Raypak R106A Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Atmospheric
Above-Ground
Pool & Spa
Heater

(Chauffe-Piscine)

Models 106 & 156

English/French

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

.

AVERTISSEMENT: Assurez-vous de bien suivre
les instructions données dans cette notice pour
réduire au minimum le risque d’incendie ou
d’explosion ou pour éviter tout dommage matériel,
toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ou ni
d’autres vapeurs ou liquides inflammables à
proximité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez á aucun interrupteur; ne pas
vous servir des téléphones se trouvant dans
la bâtiment.

• Appelez immédiatement votre fournisseur
de gaz depuis un voisin. Suivre les instruc­tions du fournisseur.

• Si vous ne pouvez rejoindere le fournisseur,
appelez le service es incendies.

L’installation et l’entretien doivent être assurés
par un installeur qualifié ou par le fournisseur de
gaz.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.

CATALOG NO. 6100.62D Effective: 05-01-16 Replaces: 01-15-15 P/N 241519 Rev. 5

Rev. 5 reflects the following:
Changes to: “Unpacking” on page 7, “Gas Connections” on page 13, Fig. 7 on page 14.
Additions: None
Deletions: None

2

CONTENTS

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 9
Installation Codes 10
Clearances 10
Base Installation 10
Outdoor Installation 10
Indoor Installation 12
Combustion & Ventilation Air 12
Gas Connections 13
Water Connections 15
Electrical Connections 17

OWNER’S OPERATING
INSTRUCTIONS 18

Control Adjustments—Analog 18
Control Adjustments—Digital 18

Thermostat Operation—Advanced Flame
Technology (AFT) Board 20
Status and Diagnostics 22
Remote Control Installation 23
Wiring Diagrams 25
Post Start-Up Inspection 26
Cold Weather Operation 26

MAINTENANCE 27
SERVICE 27

Water Pressure Switch 27
Flame Roll-Out Safety Switch 28
High Limits 28
Burner Tray Removal 29
Gas Valve Removal 29
Pilot Removal & Cleaning 30
Heat Exchanger Removal 31
Tube Cleaning Procedure 31
De-sooting Procedure 31
Replacement Parts 31

TROUBLESHOOTING 32

Mechanical 32
Electronic Control Logic Flowchart 33
Analog Control Logic Flowchart 34

ILLUSTRATED PARTS LIST 35

3

WARNINGS - Pay Attention to These Terms

DANGER:

WARNING:

CAUTION:

NOTE:

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: 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.

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

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

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.

WARNING: UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.

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

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

WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the owner’s operating instructions provided
in this manual. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.

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: Do not install within 3 feet (0.9 m) 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.

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 internal rusting or
damage electrical components, and void the warran­ty.

4

WATER CHEMISTRY

OTE: Corrosive water voids all warranties.

N

Chemical imbalance can cause severe damage to

our heater and associated equipment. Maintain your

y
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.

CAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and is not covered
under warranty.

• 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 chlo­inators are usually more efficient in heated water,

r
unless controlled, they can lead to excessive chlo­rine level which can damage your heater.

• Further advice should be obtained from your pool

r spa builder, accredited pool shop, or chemical

o
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 chemi-

cals 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: 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

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) 4500 Maximum 4500 Maximum 4500 Maximum

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

Total Dissolved Solids

(ppm)

*Free Chlorine MUST NOT EXCEED 5 ppm!
** In salt water chlorinated pools, the total TDS can be as high as 6000 ppm.

3000 Maximum** 3000 Maximum** 3000 Maximum**

Table A: Water Chemistry

Other Pool and Spa

Types

5

Spa

Return to Spa

Fig. 1: Spa/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.

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.

AVERTISSEMENT: La U.S. Consumer Product
Safety Commission indique que des températures
de l’eau élevées deuvent être dangereuses. Voir la
notice d’installation et de fonctionnement pour le
réglage de lat température. Suivre les instructions
pour une installation appropriée.

INTRODUCTION

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.

Ratings & Certifications

This pool & spa heater (chauffe-piscine) is design-cer­tified and tested under the latest requirements of ANSI
Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters
(Chauffe-Piscines). The heater can be used either
indoors or outdoors. (Installer å l’intérieur ou à l’ex­térieur.) If necessary, the top of the heater can be
changed after installation to accommodate indoors or
outdoors.

6

WARNING: Use of any parts not manufactured

P - R 106 A - E N - C

Plastic Header

R = Raypak
M = Rheem

D = Ruud

Model No.

Model Rev.

E = Electronic
A = Analog

N = Natural
P = Propane

C = Copper

nd/or approved by the manufacturer may cause

a
non-warrantable damage.

Ambient Temperature Rating of
Components

• Analog heater -40°F to +175°F (-40°C to 79.4°C)

• Electronic heater -32°F to +175°F (-35.5°C to

79.4°C)

Model Identification

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

Specifications

Shipping Weight

Model

No.

106

156

Input*

105,000

BTU/hr.

(30.75

KW)

150,000

BTU/hr.

(43.93

KW)

Gas
Conn.
(NPT)

1/2 in.

(1.27

cm)

Table B: Specifications

Water
Conn.
(NPT)

1-1/2 in.

or 2 in.
(3.8cm

or 5
cm)

Std.
Heater w/
Stackless

Top

85 lbs.

(38.6 kg)

100 lbs.

(45.4 kg)

Drafthood
Assembly

14 lbs.

(6.35 kg)

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.

These items are shipped inside a bag in the carton
with the heater:

1. 2” CPVC union with “O” rings (2)

2. Plastic pipe finish flange for gas line

3. Bonding lug with mounting screw

4. IOI Manual

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

Fig. 2: Location of Heater Rating Plate

The model identification number will be similar to the
example shown below:

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.

