Raypak P0280A-N, P0200A-N, P0350A-N, P0430A-N, P0131PCO/OD Owner's Manual
...
Models
Natural Gas
Propane
Residential Pool & Spa
Heater Models:
P0131NCO/OD
P0131PCO/OD
P0200A-N
P0200A-P
P0280A-N
P0280A-P
P0350A-N
P0350A-P
P0430A-N
P0430A-P
Premium Pool & Spa
Heater Models:
P0127NNO
P0127PNO
PC0280A-N
PC0280A-P
PC0430A-N
PC0430A-P
Raypak Pool & Spa Gas Heaters
Owner’s Guide and Installation Instructions
Residential & Premium Range
Please read this manual prior to installing this product. It contains all the necessary technical and installation information
that will be required by the contractor to correctly install this system. This product must be installed in accordance with
the installation instructions and in compliance with standards AS5601 or AS/NZS 5601.1, AS/NZS 3500.4, AS/NZS
3000, the relevant electrical authorities’ requirements and all local codes and regulatory requirements.
Page 1 of 32
Date of installation:
Model No.
Serial No.
Installed by:
Purchased from:
CONTENTS
SAFETY ...................................................................................................................................................... 3
WATER TREATMENT ................................................................................................................................ 4
INSTALLATION INSTRUCTIONS ............................................................................................................... 5
PRECAUTIONS ................................ .......................................................................................................... 9
PERIODIC MAINTENANCE ...................................................................................................................... 10
COMMISSIONING .................................................................................................................................... 11
RESET BUTTON ...................................................................................................................................... 12
OPERATING INSTRUCTIONS.................................................................................................................. 14
PROGRAMMING OF POOL OR SPA HEATER CONTROLLER ............................................................... 16
ELECTRICAL CONNECTIONS ................................................................................................................. 18
DIMENSIONAL & TECHNICAL DATA ....................................................................................................... 19
WIRING DIAGRAMS ................................................................................................................................. 22
POOL HEATER OPERATION FLOW CHART ........................................................................................... 25
RHEEM WARRANTY (Australia Only) ....................................................................................................... 30
This Owners Guide and Installation Instructions manual is provided with the necessary information for the proper
installation, operation and maintenance of your Raypak pool or spa heater. Please review and follow these procedures
carefully. Keep this manual in a safe and accessible place for easy reference in the future.
Warning: Upon completion of the installation and commissioning, leave this guide with the householder
or responsible officer.
Page 2 of 32
SAFETY
For your safety do not operate this appliance before reading this instruction booklet!
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For assistance or
additional information consult your Raypak distributor, qualified installer, or Rheem® Service agent.
For your own safety only have this appliance installed by a qualified gas fitter who must issue you with a compliance certificate
when complete. Persons taking medications which induce drowsiness should not use spas. Persons with a medical history of heart
disease circulatory or blood pressure problems, or diabetes should obtain their Doctor’s advice prior to using a spa.
WARNINGS
This pool heater is only intended to be operated by persons who have the experience or the knowledge and the capabilities
to do so.
This pool heater is not intended to be operated by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge. Children should be supervised to ensure they do not interfere with the
pool heater.
The pool heater uses 240 Volt AC electrical power for operation of the control systems. The removal of the access cover(s)
will expose 240 V wiring. They must only be removed by an authorised or qualified person.
DO NOT modify this pool heater.
DO NOT use or store flammable materials in or near this pool heater.
Flammable liquids (such as petrol), combustible materials (such as newspapers)
and similar articles must be kept well away from the pool heater and the draught
diverter or flue terminal.
DO NOT spray aerosols in the vicinity of the pool heater whilst it is operating.
Gases from some aerosol sprays corrosive when drawn into a flame.
DO NOT store swimming pool chemicals, household cleaners, etc., near the
pool heater.
DO NOT place articles on or against this pool heater or in contact with the flue
terminal. Ensure the flue terminal is not obstructed in any way at any time.
DO NOT use Propane / Butane gas mixtures in a Propane model. A Propane
model is designed to operate on Propane only. The use of Propane / Butane
mixture, such as automotive LPG fuel, in a Propane model is unsafe and can
cause damage to the pool heater.
