Raypak 055B User Manual
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models
055B
VERSA
SPA
and
HOT TUB HEATER
CATALOG NO. 6100.52-K
Effective: 3-01-00
Replaces: 3-15-99
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
— 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 kept in a safe place for future reference.
®
Part No. 240428
Contents
2 PART ONE - Owner's Operating Instructions
2 SECTION 1 / START-UP PROCEDURES
2 Before Start-Up
3 Lighting Instructions & Shut-Off Procedures
(manually lighted pilot MV)
4 Operating Instructions & Shut-Off Procedures
(automatically lighted pilot IID)
5 After Start-Up
5 SECTION 2 / CAUTION
5 SECTION 3 / MAINTENANCE & CARE PROCEDURES
6 Pool & Spa Water Chemistry
6 Winterizing the Pool and Spa Heater
7 PART TWO - Installation / Service Instructions
7 SECTION 1 / RECEIVING EQUIPMENT
7 SECTION 2/GENERAL SPECIFICATIONS
7 SECTION 3 / INSTALLATION INSTRUCTIONS
7 Code Requirements
7 Base Installation
7 Clearances
9 Combustion Air
9 Venting Connections
11 Gas Supply Connections
12 Plumbing for Water Connections
13 Electrical Wiring
17 SECTION 4 / SERVICING INSTRUCTIONS
17 General Location of Controls
17 Control Adjustments / Replacements
18 Pressure Switch
18 Flame Roll-Out Safety Switch
18 High Limit
18 High Limit Removal
18 Pilot Safety
19 Burner Drawer Removal
19 Gas Valve
19 Main Burner & Orifice
19 Pilot Removal & Cleaning
19 Heat Exchanger Removal
20 Desooting Procedure
20 Combustion Chamber Removal
20 Control Immersion Well Replacement
20 Unitherm Governor Replacement
21 SECTION 5 / TROUBLESHOOTING GUIDE
21 Mechanical
22 Electrical MV Units
24 Electrical IID Units
26 SECTION 6 / REPLACEMENT PARTS
1
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.
SECTION 1 / START-UP PROCEDURES
BEFORE START-UP
BURNERS
Clean main burners 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.
WATER
First thing, insure that system is filled with water
and have pump operating. Water must be flowing
through the heater during operation.
Fig. #8139s
2
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.
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
( MILLIVOLT SYSTEM)
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 appli-
ance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle on the floor.
*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 explosion.
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 neigh bor's phone. Follow the gas supplier's instruc tions.
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 left side of the
burner drawer. For burner drawer location,
see location of control section, page 18.
Gas control knobs shown in "Off" position
HONEYWELL
GAS VALVE
MILLIVOLT
Fig. #8081.0
ROBERTSHAW
GAS VALVE
MILLIVOLT
Fig. # 8199
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
D. Do not use this appliance if any part has been
underwater. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas
control which has been under water.
ROBERTSHAW PILOT
Fig. #8084.0 Fig. #8083.0
HONEYWELL PILOT
8. Turn knob on gas control counter-clockwise
to "Pilot".
9. Push in control knob all the way and hold in.
Immediately place flame to pilot to light.
Continue to hold control knob in for about 1
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.
*If the pilot does not stay lit after several tries,
turn the gas control knob to "Off" and 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.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
3
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.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
(ELECTRONIC IGNITION SYSTEMS)
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
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. Push in gas control knob slightly and turn clockwise to "Off".
Knob cannot be turned to "Off" unless it is
pushed in slightly. Do not force.
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.
Gas control lever shown in the "On" position.
8. Turn gas control knob counterclockwise
to "On".
*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 fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas
control which has been under water.
Gas control knob shown in "ON" position.
GAS VALVE-IID
Fig. # 8112
9. Replace heater door panel.
10. Turn on all electrical power to 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. Push in gas control knob slightly and turn
clockwise to "Off".
5. Replace heater door panel.
4
AFTER START-UP
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
SECTION 2 / CAUTION
Elevated water temperature can be hazardous,
and the U.S. Consumer Product Safety Commission
recommends the following guidelines:
WARNING: Should overheating occur or the gas sup-
ply fail to shut off, turn off the manual gas control valve
to the appliance.
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. # 8144.0
MAIN BURNER FLAME
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 subse-
quently 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
four degrees Fahrenheit (2.2°C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pres
sure problems should obtain a physician's
advice before using pools or hot tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihista
mines, or anticoagulants, should not use spas or
hot tubs.
PILOT BURNER FLAME
A yellow or "floating" flame indicates restricted air
openings 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.)
