Raypak P-1083 Installation Manual

INSTALLATION & OPERATING
INSTRUCTIONS
®
Raytherm Commercial Swimming Pool Heater
Models P-926 to P-1826
& P-2100 to P-4001
WARNING: If 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.
• 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.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference.
CATALOG NO. 6200.51S Effective: 07-01-16 Replaces: 06-16-15 P/N 240251 Rev. 20
WATER CHEMISTRY
(Corrosive water voids all warranties)
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.
Recommended Level(s) Fiberglass Pools Fiberglass Spas
Other Pool & Spa
Types
Water Temp. (Deg. F) 68 to 88 89 to 104 68 to 104
pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8
Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120
Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400
Salt (PPM) 6000 MAXIMUM 6000 MAXIMUM 6000 MAXIMUM
Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3
Total Dissolved Solids (PPM)
3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM
* Free Chlorine MUST NOT EXCEED 5 PPM!
• 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 chlorinators are usually more efficient in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater, and which is not covered under warranty.
• Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water.
Rev. 20 reflects the following: Changes to: Wiring Diagram on page 23 Additions: Deletions: Warranty on page 35
2
CONTENTS
WATER CHEMISTRY 2 WARNINGS 4
Pay Attention to These Terms 4
RECEIVING EQUIPMENT 5 GENERAL SPECIFICATIONS 5 INSTALLATION 5
Code Requirements 5 Base Installation 5 Clearances 6 Combustion Air (Indoor Units Only) 6 Venting Connections 7 Gas Supply Connections 8 Water Connections 10
CONTROLS 10
Flow Switch 10 Water Pressure Switch 11 Automatic Chlorinators and Chemical Feeders 11 Unitherm Governor Operation 11 Companion Flange Connections (Models 926-1223) 11 Mounting the Poolstat Control with Front­Mounted Loop Using Mounting Slots 12 Mounting Well into System Return Loop Pipe - Front-Mounted Loop 14 Piping Configurations for Raytherm Commercial Pool Heaters (926-1223) 15 Piping Configurations for Raytherm Commercial Pool Heaters (1287-1826) 16 Piping Configurations for Raytherm Commercial Pool Heaters (2100-4001) 17 Temperature Controls 18 External Auxiliary Bypass Valve (Where Required) Models 926-1223 Only 18 Auxiliary Bypass Valve Adjustment 18 Electrical Wiring 19
Wiring Diagram—Models 926–1223
with UG 20
Wiring Diagram—Models 926–1826
with H-Bypass 21 Wiring Diagram—Models 2100–2500 22 Wiring Diagram—Models 3001–4001 23
SERVICING 24
General Location Of Controls 24 Temperature Control 24 Pressure Switch 24 Pressure Switch Adjustment 24 Two-Speed Pumps 25 Pilot Safety 25
START-UP PROCEDURES 25
Before Start-Up 25 Start-Up 25 After Start-Up 26
INSPECTION PROCEDURES 26
Burners 26
CONTROLS 26 SERVICING PROCEDURES 27
Tube Cleaning Procedure (Typical) 27 Heat Exchanger Reassembly 27 Burner Drawer Removal 27 Gas Valve Removal 27 Main Burner and Orifice Removal 28 Pilot Removal and Cleaning 28 Heat Exchanger Removal 28 Combustion Chamber Removal 29 Control Well Replacement 29 Tube Replacement Procedure 29 Procedure For Cleaning Flue Gas Passageways 29 Unitherm Governor Replacement 30
MAINTENANCE AND CARE 30
Winterizing Your Heater 31
TROUBLESHOOTING 32
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe person-
DANGER:
I al injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the heater rating plate.
WARNING: Should overheating occur or the gas supply valve fail to shut, do not turn off or disconnect the electrical supply to the heater. Instead, shut off the gas supply at a location external to the heater.
WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
WARNING: To minimize the possibility of improper operation, serious personal injury, fire, or damage to the heater:
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.
CAUTION: Operation of this heater in low­temperature systems requires special piping. Harmful internal condensation will occur if the inlet water temperature does not exceed 105°F. Warranty claims will be denied when condensation occurs.
CAUTION: If this heater is to be installed above radiation level, it must be provided with a low water cut-off device at the time of heater installation.
CAUTION: If this heater is to be installed in a negative or positive pressure equipment room, there are special installation requirements. Consult factory for details.
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.
WARNING: Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water.
WARNING: Risk of electrical shock. More than one disconnect switch may be required to deenergize the equipment before servicing.
4
RECEIVING EQUIPMENT
INSTALLATION
On receipt of the equipment, visually check for exter­nal damage to the carton or the shipping crate. If the carton or shipping crate is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately. Remove the heater from the carton or shipping crate. Do NOT use the shipping base crate as an installation base.
On occasion, we ship some items loose. Be sure that you receive the number of packages indicated on the Bill of Lading. When ordering parts, you must specify Model and Serial Number of heater. When ordering under warranty conditions, you must also specify date of installation.
Raypak recommends that this manual be reviewed thoroughly before installing your Raypak Pool Heater. If there are any questions which this manual does not answer, please contact the factory or your local Raypak representative.
Claims for shortages and damages must be filed with carrier by consignee. Permission to return goods must be factory authorized and are subject to a stocking charge.
These instructions are intended for the use of qualified personnel only, 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 equipment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.
Code Requirements
The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is recom­mended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.
Purchased parts are subject to replacement only under the manufacturer's warranty. Debits for defec­tive replacement parts will not be accepted and will be replaced in kind only per our standard warranties.