DO NOT operate with panels, covers or guards removed from the pool heater.
DO NOT enclose this pool heater (applies to external installations only).
DO NOT operate this appliance whilst a suction plate is fitted in the skimmer box for cleaning your pool. E.g.: With a vacuum
hose suction operated cleaning device
DO NOT use this appliance to heat water for drinking.
DO NOT enter water heated by this appliance without testing temperature first. Prolonged exposure to elevated water
temperatures may be hazardous to your health.
WHAT TO DO IF YOU SMELL GAS
DO NOT try to light this appliance.
DO NOT touch any electrical switch.
TURN OFF the gas supply at the meter immediately, contact a qualified gas fitter or Rheem Service.
NOTE: Some gases are heavier than air and it may be necessary to check for gas leaks at floor level.
Ceramic Fire tile refractory is used in this appliance. For a current Material Safety Data Sheet (MSDS) go to
www.morganthermalceramics.com/en-gb/datasheets/safety-datasheets/ and enter “MSDS 244” in the search. Ceramic Fire tile
refractory may produce smoke when the appliance is first started. Ensure area is well ventilated when lighting appliance. Avoid
breathing fumes.
Page 3 of 32
WATER TREATMENT
Fibreglass Pools
(less than 31C)
Fibreglass Spas
(more than 31C)
Other Pools &
Spas
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
200 - 300
200 - 400
Salt (PPM)
6,000 MAX
6,000 MAX
6,000 MAX
Free Chlorine (PPM)*
2 - 3
2 - 3
2 - 3
Langelier Saturation Index
±0.3
±0.3
±0.3
IMPORTANT! CORROSIVE WATER VOIDS YOUR WARRANTY
This pool or spa heater must be installed in accordance with this advice to be covered by Rheem’s warranty. This pool or spa
heater is manufactured to suit the water balance specified on the table below. However, there are some known water chemistries
which can have detrimental effects on the pool or spa heater and its operation and/or life expectancy. This pool or spa heater must
be installed in accordance with this advice to be covered by the Rheem warranty
For your health and the protection of your heater it is essential that your water quality is always chemically balanced. Only incorrect
water balance will cause your heat exchanger to corrode. After corrosion occurs, subsequent water chemical tests may not reveal
the water quality at the time that the damage occurred. Do not replace any corroded parts before bringing your water quality back
into balance. The following table provides a guide to good water balance:
* FREE CHLORINE MUST NOT EXCEED 4 PPM
* FREE BROMINE MUST NOT EXCEED 5 PPM
There are several factors that need to be considered in order to avoid damage to your heater.
Automatic chemical dosing devices and chlorinators are usually more efficient in heated water and/or covered pools/spas.
Unless controlled, they may lead to excessive chlorine levels which can damage your heater.
If the sanitising level in your pool/spa is too high, your test kit or that of your pool shop may not show the correct
chlorine/bromine concentration.
If your salt chlorinator operates for extended periods whilst the pool is being heated and the weather is overcast or your
pool is enclosed / covered, the chlorine may exceed the recommended levels.
The balance of your pool water depends on a combination of pH, total alkalinity, calcium hardness and temperature.
Combined, these factors enable the Langelier Saturation Index to be calculated. It is essential these factors are maintained
at the recommended levels so that the water is balanced and the sanitation of your pool will be optimal.
When adding acid to lower your pH, it must always be added in small quantities and spread uniformly over the entire pool
surface. DO NOT add acid one litre at a time. Instead, add a cupful each day. DO NOT add acid into the skimmer box.
This may potentially lead to corrosion of your heat exchanger. Refer to “Periodic Maintenance” on page 10.
Page 4 of 32
INSTALLATION INSTRUCTIONS
Warning: This appliance must be installed in accordance with all local state and federal laws including the regulations of any
government bodies and in complete accordance with these instructions. Where these instructions are contrary to the law or
regulations of an appropriate government body those laws or regulations should take precedence subject to there being no
compromise to safety.
