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RAYPAK REPLACEMENT INSTRUCTIONS
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. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to
these instructions.
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 5.
SCOPE:
This version of the temperature control board has the capability of an integrated ignition module plus 3-wire temperature sen-
sor. The kit includes a gasket and a plastic shield that is mounted to the back side of the control panel to eliminate moisture
accumulation on the LCD display. It is a direct replacement for the following models: 185A, 265A, 335A, and 405A.
(1) PC control board
(1) Temperature sensor
(1) Remote wire harness (1) Hi tension wire extension (4) Screws #6 x 3/8
(6) Screws #8 x 1/2"
PC BOARD, TEMPERATURE CONTROL & SENSOR
(KIT #010253F) MODELS 185A, 265A, 335A & 405A
This kit includes:
(1) PC board plastic shield
(6) Plastic #8 washers
(2) Screws #10 x 1/2"
Page 1
(2) Brackets
(1) LCD gasket
(1) Instructions
MODELS
185A, 265A, 335A, 405A
PRODUCED NOV. 1998
THROUGH OCT. 2003
SERIAL # 9811 TO # 0310
241169
P/N
Rev 4
Effective: 10-01-10
Replaces: 09-05-08
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Table of Contents
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Summary of Contents for Raypak 185A
- Page 1 The kit includes a gasket and a plastic shield that is mounted to the back side of the control panel to eliminate moisture accumulation on the LCD display. It is a direct replacement for the following models: 185A, 265A, 335A, and 405A.
- Page 2 241169 Page 2 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 ACCESSING THE BOARD 1. Turn off the power to the heater. 2. Turn off the gas to the heater. 3. Remove front door. 4. Remove the four screws on the side of the heater holding the control panel.
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Page 3: Removing The Circuit Board
241169 Page 3 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 REMOVING THE CIRCUIT BOARD Make sure the power and gas are off. 1. Unplug all connectors from old circuit board. See Fig. 3. 2. Unplug keypad ribbon from old circuit board. 3. - Page 4 241169 Page 4 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 DISCONNECTING IGNITION CONTROL Make sure the power and gas are off. 1. Unplug all wires and connectors from ignition module. (See Fig. 5) Note: The replacement board has an integrated ignition module.
- Page 5 241169 Page 5 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 PROPANE HEATERS ONLY: PREPARE NEW REPLACEMENT CONTROL PCB FOR INSTALLATION 1. Locate the proper propane tab on the board as shown in Fig. 6. 2. Break off tab with pliers as shown in Fig. 7 & Fig. 8. Note: Requirements for Propane safety time vary by 15-Second...
- Page 6 241169 Page 6 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 Low NOx ONLY: PREPARE NEW REPLACEMENT CONTROL PCB FOR INSTALLATION 1. DO NOT break tab See Fig. 9 and Fig. 10. 2. No additional wiring or connections are necessary for Low NOx oper- ation.
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Page 7: Mounting Screws
241169 Page 7 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 NEW CIRCUIT BOARD & GASKET INSTALLATION USING OLD BEZEL Note: Disregard window gasket installation if already present. 1. Remove backing on gasket and install adhesive side on the control panel bezel as shown in Fig. 11. 2. - Page 8 241169 Page 8 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 LOOSEN DRAIN REMOVING & REPLACING SENSOR PLUG TO RELIEVE Make sure the power and gas are off. PRESSURE 1. Loosen drain plug to relieve pressure in heat exchanger. See Fig. 14. 2.
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Page 9: Side View
241169 Page 9 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 PLASTIC SHIELD & BRACKET INSTALLATION SHIELD BRACKETS Make sure the power and gas are off. 1. Note that the plastic shield is installed under the front bracket as pictured. Install the shield brackets and plastic shield using the existing screws (#8 x ½”) and included washers on the control panel bracket as... - Page 10 241169 Page 10 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 INSTALLING PILOT HI TENSION WIRE Fig. 22 EXTENSION TO 335A: Make sure the power and gas are off. Side ‘B’ 1. Connect pilot wire (Side B) to new board with new extension See Fig. 22 & Fig. 23. Side 2.
- Page 11 241169 Page 11 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 DIGITAL THERMOSTAT CONTROLS Thermostat operation Your heater is equipped with a microprocessor-controlled thermostat that controls the pool or spa temperature by meas- uring the temperature of the water entering the heater. It monitors the water temperature and turns the heater on when it senses that the water temperature is below the set point.
- Page 12 241169 Page 12 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 Program Button RESfl – Reset Fault History 1) To access the program screen, press the Mode button Refer to step one above to access the program screen. until the display reads OFF. Remove the four screws Press the Mode button until RESfl appears on the digital dis- holding the control cover on.
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Page 13: Status Codes
241169 Page 13 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 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. -
Page 14: Remote Operation
241169 Page 14 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 REMOTE CONTROL INSTALLATION AND OPERATION CAUTION: Before installing remote controls to the digital 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). -
Page 15: Remote Control Wiring
241169 Page 15 Rev 4 Effective: 10-01-10 Replaces: 09-05-08 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. •... - Page 16 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-9725 Litho in U.S.A.
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