Raypak 538-4224 User Manual
Raypak Commercial
Swimming Pool Heaters
Part 1: Safety warning
Part 2: Models 538 to 4224
Part 3: Warranty
3
CONTENTS
Part 1: For Your Safety
This Installation and Operating Instructions Manual is
provided with the necessary information for the proper
installation, operation and maintenance of your Raypak
Heater. Please review and follow these procedures
carefully. Keep this manual in a safe and accessible place
for easy reference in the future.
Part 2: Models 538 to 4224
Section 1. Installation Instructions
Section 2. Owners Operating
Instructions
Part 3: Warranty
Date of Installation:
Model No.
Serial No.
Installed by:
Purchased from:
// //
PART 1 FOR YOUR SAFETY
4
Keep this manual in a safe and accessible place for easy reference in
the future.
This Installation and Operating Instructions Manual is provided with
the necessary information for the proper installation, operation and
maintenance of your Raypak Heater.
Please review and follow these procedures carefully.
For your safety
do not operate
this appliance
before reading
this instruction
booklet.
WARNING
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 service agency.
WHAT TO DO IF YOU SMELL GAS?
DO NOT try to light any gas appliance
DO NOT touch any electrical switch.
Turn off the gas supply at the gas meter
Immediately, call your gas supplier or licensed gasfitter.
NOTE: Some gases are heavier than air and it may be necessary to check
for gas leaks at floor level.
DO NOT Operate this appliance before reading this instruction booklet.
DO NOT Place articles on or against appliance.
DO NOT Store chemicals or flammable materials in the same room as this
appliance.
DO NOT Store chemicals or flammable materials, on, or spray aerosols near
this appliance.
DO NOT Operate with panels, covers or guards removed from appliance.
DO NOT Enclose this appliance (applies to external models only).
CAUTION
DANGER
Water temperatures above 45 Degrees Celsius can cause severe burns.
Children, disabled and elderly persons are at the highest risk of being scalded.
Feel water before bathing or showering and supervise where necessary.
Part No. 209130.5: Effective 08/01/2001 (Replaces: 01/10/2000)
Model No. ..................... Serial No. .................... Installation Date ..................
PART 1 - FOR YOUR SAFETY
5
Ceramic Firetile Refractory is used in Raypak Heaters
Possible risks of irreversible effects
Harmful by inhalation
May be irritating to the skin, eyes and respiratory system.
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.
• Wear gloves and eye protection.
• Consult Occupational Health and Safety Authority for any further information.
• Rinse any exposed skin areas with clean water.
• Wash work clothing separately.
FIRST FIRING OF HEATER
• Fumes and smoke may be produced.
• Avoid breathing fumes, ventilate area to clear.
• Production of smoke should cease within 30 minutes
REMOVAL OF USED PRODUCT
• Wear an approved mask. Over-exposure to dust formed after service
may cause respiratory disease since cristobalite, a form of crystalline
silica may be formed above 900 degrees Celsius.
• Consult Occupational Health and Safety Authority for further
information regarding removal of used ceramic fibre linings.
AFTER HANDLING
CAUTION!
6
Raypak Commercial
Swimming Pool Heaters
Part 2: Models 538 to 4224
7
PART 2 - SECTION I INSTALLATION INSTRUCTIONS
Before commencing installation:
1. Read these instructions in full !
2. Check that the heater you have
been supplied is suitable for the type of
installation and the gas available. The gas
supply pressure must be between the
minimum and maximum shown on the
heater data plate.
GENERAL
These instructions are provided to ensure the
correct installation and operation of your
Raypak Swimming Pool Heater.
Should any questions arise regarding the
specifications, installation, operation or
servicing of this heater, we suggest that the
local representative or Raypak Customer
Service be consulted.
Raypak heaters utilise a finned copper tube
heat exchanger resulting in a low water content
and reduced "stand by" heat losses. Therefore
a circulator pump of sufficient capacity to
match the heater model must be installed in
the system.