BEFORE YOU COMMENCE INSTALLATION
1. Read these instructions in full.
2. Check that the pool or spa heater you have been supplied is suitable for the gas type that is available.
3. Ensure that your gas fitter checks that the gas supply pressure is between the minimum and maximum specified on the heater
data plate.
4. Confirm that the heater you have purchased is suitable for the location it is to be installed, i.e. Outdoor or Indoor.
5. Check that your pool system pump will provide water flow between the specified minimum and maximum flow rates required for
the heater to operate.
6. Remove packaging and timber base before installation.
7. Complete all details on the back page of this book.
PRODUCT APPLICATIONS
Raypak “Residential” pool & spa heaters are designed and built for installation in applications where the intention of its use is to heat
a pool or spa of a single family dwelling. Its use in an application other than this may shorten its life. Residential heaters are not
intended for installation in commercial applications such as multi residential apartments. For these applications a Raypak
“Commercial” pool or spa heater (also referred to as “Premium”) pool or spa heater should be selected.
See WARRANTY & SERVICE section in this book for details of the different Rheem warranties dependent on the heater type and
its intended application.
HEATER LOCATION
The heater must be located so that any possible water leaks will not damage adjacent areas or structures. When such locations
cannot be avoided it is recommended that a suitable safe tray be constructed and installed by your plumber. This must not restrict
air required for combustion.
The heater must be located on a level non-combustible surface such as concrete. All packaging must be removed before installation.
OUTDOOR HEATERS
Raypak pool & spa heaters are built for outdoor installations as standard. The installation must conform to AS5601 OR AS/NZS
5601.1 as a minimum. They must not be installed in any enclosed structure or under eaves, roof overhangs, or pool decks. Outdoor
pool & spa heaters must be installed at least 1500mm from any window or room ventilation opening. They must also have no
obstructions above the appliance.
If installing the heater on a raised base, the base must be non-combustible and contain no air openings or perforations. Drafts from
below the heater can affect its operation.
High Wind Areas
Raypak pool & spa heaters are atmospherically vented and so may not function correctly in areas of sudden changing air pressure
often caused by high or variable wind speeds. In some instances, it may be necessary to install either a Raypak High Wind Top or
a Raypak Induced Draft Fan to ensure correct operation. These options should be discussed with Rheem before installation.
In areas of "constant extreme winds" or in areas where high winds frequently occur, it is necessary to locate the heater a minimum
of one (1) metre from high vertical walls, or install a wind break so that the heater is not positioned and exposed in the direction of
the prevailing winds.
INDOOR HEATERS
Combustion / Ventilation Air
Indoor pool & spa heaters must only be installed in a protective enclosure or properly constructed room, with ventilation in accordance
with AS5601 OR AS/NZS 5601.1. Ventilation must be provided via two permanent openings, one at ceiling level and one at floor
level. Minimum vent area must be in accordance with AS5601 OR AS/NZS 5601.1. Minimum opening dimensions in the vent must
be at least 6mm.
For indoor applications the pool or spa heater must have at least the minimum clearances specified in the table below on page 6.
Increased clearances should be provided where possible to improve serviceability. If the pool or spa heater is not installed in
accordance with the sufficient and safe space for ease of service around the unit, Rheem advises that the pool or spa heater will be
disconnected and removed to enable servicing.
Page 5 of 32
Note: The following table details minimum acceptable clearances (mm) for serviceability and for indoor installations on non-
Rear
Front
Water
Side
Non-Water
Side
Above
Non-Combustible Surfaces
150
750
600
150
1200
Combustible Surfaces
500
750
600
500
1200
Rear
Front
Left
Right
Above
Non-Combustible Surfaces
300
750
300
300
1200
Combustible Surfaces
500
750
500
500
1200
combustible floors only:
Models P0127, P0200, P0280, P0350, P0430, PC0280, PC0430
Models P0131*
*Model 131 suitable for outdoor installations only.
Note: For outdoor installation clearances please refer to AS/NZS5601.1:2013
Air supply to the room must not be affected by mechanical exhausts of other equipment such as bathroom or kitchen fans, spa
blowers or air-conditioning equipment, etc.
