Raypak 130A User Manual

INSTALLATION & OPERATING

INSTRUCTIONS

CATALOG NO. 6100.59E Effective: 06-24-08 Replaces: 12-12-07 P/N 241255 Rev. 6

WARNING: If the information in 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.

Model 130A

Atmospheric
Above-Ground
Pool & Spa
Heater

2

Rev. 6 reflects the following: a formatting correction to the Clearances section on page 8.

WARNINGS 4

Pay Attention to These Terms 4

WATER CHEMISTRY 5

Automatic Chlorinators &
Chemical Feeders 5

SAFETY 6

Water Temperature Safety 6

INTRODUCTION 6

Ratings & Certifications 6
Model Identification 7
Specifications 7
Unpacking 7

INSTALLATION 8

Installation Codes 8
Clearances 8
Base Installation 8
Outdoor Installation 8
Indoor Installation 10
Combustion & Ventilation Air 10
Gas Connections 11
Water Connections 13
Electrical Connections 15
Control Adjustments—Millivolt 16
Wiring Diagrams 17
Post Start-Up Inspection 20
Cold Weather Operation 20

MAINTENANCE 21
SERVICE 21

Water Pressure Switch 21
Flame Roll-Out Safety Switch 22
High Limits 22
Pilot Safety—Millivolt Models 22
Burner Tray Removal 22
Gas Valve Removal 24
Main Burner & Orifice Removal 24
Igniter Removal & Cleaning (Electronic) 24
Ignition Control Fault Codes 24
Pilot Removal & Cleaning (Millivolt) 25
Heat Exchanger Removal 25
Tube Cleaning Procedure 25
De-sooting Procedure 25
Immersion Well Replacement— Millivolt 26
Replacement Parts 26

TROUBLESHOOTING 27

Mechanical 27
Electrical 28
General—Heater Will Not Fire 30
Electronic Control Logic
Flowchart 30

ILLUSTRATED PARTS LIST 31

CONTENTS

3

DANGER:

Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices 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.

DANGER: Failure to install the drafthood on indoor
installation and properly vent the heater to the
outdoors as outlined in the venting section of this
manual can result in unsafe operation of the heater.
To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the venting
section of this manual for more information regarding
vent system inspections.

WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
Do not handle, use, or store gasoline or other
flammable or combustible materials in the vicinity of
a heater.

WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the user's information manual provided with
this heater. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.

WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:

• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.

• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.

WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the

State of California to cause cancer, birth defects or
other reproductive harm.

CAUTION: Verify proper operation after servicing.

WARNINGS - Pay Attention to These Terms

4

WARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.

When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

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.

5

WATER CHEMISTRY

Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water chemistry according to Table A. If the mineral
content and dissolved solids in the water become too
high, scale forms inside the heat exchanger tubes,
reducing heater efficiency and damaging the heater. If
the pH drops below 7.2, this will cause corrosion of the
heat exchanger and severely damage the heater. Heat
exchanger damage resulting from chemical imbalance
is not covered by the 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.

• 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.

Automatic Chlorinators &
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 sanitizing chemicals
in the skimmer. High chemical concentrations will
result when the pump is not running (e.g. 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. See
Fig. 1.

NOTE: Corrosive water voids all warranties.

CAUTION: Free chlorine must not exceed 5 ppm

which can damage the heater and void the warranty.

NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
rapid corrosion to the heat exchanger. Such damage
is not covered under the warranty.

Recommended Level(s) Fiberglass Pools Fiberglass Spas

Other Pool and Spa

Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

Total Alkalinity (ppm) 120-150 120-150 80-120

Calcium Hardness (ppm) 200-300 150-200 200-400

Salt (ppm) 6000 Maximum 6000 Maximum 6000 Maximum

Free Chlorine (ppm)* 2-3 2-3 2-3

Total Dissolved Solids

(ppm)

3000 Maximum 3000 Maximum 3000 Maximum

*Free Chlorine MUST NOT EXCEED 5 ppm!

Table A: Water Chemistry

6

Filter

Fig. 1: Pool/Chlorinator Setup

SAFETY

This appliance is to be installed and operated by
trained personnel in accordance with this Installation
and Operation Manual. Be sure to read and under­stand the entire Installation and Operation Manual
before attempting to install or operate this appliance.
Failure to follow the warnings listed at the beginning of
this manual could result in a fire or explosion, causing
property damage, bodily injury, or death.

Should you have any problems understanding the
warnings and instructions in this manual, STOP, and
get help from a qualified installer, service technician,
or the gas supplier.

Water Temperature Safety

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 may cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.

