Raypak Swimming Pool Heater CR24 185 User Guide

INSTALLATION INSTRUCTIONS  
Raypak  
Indirect  
Pool  
Heaters  
Model Series  
RP-045 through RP-995 and  
CR24-185 through CR24-495  
NOTE: The instructions in this manual are for the use of qualified individuals specially trained and experienced  
in the installation and maintenance of this type of equipment and related system components. Installation and  
service personnel are required by some states to be licensed. Persons not qualified shall not attempt to install,  
service, or maintain this equipment.  
This manual should be maintained in legible condition and kept adjacent to the heat source or in a safe place  
for future use.  
Catalog No. 6300.50  
Effective: 07-28-10  
Replaces: NEW  
P/N 241399 Rev. 1  
 
CAUTION  
4. Before entering the spa or hot tub, users should  
Elevated water temperature can be hazardous. The  
U.S. Consumer Product Safety Commission has these  
guidelines:  
check the water temperature with an accurate ther-  
mometer; spa or hot tub thermostats may err in  
regulating water temperatures by as much as 4°F  
(2.2°C).  
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.  
5. Persons with a medical history of heart disease, cir-  
culatory problems, diabetes, or blood pressure  
problems should seek a physician's advice before  
using pools or hot tubs.  
2. Drinking of alcoholic beverages before or during  
spa or hot tub use can cause drowsiness which  
could lead to unconsciousness and subsequently  
result in drowning.  
6. Persons taking medications which induce drowsi-  
ness, such as tranquilizers, antihistamines, or  
anticoagulants, should not use spas or hot tubs.  
3. Pregnant Women Beware! Soaking in water over  
102°F (39°C) can 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.  
CAUTION: Operating control and high limit are  
NOT part of the Indirect Pool Heater. These items  
must be supplied separately.  
3
 
Nominal*  
Capacity  
Overall  
Length  
Boiler  
Pool  
Model  
Diameter  
Connection Connection  
CR24**  
Super Alloy  
SS316L  
BTU/hr  
Inches  
Inches  
NPT  
NPT  
RP-045  
RP-075  
RP-125  
RP-185  
RP-245  
RP-305  
RP-495  
RP-995  
45,000  
75,000  
3.15  
3.15  
3.15  
4.0  
10.5  
13.5  
15.5  
15.0  
20.2  
25.0  
43.0  
36.1  
3/4”  
3/4”  
3/4”  
1”  
1”  
1-1/2”  
1-1/2”  
1-1/2”  
1-1/2”  
1-1/2”  
2”  
125,000  
185,000  
245,000  
305,000  
495,000  
995,000  
CR24-185  
4.0  
1”  
CR24-305  
CR24-495  
4.0  
1”  
4.0  
1”  
5.5  
2”  
2”  
*
Nominal values are based on 140 °F temperature differential between incoming heating and heated water.  
** CR24 Super Alloy - widely used in industrial salt water environments. Due to its unsurpassed corrosion resistance, this  
unique super alloy option is a ‘true’ salt water product, now available from Raypak for the most demanding of applica-  
tions, from high chlorination to high salt content.  
Table 1: Specifications  
POOL WATER OUT  
HEAT SOURCE  
WATER IN  
HEAT SOURCE  
WATER OUT  
POOL WATER IN  
Figure 1: Dimensions  
CR24  
Super Alloy  
L
(in.)  
A
(in.)  
B
(in.)  
C
(in.)  
D
(in.)  
F
G
(NPT)  
SS316L  
(NPT)  
RP-045  
RP-075  
RP-125  
RP-185  
RP-245  
RP-305  
RP-495  
RP-995  
10.5  
13.5  
15.5  
15.0  
20.2  
25.0  
43.0  
36.1  
4.17  
4.17  
4.17  
5.04  
5.04  
5.04  
5.04  
6.57  
4.39  
6.89  
3.05  
3.35  
3.35  
3.74  
3.74  
3.74  
3.96  
4.72  
3.15  
3.15  
3.15  
4.0  
1”  
3/4”  
3/4”  
3/4”  
1”  
1-1/2”  
1-1/2”  
1-1/2”  
1-1/2”  
1-1/2”  
2”  
8.86  
CR24-185  
7.60  
12.72  
17.40  
34.80  
26.63  
4.0  
1”  
CR24-305  
CR24-495  
4.0  
1”  
4.0  
1”  
5.5  
2”  
2”  
Table 2: Physical Dimensions  
4
 