Raypak heaters are fitted with Australian Gas
Association approved components and all
boilers in this range are designed to comply
to AG501.
Some models are designed for either indoor or
outdoor installation subject to the appropriate
indoor draft hood or outdoor stackless top
being fitted.
Check that the correct top for your installation
has been supplied.
INSTALLATION PROCEDURES
All electrical, gas piping, gas connection and
flueing of the heater must only be undertaken
by a properly authorised person. The
installation must comply with local gas, AG6012000 and electrical codes and/or statutory
body codes and regulations.
Raypak heaters must be installed in the
filtration system, in the pool return line,
downstream from the filter.
INSPECTION OF EQUIPMENT
Check the heater and associated equipment for any
damage and if so notify your local representative or
Raypak for any further instructions.
DO NOT INSTALL OR START UP ANY
RAYPAK SUPPLIED PRODUCT THAT HAS
BEEN DAMAGED, WITHOUT FIRST
CONSULTING RAYPAK, AS ANY DAMAGE
OR FAULTS CAUSED BY UNAUTHORISED
START UP MAY NOT BE COVERED BY
OUR WARRANTY.
HEATER LOCATION AND
CLEARANCES
The heater should be located so that any
possible water leaks will not cause damage to
any adjacent areas or structures.
When such locations cannot be avoided, it is
recommended that a suitable drain pan,
adequately drained, be installed under the heater.
This pan must not restrict combustion air flow.
The heater must be mounted on a level noncombustible base such as a concrete slab,
concrete plinth, steel plate etc.
Raypak heaters and equipment must not be
installed on carpeting.
The front of the heater must not be obstructed
by any gas or water piping, electrical conduits,
trees, fences, or other equipment, etc.
COMBUSTION/VENTILATION
AIR
Indoor model heaters must only be installed in
a protective enclosure or properly constructed
plant room with adequate ventilation in
accordance with AG 601 - 2000 Gas
Installation Code.
Ventilation shall be via 2 permanent openings
directly to outside, one at an upper level and
one at low level.
The minimum free area provided by each vent
shall be as calculated by using the following
formula, unless otherwise stated in AG 601.
A =1.5 X T
Where A = Minimum free ventilation area (cm2)
T = Total hourly input of all appliances (Mj/h)
Note: The minimum dimension of any opening
shall be 6mm.
Please take the heater location into account
when locating the fresh air vents because any
excessive draft will cause flame disturbance
and probable pilot outage. In some cases
where excessive draft effects the burner, the
risk of major damage is high due to
incomplete combustion.
Installations which obtain air from a source
other than directly from outside must comply
to AG601.
Warning: Air supply to the heater room
must not be affected by mechanical
exhaust vents located in other parts of
the house or building, such as kitchen or
bathroom fans, spa blowers, etc.
Mechanical exhaust vents may create a negative
pressure in the heater room that can become a
hazard by asphyxiation, explosion or fire.
Caution: Do not store chemicals or flammable
materials in the same room or near this
heater. Do not use aerosols near this heater
whilst it is in operation.
FLUEING
The correct Draft hood must be fixed to the top
of the heater and connected to a properly
constructed flue, vented to the outside using
only approved fittings.
Reduction of the flue diameter or alteration to
the draft hood voids all warranty. Where
flueing may be difficult, please contact Raypak
for advice, we will have solutions, particularly
where a fan assisted flue may be the answer.
The weight of the flue must not rest on the
heater draft diverter, the flue must be self
supporting and be fitted with a disconnection
section (bolted sleeve) to enable the heater top
and draft diverter to be removed easily, for
servicing. Where practicable the flue should run
vertically. Lateral (raised above horizontal) is
acceptable but the run of a flue shall not
exceed 50% of total flue height and shall be
designed to rise not less than 20 mm per 1 m
run. The flue must be terminated with an
approved cowl.
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