3. Pregnant Women Beware! Soaking in water over
102°F (39°C) may 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 obtain a physician's advice
before using spas or hot tubs.

6. Persons taking medications which induce drowsi­ness, such as tranquilizers, antihistamines,
anticoagulants, or recreational drugs should not
use spas or hot tubs.

INTRODUCTION

Ratings & Certifications

This pool & spa heater is design-certified and tested
under the latest requirements of ANSI Z21.56 / CSA

4.7 Standard for Gas-Fired Pool Heaters. The heater

can be used either indoors or outdoors. If necessary,
the top of the heater can be changed after installation
to accommodate indoors or outdoors.

Heater

Auto-Chlorinator

Check Valve

Pump

Skimmer

Pool

Check Valve

Return to Pool

7

WARNING: Use of any parts not manufactured
and/or approved by the manufacturer will void the
warranty.

Ambient Temperature Rating of
Components

• Millivolt heater +32°F to +175°F

• Electronic heater only -40°F to +175°F

Model Identification

The model identification number and heater serial
number are found on the heater rating plate.

The model identification number will be similar to
PR130A- EN-X, where:

• "EP" designates an Electronic heater using Propane
gas

• "EN" designates an Electronic heater using Natural
gas

• "MP" designates a Millivolt heater using Propane gas

• "MN" designates a Millivolt heater using Natural gas

• "P" prefix designates plastic (Polymer) headers

• "X" suffix designates Cupro-Nickel tubing

• "C" suffix designates Copper tubing

Heater
Rating
Plate

Fig. 2: Location of Heater Rating Plate

Specifications

Unpacking

On receipt of the heater it is suggested that visual
checks are made for external damage to the shipping
carton. If the carton is damaged, make a note to that
effect on the Bill of Lading when signing for the ship­ment. Remove the heater from the shipping
packaging. Report any damage to the carrier immedi­ately.

On occasion, items are shipped loose. Be sure that the
correct number of packages are received, as indicated
on the Bill of Lading.

Claims for shortages and damages must be filed with
the carrier by consignee. Authorization to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.

When ordering parts, specify the model and serial
number of the heater. When ordering under warranty
conditions, specify the date of installation. Records of
the installation must be provided, when requested, to
substantiate a claim.

Debits for defective replacement parts will not be
accepted and will only be replaced in kind per the
manufacturer's standard warranties.

Model

No.

Input

(BTUH)

Gas

Conn.

(NPT)

Water
Conn.

Shipping

Weight, Std.

Heater

w/Stackless

Top

130A 130,000 1/2 in.

1-1/2

in. or 2

in.

NPT

140 lbs.

Table B: 130A Specifications

8

INSTALLATION

Installation Codes

Installations must be in accordance with local, state,
provincial, and national codes, laws, regulations and
ordinances. In the absence of local codes, installations
must be in accordance with the latest editions of the:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, ANSI/NFPA 70

• For Canada only: CAN/CGA B149 installation Code
(B149) and CSA C22.1 C.E.C. Part 1 and Part 2

Clearances

The required minimum clearances from combustible
surfaces are shown in Table C below.

When installed according to the listed minimum clear­ances from combustible construction, the pool heater
can be serviced without removing permanent con­struction around the heater.

However for ease of servicing, we recommend a clear­ance of at least 24" in the front, and at least 18" on the
rear. This will enable the heater to be serviced in its
installed location, that is, without movement or
removal of the heater.

Heater Side

Outdoor

Installations

Indoor

Installations

Top* Unobstructed 42 in.

Front 6 in. Alcove

Vent N/A 6 in.

Back 12 in. 12 in.

Right Side 6 in. 6 in.

Left Side 6 in. 6 in.

*Clearance from top of vent terminal.

Table C: Required Minimum Clearances from

Combustible Surfaces.

Fig. 3: Alternate Method for Providing a Non-

Combustible Base

Clearances less than these 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.

Base Installation

Heater must be mounted on a level base, such as
cementable slab, cement blocks or another non-com-
bustible surface. An alternate method for providing a
base for combustible floors is illustrated. Heaters may
not be installed on carpeting.

Outdoor Installation

NOTE: This heater is design-certified for outdoor

installation when equipped with the approved top(s)
for outdoor use.

WARNING: The heater should 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 electrical components, and void the
warranty.

WARNING: Do not install within 3 feet of a heat
pump or an outdoor condensing unit. strong air
intake from this type of equipment can disturb the
combustion process and cause damage or personal
injury

NOTE: The heater should not be located in an area
where possible water leakage will result in damage
to the area adjacent to the heater or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, with
adequate drainage, be installed under the heater.
The pan must not restrict combustion air flow.