Pressure  
235 PSI  
Temperature  
406°F  
Tubeside  
Shellside  
190 PSI  
406°F  
Designed and fabricated to the  
ASME B31.3 Process Piping Code  
Table 3: Design Ratings  
Boiler  
Boiler  
Head Loss  
Pool  
Flow  
Pool  
Head Loss  
Heating  
Surface  
Model  
Flow  
GPM  
Max  
Feet  
GPM  
Feet  
CR24  
Super Alloy  
SS316L  
Sq. Ft.  
Min  
Min  
Max  
Min  
Max  
Min  
Max  
RP-045  
RP-075  
RP-125  
RP-185  
RP-245  
RP-305  
RP-495  
RP-995  
5
15  
20  
20  
30  
30  
35  
35  
100  
0.5  
1.0  
20  
20  
20  
20  
30  
30  
40  
70  
40  
1.5  
6.0  
2.0  
2.8  
10  
10  
20  
20  
20  
25  
50  
1.0  
1.0  
1.0  
1.0  
1.5  
3.5  
4.0  
2.5  
2.5  
2.0  
2.5  
4.0  
6.5  
13.0  
50  
50  
1.5  
2.0  
1.5  
2.5  
1.5  
3.0  
5.5  
7.0  
10.0  
9.5  
3.3  
CR24-185  
50  
4.9  
60  
9.0  
7.3  
CR24-305  
CR24-495  
60  
6.0  
9.4  
80  
12.0  
15.0  
17.3  
23.7  
120  
Table 4: Flow & Pressure Drop Specifications  
The connection diagram, Figure 2, is shown for refer-  
ence only. The system must be designed and installed  
by a qualified installer and all local, state, provincial  
and national codes, laws, regulations and ordinances  
must be followed.  
Installation Guidelines  
Plumbing  
Connections to the Indirect Pool Heater must be made  
with materials that have similar galvanic properties to  
the passivated 316 stainless steel or CR24 super alloy  
of the heat exchanger. Connections to the heat source  
plumbing should be made with 300 series stainless  
steel nipples. Dielectric unions are recommended if  
dissimilar plumbing is used. Connections to the pool  
system should be made with CPVC or PVC adapters  
or 300 series stainless steel nipples. Dielectric unions  
are recommended if dissimilar plumbing is used.  
Flow  
For optimal heat transfer, counter flow should be uti-  
lized, that is the supply water from the heat source  
should flow in the opposite direction of the return water  
from the pool/spa, as shown in the connection dia-  
gram, Figure 2. Systems must be designed to provide  
flow rates within the range provided in Table 4. Do not  
exceed the published maximum flow rates. On the  
heating side, desired flow rates can be accomplished  
with the pump sizing and/or use of balancing valves.  
5
 
