rates. On the
heating side, desired flow rates can be accomplished
with the pump sizing and/or use of balancing valves.
Table 4: Flow & Pressure Drop pecifications

6
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 chlorine 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 flow may be variable either due to
variable speed pumps or changes in the pressure drop
through the filtration system. These variances can be
accommodated by installing a 2lb 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 con-
trol bypass flow by directing all flow through the
exchanger under low flow conditions, and avoiding
excessive flow through the heat exchanger under high
flow conditions. On 995 models the 2lb check valve
does not provide enough resistance to direct adequate
flow through the heat exchanger, and must be aug-
mented by using the manual valve to throttle flow to
provide approximately 6 to 15 ft of head across the
995 exchanger.
Controls
The Indirect Pool Heater must be installed with tem-
perature and flow 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. 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 maximum. In addition to the temperature con-
trols, a flow switch should be installed in the pool/spa
supply line to prove adequate flow through the heat
exchanger. All three of these controls must be satis-
fied to provide a call for heat to the heat source.
Chlorine feeders or salt water
generators
The chlorine feeder or salt water generator (with CR24
exchangers only) must be installed after (downstream
of) the Indirect Pool Heater and be installed with an
anti-siphoning valve to prevent chlorine from backing
up into the Indirect Pool Heater. During periods of high
or fluctuating chlorine levels the Indirect Pool Heater
must be isolated from the system by closing the isola-
tion 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.

7
LIMITED WARRANTY
RAYPAK INDIRECT POOL HEATERS
Models: RP-045, RP-075, RP-125, RP-185, RP-245, RP-305, RP-495, RP-995,
CR24-185, CR24-305 and CR24-495
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
bythe manufacturer;

8
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
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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