7

INSTALLATION

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California

o cause cancer, birth defects or other reproductive harm.

t

ARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as

W

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.

IMPORTANT NOTICE
These instructions are intended only for the use by qualified personnel, 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 equip-

ment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.

8

9

Installation Codes

Installations must be in accordance with local, state,

rovincial, and national codes, laws, regulations and

p
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/CSA-B149 Installation Code

(B149) and CSA C22.1 C.E.C. Part 1 and Part 2

owever for ease of servicing, we recommend a

H
clearance of at least 18" (45.7cm) on the rear. This

will enable the heater to be serviced in its installed
location, that is, without movement or removal of the

eater.

h

Minimum clearance from drafthood to combustible
construction 6 inches from the vent.

Degagement minimal de 6 po requis entre le coupe­tirage et une construction combustible. 2 po du conduit
de raccordement.

AVERTISSEMENT: Cet appareil doit être installé
conformément au National Fuel gas Code ANSI
Z223.1, et aux exigences de l’autorité competente.

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.

Clearances

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

Heater Side

Top* Unobstructed 30 in. (76.2 cm)

Front 24 in. (61 cm) Alcove

Vent N/A 6 in. (15.2 cm)

Back 12 in. (30.5 cm) 12 in. (30.5 cm)

Right Side 6 in. (15.2 cm) 6 in. (15.2 cm)

Outdoor

Installations

Indoor

Installations

Clearances less than recommended 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.

FLOORING: This heater can be installed on com­bustible flooring.

Base Installation

Heater must be mounted on a level base, such as
cementable slab or cement blocks. Heaters may not
be installed on carpeting.

This heater must b e installed at least 5ft (1.52m) from
the inside wall of a pool unless separated from the
pool by a solid fence, wall or other permanent solid
barrier.

Ce chauffe-piscine doit êntre installè à au moins 5
peds (1.52m) de la paroi interne de la piscine à moins
d’êntre isolé de la piscine par un clôture, un mur ou
autre barrière permanente.

Outdoor Installation

Left Side 6 in. (15.2 cm) 6 in. (15.2 cm)

*Clearance from top of vent terminal.

Table C: Required Minimum Clearances from

Combustible Surfaces.

Dégagements minimaux à assurer entre les parois de
l”appareil et les contructions combustibles: 6po
(côtés), 12po (arrière) et 30po (dessus).

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

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 will not be
covered under warranty.

WARNING: Do not install within 3 feet (0.9m) 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.

10

Fig. 3: Overall Dimensions

OUTDOOR
STACK

Amp Draw

20 Volt240 Volt

1

4 2

NOTE: This heater is design-certified for outdoor
installation when equipped with the approved top(s)
for outdoor use.

Heater with Outdoor Stackless Top

Heaters must not be installed under an overhang of
less than 3 ft (0.9m) 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.

Ne pas installer ce chauffe-piscine sous une saillie
mesurant moins de 3 pi de hauteur. La partie sous Ia
saillie doit etre ouverte sur 3 côtes.

• For U.S. installations, the point from where the flue
products exit the heater must be a minimum of 4 ft
(1.2m) below, 4 ft (1.2m) horizontally from, or 1 ft
(0.3m) above any door, window or gravity inlet into
any building. The top surface of the heater shall be at
least 3 ft (0.9m) above any forced air inlet, or intake
ducts located within 10 ft (3m) horizontally. See
Fig. 5.

Outdoor Stack

NOTE: The outdoor stack is optional equipment and

does not come standard with the heater. Use part
number 014718 for the 106 and 014719 for the 156.

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 ft (0.9m)
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. 4.

• For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10 ft
(3m) below, or to either side, of any opening into the
building. Refer to the latest revisions of CAN/CSA­B149. The heater must be raised 7 in (0.2m) above
the surface which could support snow, ice or debris.
Refer to the latest revisions of CAN1-2.21-M85.

Fig. 4: Outdoor Stack

11

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 Outdoor
Stack Kit for installation.

AUTION: Combustion air must not be

C

contaminated by corrosive chemical fumes which

an damage the heater and void the warranty. Do

c
not store chlorine, bromine, baquasil or acid in the
same room as the heater.

Indoor Installation

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

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/CSA-B149 for specific
requirements.

WARNING: Indoor heaters require a drafthood
that must be connected to a vent ppe and properly
vented to the outside. Failure to follow this
procedure can cause fire or fatal carbon monoxide
poisoning.

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 rating plate. Follow
the installation instructions provided with the Indoor
Drafthood Kit for installation.

All Air from inside the building each opening shall•
have a minimum net free area as noted in Table E.

Model Area

106 105 in² (677 cm²)

156 150 in² (968 cm²)

Table E: Minimum Air Area

All air from outdoors when air is supplied directly•
from outside the building each opening shall have
a minimum net free area as noted in Table D.

Vent Piping

Vent piping the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least 10 ft (3m) (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/CSA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows.

This drafthood must be installed without alteration. see
rating plate.

Ce coupe-tirage doit être installé sans modification.
Voir Ia plaque signalétique.

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 (30.5 cm)
from the ceiling for ventilation, and one opening that is
12 inches (30.5 cm) from the floor for combustion air
as outlined in the latest edition of the National Fuel
Gas Code, ANSI Z223.1 (Canada-CAN/CSA-B149)
and any local codes that may have jurisdiction.

Model

106 27 in² (174 cm²) 41 in² (265 cm²) 54 in² (348 cm²)

156 38 in² (245 cm²) 57 in² (368 cm²) 76 in² (490 cm²)

Unrestricted

opening

If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 in. (2cm per m) 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 5 ft (1.5m) 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/CSA-B149).

Typical screened

or louvered opening

Typical screened

and louvered opening

Table D: Minimum Air Net Area

12