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
SECTION 3 / MAINTENANCE
AND CARE PROCEDURES
To be followed one month after start-up and then
semi-annually.
1. Inspect top of heater and draft hood for soot, (a
sticky black substance around finned tubes,
baffle and open flue gas passageways).
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.
5
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is
indicated 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.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
6. Keep area around heater clear and free from
combustible materials and other flammable and
corrosive vapors and liquids.
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.
COLD WEATHER OPERATION
MODERATE CLIMATE: Heater operation can con-
tinue during short term cold spells. When temperatures are below freezing, flow (continuous pump operation) must be maintained.
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, the gauge pressure
will be higher than usual).
6. The pump may have lost it's prime. It may be
running dry, check the pressure gauge 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.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze protection. When heaters are 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
temperatures below 50°F is not recommended. When
starting the heater with pool temperatures below 50°F,
operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged
periods with pool water below 50° can seriously damage the heater, and is not covered by the warranty.
For cold climate areas please follow the winterizing
procedures listed below.
WINTERIZING THE SPA HEATER
When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe
the following step-by-step procedure:
1. Turn off gas valve, manual gas valve, and electri-
cal supply to the heater.
2. Open drain cock located on the return header.
3. Disconnect compression fittings from the pressure
switch and header that connect to the 1/4"
copper tube and allow the tube to drain.
6
PART 2 - INSTALLATION / SERVICE INSTRUCTIONS
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.
On occasion, we ship some items loose. 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 SPECIFICATION
These heaters are design certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard / CSA standards for gas-fired pool
heaters
The heater is interchangeable 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 heaters contain 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
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. For Canada, reduce input
10% when installed at 2000-4500 foot elevation.
SECTION 3 / INSTALLATION
INSTRUCTIONS
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
licensed. 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.
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.
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 recommended 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 editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70. For Canada,
the latest edition of CAN/CGA B-149.1 and B-149.2
BASE INSTALLATION
Heater must be mounted on a level surface. It can
be installed on combustible flooring. Heaters may not
be installed on carpeting.
CLEARANCES
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 heavy internal rusting or
damage some electrical components and this would void
the warranty.
7
ALL HEATERS
For clearances from combustible surfaces, see
chart below.
OUTDOOR HEATERS
These heaters are design certified for outdoor
installation, when equipped with the approved top designated for outdoor use.
Clearances from Combustible construction.
Indoor Installation:
Top* (Drafthood) - 35"; Vent - 6";
Heater with
outdoor Top
Back - 2"; Right Side - 6";
Left Side - 6"; Floor - 0.
Outdoor Installation:
Top* (Stackless Top) unobstructed; Back - 2"; Sides - 6".
* Clearance from Top of Vent Terminal
Fig. # 8139
WARNING: Do not install within 3 feet of a Heat Pump
For servicing, provide at least 24" in front of the
heater for burner tray removal, and at least 18" on the
left side of the heater to inspect and delime the heat
or an outdoor condensing unit. Strong air intake from
these equipment can disturb the combustion process
and cause damage or personal injury.
exchanger.
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 to a 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.
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 revision of CAN/CGA-B149.1 and B149.2.
Minimum
Forced Air Inlet
U.S. Installation Only
4
foot
Minimum
4
foot
Minimum
4
foot
Minimum
3
foot
1
10
foot
Minimum
foot
Minimum
Fig # 8245.1
8
HIGH WIND CONDITIONS (OUTDOOR UNITS ONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 3' from
high vertical walls, or install a wind break so the heater
is not in direct wind current.
INDOOR HEATERS
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.
Heater with
Indoor Top
VENTING CONNECTIONS
VENT TERMINAL (Outdoor)
STEP 1: Remove the (4) screws which fasten
jacket top to heater.
STEP 2: Lower outdoor top onto unit lining up
slots in outdoor top with screw holes in
jacket top.
STEP 3: Reinstall (4) screws to secure jacket top
and outdoor top to unit.
Outdoor Top
Jacket Top
Fig. # 8138
COMBUSTION AIR (INDOOR UNITS ONLY)
Air For combustion And Ventilation
(Indoor Units Only)
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,
Z223.1(Canada-CAN/CGA-B149.1 and B149.2) and
any local codes that may have jurisdiction.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
a. All Air From Inside The Building:
Each opening shall have a minimum of 50 net free
square inches.
b. All Air From Outdoors:
When air is supplied directly from outside of
building, each opening shall have a minimum of 13
net free square inches.
Fig. # 8137
VENT TERMINAL (Indoor)
Locate and assemble as shown. Secure with
screws supplied in envelope inside carton.
Draft Hood
Mounting
Screws
Fig. # 8143
9
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