FLUEING
Flueing must be in accordance with AS5601 OR AS/NZS 5601.1.
Only the correctly-sized Raypak draft diverter must be fixed to the
heater and connected to a properly constructed flue, vented to
atmosphere using approved fittings and cowl. Alteration to the
Raypak draft hood or reduction in cross section of connected
flueing will void the Rheem warranty.
Where standard flueing options cannot be implemented Rheem
should be contacted for flueing advice.
Additional ductwork connected to the Raypak draft hood must be
self-supporting and allow the removal of the Raypak pool or spa
heater and draft hood without removal of the flue. The flue system
beyond the Raypak draft hood must in no circumstances be
supported by the heater.
Where practical, the flue should be run vertically. Lateral flueing is
allowed but must rise a minimum of 20mm per 1m of lateral run
and the total lateral run must not exceed 50% of the total flue
height.
for this appliance.
Indoor Hood Conversion
To convert Model P0200 to P0430 and PC0280 to PC0430 heaters from outdoor configuration to indoor:
1. Remove all screws from the appliance top panel and discard sheet metal.
2. Fit the indoor flue “stack adaptor” supplied with the indoor conversion kit to the flue collector and screw in position.
3. Fit the “draft diverter” over the indoor flue “stack adaptor” spigot.
4. Ensure that all connections are secure and will not allow products of combustion to escape into the room.
To convert Model P0127 heaters from outdoor configuration to indoor:
1. Remove all 4 screws on the supports for the appliance’s top hood and discard hood.
2. Fit the indoor “draft diverter” to the flue collector and screw in position.
3. Ensure that all connections are secure and will not allow products of combustion to escape into the room.
WARNING! Do not use an unlined masonry chimney as the flue
Page 6 of 32
GAS SUPPLY
The gas supply pipe and gas meter must be sized so that both are capable of providing sufficient gas for all gas appliances on the
site to operate at the same time. Insufficient gas supply will cause the heater to operate below its designed performance or not at all.
Correct pipe sizing for the gas fitting line should be obtained from AS5601 OR AS/NZS 5601.1. During commissioning of the heater
the burner pressure must be adjusted by the gas fitter to conform to the specifications provided on the Raypak pool or spa heater
rating label - located on the left hand side of the heater (refer to “. The heater and its gas line must be fully leak-tested prior to normal
operation.
Note: It is more important than ever that when installing a new gas pool or spa heater, the commissioning must be carried out by a
qualified plumber. Gas supply companies are increasingly supplying natural gas to new installations with 2.75kPa. This means if
the gas pressure is not adjusted to the correct working pressure (see rating label) the heater will be over gassed and cause serious
damage within minutes. This damage is not covered under the Rheem Warranty.
Warning: Excessive Gas Pressure will damage the gas valve and void the Rheem warranty.
HOW LONG WILL THE POOL & SPA HEATER LAST
Your pool & spa heater is supported by a manufacturer’s warranty (refer page 28 & 29). There are a number of factors that will
affect the length of service the pool or spa heater will provide. These include but are not limited to the water chemistry, the water
flow rate, service & maintenance program and usage pattern. Refer to Precautions on page 9 and Periodic Maintenance on page
10.
Page 7 of 32
Page 8 of 32
PRECAUTIONS
Warning: Ceramic fire tile refractories are used in Raypak pool and spa heaters. Refractories must be treated with care because
they can be harmful by inhalation and irritating to the skin, eyes and respiratory system.
DURING FIRST FIRING OF THE WATER HEATER
Fumes and smoke may be produced.
Avoid breathing fumes and ventilate the area to clear.
Production of smoke should cease within 30 minutes.
WHEN HANDLING
Minimise airborne dust.
Wear an approved mask or respirator.
Avoid any contact with the skin and eyes.
Wear suitable loose-fitting, long-sleeved clothing or disposable overalls.
Wear gloves and eye protection.
Consult Occupational Health and Safety Authorities for any further information.
AFTER HANDLING
Rinse any exposed skin areas with clean water.
Wash work clothing separately.