Sample Installation Diagram  
TO BOILER CONTROL  
BOILER WATER FLOW  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
Indirect Pool Heater  
Gate valve  
2
6
3
4
Check valve  
POOL WATER FLOW  
POOL WATER FLOW  
2
Flow switch  
Thermostat or Aquastat  
Thermometer  
Drain valve  
11  
12  
11  
1
Filter  
5
6
10  
Pool/Spa Pump  
Bypass valve  
Union  
9.  
BOILER WATER FLOW  
10.  
11.  
12.  
11  
Boiler Pump  
2
2
3
11  
8
7
9
NOTE:  
-
-
Damage to the Indirect Pool Heater due to improper water chemistry is not covered under the warranty  
Chlorine feeder must be installed after (downstream of) the Indirect Pool Heater and be installed with an  
anti-siphoning valve to prevent chlorine from backing up into the Indirect Pool Heater.  
-
This is only a conceptual drawing. A qualified installer must determine whether this system setup  
will work in each application. Installer must also ensure compliance with code requirements.  
On the pool side the flow may be variable either due to temperature of 104°F. A second temperature control  
variable speed pumps or changes in the pressure drop must be installed in the outlet piping of the Indirect  
through the filtration system. These variances can be Pool Heater to limit pool/spa supply temperatures to  
accommodated by installing a 2lb spring loaded check 140°F maximum. In addition to the temperature con-  
valve in the bypass line along with a manual valve (see trols, a flow switch should be installed in the pool/spa  
Figure 2 for details).  
supply line to prove adequate flow through the heat  
exchanger. All three of these controls must be satis-  
On model sizes 045 to 495, the check valve will con- fied to provide a call for heat to the heat source.  
trol bypass flow by directing all flow through the  
exchanger under low flow conditions, and avoiding  
excessive flow through the heat exchanger under high  
flow conditions. On 995 models the 2lb check valve  
does not provide enough resistance to direct adequate  
flow through the heat exchanger, and must be aug-  
mented by using the manual valve to throttle flow to  
provide approximately 6 to 15 ft of head across the  
995 exchanger.  
Chlorine feeders or salt water  
generators  
The chlorine feeder or salt water generator (with CR24  
exchangers only) must be installed after (downstream  
of) the Indirect Pool Heater and be installed with an  
anti-siphoning valve to prevent chlorine from backing  
up into the Indirect Pool Heater. During periods of high  
or fluctuating chlorine levels the Indirect Pool Heater  
must be isolated from the system by closing the isola-  
tion valves, protecting the unit from chemical damage.  
Controls  
The Indirect Pool Heater must be installed with tem-  
perature and flow controls to protect the heat  
exchanger and control water temperature supplied to  
the pool or spa. The return from the pool/spa must be  
controlled at the inlet to the Indirect Pool Heater by a  
thermostat set to the desired temperature for the  
pool/spa, with the maximum recommended operating  
CAUTION: Operating control, high limit and flow  
switch are NOT part of the Indirect Pool Heater.  
These items must be supplied separately.  
6
 
LIMITED WARRANTY  
RAYPAK INDIRECT POOL HEATERS  
Models: RP-045, RP-075, RP-125, RP-185, RP-245, RP-305, RP-495, RP-995,  
CR24-185, CR24-305 and CR24-495  
SCOPE OF WARRANTY  
Raypak, Inc. (Raypak) warrants to the original owner that the above model HEATER, when  
installed in the contiguous 48 states with a pool or spa by a properly licensed installer will be free  
from defects in materials and workmanship under normal use and service for the Applicable  
Warranty Period. In accordance with the terms of this Limited Warranty, Raypak will, at its option,  
repair or furnish a replacement for any defective part of the HEATER if it fails in normal use and  
service during the Applicable Warranty Period. The repair or replacement will be warranted for  
only the unexpired portion of the original Applicable Warranty Period.  
EFFECTIVE DATE  
The Effective Date of this Limited Warranty is the date of original installation if properly  
documented; if you are not able to provide documentary proof of the date of original installation,  
the Effective Date will be the date of manufacture plus 30 days.  
APPLICABLE WARRANTY PERIOD  
If the HEATER is installed with a pool or spa, the Applicable Warranty Period is one (1) year from  
the Effective Date, parts and labor, for the HEATER and component parts.  
LABOR AND SHIPPING COSTS  
This Limited Warranty covers the normal cost of Raypak authorized labor repairs or replacements  
covered by this Limited Warranty which are performed by a Raypak designated service provider  
during the Applicable Warranty Period. Do not attempt to repair or replace any in-warranty  
product or component part(s) without prior authorization from Raypak. This Limited Warranty  
does not cover any travel time or other labor costs. This Limited Warranty does not cover any  
shipping costs to and from Raypak's designated service provider or to and from the installation  
site. All of the foregoing costs and expenses are your responsibility.  
WARRANTY EXCLUSIONS  
This Limited Warranty doesNOT apply;  
1. if the product has been moved from its original place of installation, or if the original  
owner no longer owns the property where the original installation was made;  
2. if the product is not properly installed with a pool or spa by a qualified licensed installer in  
accordance with applicable local codes and ordinances, good trade practices, and the  
manufacturer’s installation instructions;  
3. if the rating plate(s) or serial number(s) are altered or removed;  
4. if the product is modified in any way, or non-factory authorized accessories or other  
components are used in conjunction with the product;  
5. to conditions including damage, malfunctions or failures resulting from failure to properly  
install, operate or maintain the product in accordance with the manufacturer's  
instructions;  
6. to conditions including damage, malfunctions or failures from abuse, act of nature,  
accident, fire, flood, freeze, lightning or the like;  
7. to conditions including damage, malfunctions or failures resulting from or due to  
connected system control devices;  
8. to conditions including performance problems caused by improper sizing of the heater;  
9. to conditions including damage, malfunctions or failures resulting from any alteration,  
including the use of any attachment, including any energy saving device, not authorized  
by the manufacturer;  
7
 
