Raypak 013464F Replacement Instructions Manual

PC BOARD & TEMPERATURE CONTROL (KIT #013464F) FOR GAS POOL HEATERS WITH ELECTRONIC IGNITION (SEE “SCOPE” FOR MODELS) IMPORTANT NOTICE These instructions are intended for 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 to be li- censed in some states. Installation or repairs performed by unqualified persons may void the warranty. DANGER - SHOCK HAZARD Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. DANGER - PROPANE HAZARD Make sure to determine if unit is propane and see special instructions on page 6. SCOPE: This version of the temperature control board has an integrated ignition module plus 3-wire temperature sensor. It is a di- rect replacement for the following models: 185B, 206A, 207A, 265B, 266A, 267A, 268, 335B, 336A, 337A, 405B, 406A, 407A, 408. P/N 241417 Rev 4 Effective: 12-04-12 Replaces: 10-07-11 MODELS 185B, 265B, 335B, 405B PRODUCED NOV. 2003 THROUGH OCT. 2004 SERIAL # 0311 TO # 0410 MODELS 206A, 266A, 336A, 406A 207A, 267A, 337A, 407A 268, 408 PRODUCED NOV. 2004 THROUGH CURRENT SERIAL # 0411 TO CURRENT This Kit Includes: (1) PC Control Board (1) LCD Gasket (5) Screws #6 x 3/8” (1) Remote Mode Label (1) Instructions

Effective: 12-04-12 Replaces: 10-07-11 Page 2 ACCESSING THE CONTROL BOARD 1. Turn off the power to the heater. 2. Turn off the gas to the heater. 3. B-Series: Remove front door by removing the 4 door panel screws shown in Fig. 1 and Fig. 2. 4. A-Series: Remove front door by removing the large door screw in front of unit as shown in Fig. 1. 5. Remove the four screws on the side of con- trol panel. See Fig. 3 and Fig. 4. 6. Lay control panel forward toward you to ac- cess the back of the temperature control board. REMOVE THESE SCREWS FOR B - SERIES LARGE DOOR SCREW FOR A-SERIES Close-up REMOVE THESE SCREWS Fig. 1 Fig. 2 Fig. 3 Fig. 4

Effective: 12-04-12 Replaces: 10-07-11 Page 3 REMOVING THE CIRCUIT BOARD Make sure the power and gas are off. 1. Unplug all connectors from old circuit board. See Fig. 5. 2. Unplug keypad ribbon from old circuit board. 3. Remove screws as shown in Fig. 6. 4. Remove old circuit board. UNPLUG ALL CONNECTORS REMOVE KEYBOARD RIBBON REMOVE MOUNTING SCREWS Fig. 5 Fig. 6

Effective: 12-04-12 Replaces: 10-07-11 Page 4 PROPANE HEATERS ONLY: PREPARE NEW REPLACEMENT CONTROL PCB FOR INSTALLATION 1. Locate the proper propane tab on the board as shown in Fig. 7. 2. Break off tab with pliers as shown in Fig. 8 & Fig. 9. Note: Requirements for Propane safety time vary by area. Check your local and state code regula- tions to determine whether your required Propane safety time is 15 seconds or 90 sec- onds. PROPANE TABS 15-Second Safety Time 90-Second Safety Time BROKEN TAB Fig. 7 Fig. 8 90-second safety time shown Fig. 9 90-second safety time shown

Effective: 12-04-12 Replaces: 10-07-11 Page 5 MODELS 185B, 265B, 335B & 405B, Lo NOx ONLY: PREPARE NEW REPLACEMENT CONTROL PCB FOR INSTALLATION 1. DO NOT break tab See Fig. 10 and Fig. 11. 2. No additional wiring or connections are necessary for Lo NOx operation. DO NOT break tab. DO NOT break tab. After control PCB is installed, remove and discard flag label. Fig. 10 Fig. 11

Effective: 12-04-12 Replaces: 10-07-11 Page 6 Lo NOx MODELS 207A, 267A, 337A & 407A ONLY: PREPARE NEW REPLACEMENT CONTROL PCB FOR INSTALLATION 1. Locate Lo NOx tab and P-10 air switch terminal on the board as shown in Fig. 12 and Fig. 13. 2. Use pliers to break off the tab shown in Fig. 14. 3. Attach the wire from the air switch to the P-10 location shown in Fig. 14. P-10 Terminal Lo NOx Tab Break tab Wire Air Switch to P-10 here. Break and remove tab P10 Fig. 12 Fig. 13 Fig. 14

