Raypak 105B User Manual

OPERATING AND
INSTALLATION
INSTRUCTIONS

Model

105B Cast Iron

VERSA

ABOVE GROUND POOL
and

CATALOG NO. 6100.60A
Effective: 10-1-99
Replaces: 6-15-99

SPA HEATER

Fig. # 9258

WARNING: If the information in these instructions are not followed exactly, a fire or explosion
may result causing property damage, personal injury or death. Installation and service must
be performed by a qualified installer, service agency or the gas supplier.

FOR YOUR SAFETY

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.

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. 240776

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
8 Clearances
9 Combustion Air
10 Venting Connections
12 Gas Supply Connections
13 Plumbing for Water Connections
14 Electrical Wiring

18 SECTION 4 / SERVICING INSTRUCTIONS

18 General Location of Controls
18 Control Adjustments / Replacements
18 Pressure Switch
19 High Limit
19 Pilot Safety
20 Burner Drawer Removal
20 Gas Valve Removal
20 Main Burner & Orifice Removal
20 Pilot Removal & Cleaning
20 Heat Exchanger Removal
21 Tube Cleaning Procedure
21 Tube Replacement Procedure
21 Desooting Procedure
21 Combustion Chamber Removal

22 SECTION 5 / TROUBLESHOOTING GUIDE

22 Mechanical
23 Electrical MV Units
24 Electrical IID Units

25 SECTION 6 / REPLACEMENT PARTS

1

PART ONE - OWNER'S OPERA TING 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. #9258

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

*If you cannot reach your gas supplier, call the
fire department.

instructions exactly.

C. Use only your hand to push in or turn the gas

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.

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 right side panel 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. Turn gas control knob clockwise to "Off".

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".

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.

*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
INLET

HONEYWELL VR8300 GAS VALVE IID

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. Turn gas control knob clockwise to "Off".
Make sure knob rest against stop.

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 supply
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

MAIN BURNER FLAME

Fig. # 8144.1

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!

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 pres­sure problems should obtain 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.

Soaking in water over

Fig. # 8958

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:

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.

Soot may be combustible. Wet sooted

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
corrosive chemical fumes which can damage the
heater.

6. Keep area around heater clear and free from

combustible materials 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, the gauge pressure
will be higher than usual).

6. The pump amy 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.

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.

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
electrical supply to the heater.

2. Open drain cock located on the inlet/outlet
header, (under water pipes). Remove
drain changer inspection panels on the side
opposite water piping to gain access to the
plug on the return header.

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.

Fig. # 9249

DRAIN COCK IN/OUT

HEADER

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

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

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:

tion, service or maintenance may damage the equip­ment, create a hazard resulting in asphyxiation, explo­sion or fire, and will void the warranty.

CODE REQUIREMENTS

NOTE:

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.

BASE INSTALLATION

Heater must be mounted on a level surface. It can
be installed on combustible flooring. Heaters must not
be installed on carpeting.

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.

Improper installation, adjustment, altera-

The heater should not be located in an area

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.

7

CLEARANCES

ALL HEATERS

For clearances from combustible surfaces, see

chart below.
Clearances from Combustible construction.

Indoor Installation:

Top* (Drafthood) - 30"; Vent - 6";

Back - 5"; Right Side - 6";

Left Side - 6"; Floor - 0.

Outdoor Installation:

Top* (Stackless Top) -

unobstructed; Back - 5"; Sides - 6".
* Clearance from Top of Vent Terminal

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
exchanger.

OUTDOOR HEATERS

These heaters are designed certified by A.G.A. for
outdoor installation, when equipped with the approved
top designated for outdoor use.

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.

Heater with outdoor top Fig # 9259

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:

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.

4'
Min

4'
Min

4' Min

1' Min

3' Min

Fig. # 8245.0

10'
Min

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.

In areas of daily high winds, it may be necessary to
replace the outdoor stackless top with a stack adapter in
combination with a wind resistant/weather proof outdoor
stack. See illustration below.

The outdoor stack serves the same function as the
low profile stackless top and should be installed in
accordance with the same clearance requirements.

OUTDOOR STACK

STACK ADAPTER

INDOOR HEATERS

The design is certified by A.G.A. for indoor installa­tion when equipped with the approved draft hood.
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.

INDOOR TOP

Fig # 9253

Fig # 9254

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
and any local codes that may have jurisdiction.

CAUTION:

by corrosive chemical fumes which can damage the
heater.

a. All Air From Inside The Building:

Each opening shall have a minimum of 105 net free

square inches.

Combustion air must not be contaminated

b. All Air From Outdoors:

When air is supplied directly from outside of

building, each opening shall have a minimum of 27

net free square inches.

9