10. to conditions including damage, malfunctions or failures from misuse or neglect, including  
but not limited to, freeze-ups, having flow restrictions or obstructions between the heater  
outlet and the pool/spa, or not maintaining a proper chemical balance (PH level must be  
between 7.3 and 7.8 and total alkalinity between 80 and 150 PPM. Total dissolved solids (TDS)  
must be no greater than 1000 PPM, or 3000 PPM for CR Super Alloy models).  
HOW TO MAKE A WARRANTY CLAIM  
You should immediately notify your dealer and provide proof of purchase, model number, serial  
number and date of installation. Your dealer will contact the factory for instructions regarding the  
claim and to determine the location of the nearest authorized service center. If the dealer is not  
available please contact warranty service at 805-278-5300, supplying model number, serial  
number, date of original installation and a description of the problem. Proper authorization  
MUST be obtained PRIOR to any repairs for this Limited Warranty to apply. This Limited  
Warranty is VOID if the product is repaired or altered in any way by ANY persons or  
agencies other than those authorized by Raypak. Raypak reserves the right at all times to  
inspect, or require the return of, the defective product or component part and to verify warranty  
coverage at its factory.  
EXCLUSIVE WARRANTY-LIMITATION OF LIABILITY  
The Limited Warranty is the only warranty for this product and its component parts given by  
Raypak. No one is authorized to make any other warranties on Raypak's behalf. ANY IMPLIED  
WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR  
PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS  
SPECIFIED IN THIS LIMITED WARRANTY. RAYPAK'S SOLE LIABILITY WITH RESPECT TO  
ANY DEFECT SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY. IT IS AGREED  
THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS LIMITED WARRANTY  
OR IN CONTRACT, TORT OR NEGLIGENCE OR OTHERWISE FOR CLAIMS FOR SPECIAL,  
INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING NO LIABILITY FOR DAMAGE  
FROM WATER LEAKAGE) WHICH ARE EXPRESSLY EXCLUDED, NOTWITHSTANDING  
ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY. Some states do not  
allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or  
consequential damages, so the above limitation or exclusion may not apply to you.  
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO  
.
HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.  
We suggest you immediately record the model and serial number and date of original installation  
and retain this Limited Warranty Certificate along with your original proof of purchase and date of  
installation/start-up in the event warranty service is needed.  
DO NOT RETURN THIS DOCUMENT TO RAYPAK. KEEP IT WITH YOUR POOL HEATER OR  
BUSINESS RECORDS.  
Name of Owner  
Owners Address  
Name of Installer  
Installers Address  
Date of Pool Heater Installation  
Model Number of Your Pool Heater  
Telephone Number of Installer  
Serial Number of Your Pool Heater  
8
 

Radio Shack Portable CD Player 14 518 User Guide
Reliable Sewing Machine MSK 755H User Guide
Renesas Computer Hardware H8SX 1582 PLQP0120LA A User Guide
Renesas Network Card M37549T RLSS User Guide
Rheem Water Heater Gas Hot Water Supply Heaters User Guide
Riccar Vacuum Cleaner 1500P User Guide
Robic Outdoor Timer SC 502T User Guide
Roland Recording Equipment SCWS01 User Guide
Rotel Stereo Amplifier RC 06 User Guide
Sanyo Car Stereo System NV E7000 User Guide