Effective: 12-04-12 Replaces: 10-07-11 Page 7 GASKET INSTALLATION - ALL MODELS 1. If the existing bezel gasket is shorter than the new gasket included with this kit (see Fig. 15), remove the gasket completely from the bezel (Fig. 16). 2. Before removing the backing on the new gasket, verify the installation place- ment as per Fig. 17. The gasket is flexible and MUST be installed with all edges straight. Verify the fit before peeling the adhesive backing. Old Gasket (Shorter) NEW Gasket (Longer) Remove shorter gasket. Line gasket up along this edge. Touch gasket against these two stand-offs. Fig. 15 Fig. 16 Fig. 17

Effective: 12-04-12 Replaces: 10-07-11 Page 8 GASKET INSTALLATION - ALL MODELS (Continued) 3. Remove the backing on the new gasket (Fig. 18) and install as per Fig. 19. Peel adhesive backing. Fig. 18 When the gasket is installed correctly,there will be a small part of the bezel showing within the display window area. The other side of the gasket will be even with the bezel display window edge. Fig. 19

Effective: 12-04-12 Replaces: 10-07-11 Page 9 REPLACEMENT CONTROL BOARD - ALL MODELS 1. Mount the replacement control board to plastic bezel using (5) five mounting screws as shown in Fig. 20. 2. Reconnect all cable connections. WARNING: See page 10 for specific directions on connecting P2 and P4. 3. When installation is complete, attach the new Remote Mode Label as shown in Fig. 21. Mount Screws Mount Screws Fig. 20 Fig. 21

Effective: 12-04-12 Replaces: 10-07-11 Page 10 IMPORTANT INSTALLING THE SAFETY AND GAS VALVE HARNESS ONTO P2 AND P4 Care must be taken when reinstalling the harness connections to P2 and P4. The mating connections on the Advanced Flame Technology (AFT) board are rotated 180 degrees compared to the connections on the previous Digital board. See Fig. 22 and Fig. 23. Be sure the locking edge of the harness connector (Fig. 24) is oriented towards the board connector locking tabs when installing all Control PCB wire connectors. P2 P4 Digital Board locking tabs face out. P2 P4 AFT Board locking tabs face in. Harness Connector Locking Edge Fig. 22 Fig. 23 Fig. 24

Effective: 12-04-12 Replaces: 10-07-11 Page 11 THERMOSTAT OPERATION - ADVANCED FLAME TECHNOLOGY (AFT) BOARD PROGRAM BUTTON LCD Display Temp Buttons Mode Button The pool heater touchpad, located on the upper front panel of the heater, allows the user to select either POOL or SPA operation, and to adjust the setpoint temperature. The LCD display window indicates the mode (OFF, SPA, POOL) and the actual water temperature. A manual power switch pro- vided below the touchpad turns the control power ON or OFF. Mode Button The MODE button is used to select either POOL or SPA op- eration. It also allows the user to turn the heater off elec- tronically, allowing the LCD display to remain energized and to continue showing the actual water temperature. Temp Buttons If the heater is in POOL or SPA mode, the desired water tem- perature (SETPOINT) will also be displayed and may be ad- justed using the UP or DOWN buttons. Operation In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SET- POINT). When the water temperature is above the setpoint, “Water Temp” will alternate with “No Demand.” When the water temperature is below the setpoint and the heater is fir- ing, “Water Temp” will alternate with “Heating.” To adjust the setpoint temperature, make sure the control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons. Service Menu and Fault History To access the Service Menu and fault history, press the MODE and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate normally while in the Service Menu. The first screen displayed is the Flame Strength indicator, which indicates the pilot flame current ALTERNATING DISPLAYS DURING HEATING FLAME STRENGTH INDICATOR SUPPLY VOLTAGE INDICATOR RUN TIME INDICATOR Press the DOWN button. The Supply Voltage screen indi- cates the voltage supplied to the control board. Normal read- ings range from 24 to 29 volts. Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured by the amount of time that the main gas valve has been powered. The Cycle count indicates the number of on/off cycles of the heater, as measured by the number of times the pilot valve has been powered. using a bar graph and numerical display. A signal of less than 4 indicates a weak flame signal and may require serv- ice. Refer to Section 5 – Troubleshooting for possible causes and corrections. FAULT HISTORY Press the DOWN button. The Fault History can display up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, and proceeds through ten most recent messages in chronological order. The second line of the display shows the fault message. If there are no faults in the history buffer, the second line reads “All Faults Clear.”