Minimum

12"

Minimum

4"

Minimum

HEATER

Sheet Metal

24 Gauge

Hollow concrete cinder block,
align holes and leave ends open.

12"

9

Fig. 4: 130A Dimensions

Heater with Outdoor Stackless Top

Heaters must not be installed under an overhang of
less than 3 ft from the top of the heater. Three sides
must be open in the area under the overhang. Roof
water drainage must be diverted away from 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 4 ft
below, 4 ft horizontally from, or 1 ft above any door,
window or gravity inlet into any building. The top sur­face of the heater shall be at least 3 ft above any
forced air inlet, or intake ducts located within 10 ft
horizontally. See Fig. 7

• For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10
ft below, or to either side, of any opening into the
building. Refer to the latest revisions of CAN/CGA­B149

Outdoor High-Wind Top

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 Fig. 5.

The outdoor stack serves the same function as the low
profile stackless top and should be installed in accor­dance with the same clearance requirements. Follow
the installation instructions provided with the High
Wind Kit for installation.

NOTE: The outdoor high-wind top is optional
equipment and does not come standard with the
heater. Use the following part numbers: P/N 004301
(Green), P/N 011558 (Gray)

Fig. 5: Outdoor High-Wind Top

HIGH-WIND
TOP

10

Indoor Installation

The heater is design-certified for indoor installation
when equipped with the approved drafthood.

Locate heater as close as is practical to a chimney or
gas vent. Heater must always be vented to the out­side. See Vent Piping section for details. Minimum
allowable space is shown on the nameplate. Follow
the installation instructions provided with the Indoor
Drafthood Kit for installation.

Indoor Drafthood

Combustion & Ventilation Air

(Indoor Units Only)

The heater must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are one opening that is 12 inches from the
ceiling for ventilation, and one opening that is 12 inch­es from the floor for combustion air as outlined in the
latest edition of the National Fuel Gas Code, ANSI
Z223.1(Canada-CAN/CGA-B149) and any local codes
that may have jurisdiction.

NOTE: For Canada, indoor installation is restricted
to an enclosure that is not occupied and does not
directly communicate with an occupied area. Refer
to the latest edition of CAN/CGA-B149 for specific
requirements.

Fig. 6: Indoor Drafthood

NOTE: The indoor drafthood is optional equipment
and does not come standard with the heater. Use the
following part number: P/N 003723.

All Air From Inside the Building

Each opening shall have a minimum net free area of
130 sq. in.

All Air From Outdoors

When air is supplied directly from outside of building,
each opening shall have a minimum net free area of
33 sq. in.

Vent Piping

Vent piping the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least 10 ft (drafthood relief opening to vent terminal),
the vent pipe size may be reduced as specified in the
National Fuel Gas Code, ANSI Z223.1 (Canada ­CAN/CGA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows.

If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 in. per ft 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 recom­mend use of insulated vent pipe spacers through the
roof and walls.

For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which com­plies with local codes or, in the absence of such codes,
the latest edition of the National Fuel Gas Code, ANSI
Z223.1 (Canada - CAN/CGA-B149).

The discharge opening must be a minimum of 2 ft ver­tically from the roof surface and at least 2 ft higher than
any part of the building within 10 ft. Vent stack shall be
at least 5 ft in vertical height above the drafthood out­let. The vent cap location shall have a minimum
clearance of 4 ft horizontally from, and in no case
below, unless a 4 ft horizontal distance is maintained,
from electric meters, gas meters, regulators and relief
equipment.

CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. Do
not store chlorine, bromine, baquasil or acid in the
same room as the heater.

Indoor
Drafthood

11

4 ft

Fig. 7: Outdoor Installation Clearances

Fig. 8: Vent Piping Requirements

The weight of the vent stack or chimney must not rest
on heater drafthood. Support must be provided in
compliance with applicable codes. The heater top and
drafthood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup­ported to maintain proper clearances from combustible
construction.

Type "B" double-wall or equivalent vent pipe is recom­mended. However single-wall metal vent pipe may be
used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1 (Canada - CAN/CGA­B149).

Gas Connections

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 accordance with local codes.

CAUTION: Do not use 5, 10 or 20 gallon propane
tanks, like those used with consumer bar-b-ques, to
supply gas to this heater.

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 (3.5 kPa). 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.

Minimum

3 ft

Minimum

Forced Air Inlet

Minimum

10 ft

Minimum

4 ft

4 ft

Minimum

1 ft

Minimum