REMOVAL OF USED PRODUCT
Follow the precautions as detailed in the section ‘WHEN HANDLING’ above, over-exposure to dust formed after service
may cause respiratory disease as cristobalite, a form of crystalline silica, may be formed above 900 degrees Celsius.
Seal used product in a disposable bag and dispose of via normal garbage collection methods.
Consult Occupational Health and Safety Authorities for further Information regarding removal of used ceramic
fibre lining.
Where damage to property can occur in the event of the pool or spa heater leaking, the pool or spa heater must be installed in
a drained safe tray. Construction, installation and draining of a safe tray must comply with AS/NZS 3500.4 and local codes and
regulatory authority requirements
The pool or spa heater must be maintained in accordance with the Owner’s Guide and Installation Instructions. Refer to Periodic
Maintenance on page 10.
If the pool or spa heater is to be used in a commercial application you should ensure that you have adequate redundancy within
the pool or spa heating system design. This should ensure the continuity of heating the pool or spa in the event that the pool or
spa heater was to become inoperable for any reason. We recommend you seek advice from your Rheem representative, your
plumber or specifier about your needs and building redundancy into your pool or spa heating system.
The most frequent cause of damage to a Raypak pool or spa heater is incorrect water balance resulting from overdosing of
chemicals. All chlorinators must feed downstream of the pool or spa heater and have an anti-siphoning device to prevent
chemical back up into the heater when the pool or spa heater pump is shut off
Page 9 of 32
PERIODIC MAINTENANCE
Recommended Weekly Maintenance (Residential & Premium models)
Minor maintenance should be performed every week by the dwelling occupant. The minor maintenance includes:
Monitoring your chlorine and pH levels on a weekly basis or everyday if the pool or spa is in high use.
Total Alkalinity and Calcium hardness levels can be monitored less frequently
Regularly check that the heater cabinet and air louvres are free of any dust, lint and debris
Do not operate the pool or spa heater if water balance is outside the parameters as specified on page 4 under water treatment
as this will void the Rheem warranty.
Annual Service (Residential & Premium models)
It is a requirement of Rheem and all gas authorities that the pool or spa heater be serviced at least once per year. Where it is used
in a specific application, e.g. pool heating, it would be practical to perform the service at the commencement of the pool heating
season, or at any time there is an indication of a problem.
To ensure you receive timely and accurate service assistance state the model number, serial number and type of gas used. This
information will be found on the heater data plate.
Your local Rheem Service centre will arrange for your service or recommend a qualified service agent or organisation.
Annual maintenance should only be performed by a qualified service technician. The maintenance includes:
Inspection/Cleaning of pilot assembly, including injector
Inspection/Cleaning of main burner injectors and burner bars
Inspection/Cleaning of the heat exchanger
Inspection of file tiles for damage or deterioration and replacement where necessary
Leak testing heat exchanger and waterways
Operation of Pressure Relief Valve (if fitted) manually to ensure the drain is clear and the valve reseals
Leak testing gas connections
Inspection/Cleaning of air vents and louvers
Testing of all safety devices
Testing of controls
Biannual Service (Premium models only).
Biannual/Six monthly maintenance should only be performed by a qualified service technician. The maintenance includes:
Inspection/Cleaning of pilot assembly, including injector
Inspection/Cleaning of main burner injectors and burner bars
Inspection/Cleaning of the heat exchanger
Inspection of file tiles for damage or deterioration and replacement where necessary
Pressure testing heat exchanger and waterways
Operation of Pressure Relief Valve (if fitted) manually to ensure the drain is clear and the valve reseals
Leak testing gas connections
Inspection/Cleaning of air vents and louvers
Testing of all safety devices
Testing of controls
Warning: Always isolate all electrical connections to the heater, including any pump connections, before commencing any
service work. Only a qualified service technician should carry out work on your pool or spa heater. Regular service (at least annually)
should be carried out to ensure that the gas valves and burners are clean and free from obstruction or damage and that the heat
exchanger has not been impaired by sooting or corrosion.
It is recommended that prior to commencing operation of your pool or spa heater each year a service inspection be undertaken by a
qualified service technician. Please call Rheem Service on 131 031.
Page 10 of 32
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