Effective: 12-04-12 Replaces: 10-07-11 Page 12 Resets board to factory default settings. Resets faults in the History File. Change from Fahrenheit to Celsius. SPA setpoint maximum adjustment. POOL setpoint maximum adjustment. Set Factory Defaults Refer to step one above to access the program screen. Set Factory Defaults should appear on the screen. If it does not, press the Mode button until Set Factory Defaults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Defaults Set appears. This op- eration resets the operating program to its factory default val- ues. Both the POOL and SPA setpoints will revert to 65°F (18.5°C) and both POOL and SPA maximum temperature settings will be 104°F (40.0°C). The Control Lockout PIN will be cleared and the control will resume normal operation. Clear Faults Refer to step one above to access the program screen. Press the Mode button until Clear Faults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Faults Cleared appears. This operation resets the Fault History file to “0” and clears all the stored faults. Program Button 1) Remove the four screws holding the control cover, and swing the panel down so the back side of the board is visible (see page 2). Locate the Program Mode button (marked as SW1) as shown on page 15. Press and hold the button (5-7 seconds) until Set Factory Defaults ap- pears on the display. Release the program button. 2) Press the Mode button sequentially until the desired pro- gram event is reached. There are 5 different events that can be programmed. They appear in the sequence listed below: Fahrenheit or Celsius Refer to step one above to access the program screen. Press the Mode button until Fahrenheit or Celsius appears on the digital display. The digital display is capable of dis- playing Celsius as well as Fahrenheit temperatures. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale. Spa Max Temp – Spa Set Point Maximum Adjustment Refer to step one above to access the program screen. Press the Mode button until Spa Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F. Pool Max Temp – Pool Set Point Maximum Adjustment Refer to step one above access into the program screen. Press the Mode button until Pool Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F. Control Lockout The heater is equipped with a Control Lockout feature to pre- vent unauthorized tampering or adjustment of the control set- tings. To lock out the controls, press the DOWN button and Mode button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the Mode button to lock in selections. Confirm your selection and record your PIN. To unlock the controls, press any button to bring up the Enter PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Success- fully unlocking the control will display “Lockout Cleared.” Failure to enter the correct PIN will display “Invalid PIN.” In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to Set Factory Defaults. This will clear the PIN and allow normal operation and selection of a new PIN if desired. See the Program Button directions on this page for details. NOTE: Both the POOL and SPA setpoints will revert back to 65°F (18.5°C) and the POOL and SPA maximum tem- perature settings will be 104°F (40.0°C). These setpoints will need to be readjusted to desired settings.

Effective: 12-04-12 Replaces: 10-07-11 Page 13 STATUS AND DIAGNOSTICS The digital thermostat models are programmed to display a variety of status and diagnostic messages, depending on the operating conditions. NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water tem- perature at the inlet to the heater may differ from that observed at a given location in the pool or spa. Display Condition Heating Call for heat established, flame present Spark Spark operating No Demand Heat demand is satisfied The following conditions are displayed in Pool, Spa and Re- mote modes. Display Condition Sensor Failure Thermistor temperatures disagree by more than 2°F Sensor Open Thermistor sensor failed open. (Below -20°F) Sensor Short Thermistor sensor failed short. (Above 217°F) Flame w/o CFH Board is sensing flame when both main and pilot valves are commanded shut. PV Output Fault Pilot gas valve output is not in com- manded state. MV Output Fault Main gas valve output is not in com- manded state. LoNox Tab Fault Voltage is sensed at the Lo NOx termi- nal on a non-Lo NOx heater (Lo NOx tab is intact). Internal Fault Board fault, replace board. EEPROM Fault Memory fault, reset set points, replace board if fault does not clear. Clock/ Fire- man Sw Time clock/fireman switch circuit is open. Low Temp Lockout Water temperature below 36°F. The following heat status messages are displayed in Pool, Spa, and Remote modes when there are no active fault con- ditions. The following conditions are displayed only while there is a demand for heat present. Display Condition Water Sw Open Water pressure switch open. Vent/Field Sw #1 Vent spill switch/field switch #1 open. Hi Limit 1 Fault High limit 1 open. Hi Limit 2 Fault High limit 2 open. Rollout Sw Open Rollout switch open. Flow/Field SW #2 Flow switch/field switch #2 open. Fan Lockout 3 fan switch faults within same heat demand cycle, power must be cycled to clear the fault. Fan 5 Min Delay Heater shut down for 5 minutes be- cause LoNox fan switch didn't close. Ignition Lockout (Propane Tab Broken) Alternating with “No pilot sensed” - Pilot flame not established within the required time (15 sec or 90 sec). Alternating with “Main Ign Failure” - Pilot flame lost during the 8 second trial to ignite the main burner. Ignition Failure (Propane Tab Not Broken) Alternating with “No pilot sensed” - Pilot flame not established within 90 seconds. Ign 6min Delay (Propane Tab Not Broken) Alternating with “Main Ign Failure” - Pilot flame lost 4 times within the 8 second trial to ignite the main burner. Heater will lockout for 6 minutes be- fore retrying.

Effective: 12-04-12 Replaces: 10-07-11 Page 14 Pool Common (BLK/ORN) Spa Common (ORN/BLK) 24VAC HOT (BLU) 7-PIN Remote Wiring Connector REMOTE CONTROL INSTALLATION AND OPERATION CAUTION: Before installing remote controls to the AFT thermostat model heaters, read the following: The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad on the control panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is controlling the heater by display- ing Remote in the display. When connecting the heater to a remote system, identify whether it is a two- or three-wire re- mote system. Select the appropriate instruction listed below to properly install the remote to the heater. OFF Mode Heating in the POOL Mode Heating in the SPA Mode Remote Mode REMOTE OPERATION The AFT model heaters are equipped with the ability to work with external remote controls. The supplied 7-pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote. The remote works by either making or breaking the circuit created by the remote wiring. Typically, a remote does not supply power to the heater, it only provides a switching function to turn the heater On or Off. If your remote is supplying its own volt- age to the heater, it will not work with this heater and may damage the digital circuit board. For operation of the heater using the onboard thermostatic controls with a time clock, see the “Time Clock / Fireman’s Switch” section. ACTIVATING THE REMOTE To activate or deactivate the remote function, follow these steps: Note: Electrostatic Discharge (ESD) damage can be caused by direct or in- direct contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact of a finger allows the body to discharge, possibly causing device damage. This dam- age can be limited if the service person discharges himself, following ESD preventive/removal practices, and holds on to the heater enclosure for 5 sec- onds before proceeding. Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds. NOTE: When in remote operation, the keypad mode and temp buttons are disabled. The second line of the display will alternate even when the unit is off (“No Demand”).

Effective: 12-04-12 Replaces: 10-07-11 Page 15 REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration • Remote wiring must be run in a separate conduit. • Remote wiring must not be run parallel to high voltage lines. • For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5 to 2.5 in. lay and jacketed. • For runs over 30 feet, the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to 2.5 inch lay that is shielded and jacketed. • Maximum cable length is 200 feet. • For both two- and three-wire remote systems, the provided 7-pin wiring connector must be utilized. Please refer to the wiring instructions. NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board. 2-Wire Remote Control (On-Off) This application assumes that only one heating function (pool or spa) is required. 1. Turn on power to the heater. 2. For a 2-Wire Remote Control from a remote without its own sen- sor, push the mode button to the “POOL” or “SPA” mode and set the desired setpoint (eg. 102 °F for spa). 3. For a 2-Wire Remote Control from a remote with its own sensor, push the mode button “POOL” or “SPA” mode and set the tem- perature to the highest setting available on the control. The actual setpoint will be controlled by the remote control. 4. Turn the mode button to "OFF" and remove power from the heater. 5. On the "Remote Interface Harness", connect the BLUE wire to one side of the "REMOTE" switch and connect the other side to either the ORANGE/BLACK wire for "SPA" operation or the BLACK/OR- ANGE wire for "POOL" operation. 6. Attach wire nut on unused wire to the "Remote Interface Harness." 7. Install the "7-Pin Remote Interface Harness" to the P8 connector and turn power “On” to the heater. See instructions on previous page to activate the remote control. 3-Wire Remote Control Using Three-Position Switch (Pool-Off-Spa, or Low-Off-High) This application assumes that both heating functions (pool and spa) are required. 1. Turn on power to the heater. 2. Push the mode button to the "POOL" or "SPA" mode and set the desired temperature for each (eg. 80°F for Pool and 102°F for Spa). 3. Turn the mode button to "OFF" and remove power from the heater. 4. On the "Remote Interface Harness" connect the BLUE wire to one side of the "REMOTE" switch and connect the ORANGE/BLACK wire for "SPA" operation and the BLACK/ORANGE wire for the "POOL" operation. 5. Install the "Remote Interface Harness" to the P8 connector and turn power "ON" to the heater. See instructions on previous page to activate the remote control. P8 Connector Wire Nut - BLK/ORN To Pool (COMM) ORN/BLK - To Spa (COMM) BLU - 24VAC P8 Connector ORN/BLK - To Spa (COMM) BLU - 24VAC BLK/ORN - To Pool (COMM)