GENERAL SPECIFICATIONS
Models 962, 1125, 1223, 1336, 1468, 1631, 1826 & 2100 through 4001 are specifically designed for indoor installation ONLY 1414, 1571 & 1758 are specifically designed for out­door installation ONLY. All heaters are standard with electronic ignition for both natural and propane appli­cations. Heaters require 120V power supply. Control circuits operate at 24V, supplied by an internal 120V to 24V transformer.
These heaters are design certified and tested under the requirements of ANSI Z21.56 / CSA 4.7 American National Standard for Gas-Fired Pool Heaters. Rated inputs are suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000 feet above sea level, as high elevation reduces combustion performance.
. Models 926, 1083, 1178, 1287,
Installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions of the National Fuel Gas Code (NFGC), ANSI Z223.1/NFPA 54, and National Electrical Code (NEC), ANSI/NFPA 70.
Base Installation
Do NOT use the shipping base crate as an installation base. Heater must be mounted on a level base, such as cement slab, cement blocks or other non-com­bustible surface. An optional non-combustible base is available for Indoor Models 962 through 1826. An alternative method for providing a base for com­bustible floors as illustrated below. Heaters may not be installed on carpeting.
Fig. 1: Alternate Mounting Base
5
Clearances
All Heaters
or clearances from combustible surfaces, see
F Table A below. A minimal vertical clearance of three feet between the upper surface of the flue outlet to a noncombustible material is required.
Indoor Heaters
Heater
Side
Top 24 Top 24
Back 24 Back 24
Right Side 24 Right Side 24
Left Side 24 Left Side 24
Vent* 6
*Vent includes factory supplied drafthood and does not include field supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into heater. For servicing provide a front clearance as shown below: Model 926/962-758/1826 - 24" Model 2100-4001 - 48"
Table A: Minimum Clearances from Combustible
For servicing, provide at least 24" in front of the heater on Models 926-1826 & 48" in front of the heater on Models 2100-4001 for burner tray removal, and at least 18" on the right side of the heater to inspect and delime the heat exchanger.
Clearance
(Inches)
Construction
Outdoor Heaters
(926–1758)
Heater
Side
Clearance
(Inches)
Outdoor Heaters (Models 926-1758)
Fig. 2: Minimum Distance from Openings
The point from where the flue products exit the heater must be a minimum of four (4) feet below, four (4) feet horizontally from or one (1) foot above any door, win­dow or gravity inlet to a building. The top surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10 ) feet horizontally.
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' from high vertical walls, or install a wind break so the heater is not in direct wind current.
Indoor Heaters
The design is certified for indoor installation when equipped with approved drafthood. Locate the heater as close as practical to a chimney or gas vent.
These heaters are design-certified for outdoor installa­tion, when equipped with the approved top designated for outdoor use. Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three (3) 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.
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 heavy internal rusting or damage some electrical components, and this would void the warranty.
Combustion Air (Indoor Units Only)
The heater must have both combustion and ventilation air. Openings must not be obstructed. Minimum requirements are from the National Fuel Gas Code (ANSI Z223.1/NFPA 54).
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can cause unwarrantable damage to the heater.
6
he “two-opening” method requires:
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
T
1. Free combustion air 1 sq. in. per 1000 BTU input within 12" of the floor.
2. Free ventilation air 1 sq. in. per 1000 BTU input within 12" of the ceiling level.
NOTE: If the room the heater is installed in is located against an outside wall and air openings communicate directly with the outdoors, the openings may be 1/4 the size specified above (ANSI Z223.1/NFPA 54, latest edition)
Venting Connections
hould be supported at not more than five foot inter-
s vals. Plumber’s tape, criss-crossed, will serve to space both horizontal and vertical piping.
as vents supported only by the flashing and extend-
G ing above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacer through the roofs and walls.
For protection against rain or blockage by snow, the vent pipe must terminate with a vent cap which com­plies with the local codes or, in the absence of such codes, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
Drafthood (Indoor) Models 962-1826
Locate and assemble as shown in Fig. 3. Secure with screws supplied in envelope in carton. Do not modify the drafthood. The height of the relief openings above the cabinet is critical to proper operation.
Fig. 3: Indoor Drafthood
Models 2100-4001 have built-in drafthoods that must be properly vented to the outside.
The discharge opening must be a minimum of two feet vertically from the roof surface and at least two feet higher than any part of the building within ten feet. Vent stack shall be at least five feet in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 feet horizontally from, and in no case above or below, unless a 4-foot hori­zontal distance is maintained, from electric meters, gas meters regulators and relief equipment.
The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood must be readily removable for maintenance and inspection. Vent pipe should be adequately sup­ported to maintain proper clearances from combustible construction.
Type "B" double-wall or equivalent vent pipe, certified for Category I conditions, is recommended. However, single-wall metal vent pipe may be used as specified in the latest edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.
Vent Piping
WARNING: An indoor heater requires a drafthood
that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.
Vent piping the same size or larger than the drafthood outlet is recommended, however, when the total vent height is at least ten (10) feet (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition. Avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal or non-vertical runs, the vent pipe must have a minimum of 1/4 inch per foot rise and
Fig. 4: Venting Clearances
7
S
EDIMENT
T
RAP
MANUAL
SHUT-OFF
VALV E
At the time of removal of an existing heater, the follow­ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain­ing connected to the common venting system are not in operation.
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which the appliances remaining connected to the com­mon venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will oper­ate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a ciga­rette, cigar or pipe.
(f) After it has been determined that each appliance
remaining connected to the common venting sys­tem properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
(g) Any improper operation of the common venting
system should be corrected so the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When re­sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
For special venting applications that require reduced vent sizes or through-the-wall venting, the optional D Series Power Vent can be used. Consult the factory or your local Raypak representative.
Gas Supply Connections
Per NFGC requirements, gas piping must have a sed­iment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jack­et. All gas piping should be tested after installation in
ccordance with local codes.
a
Fig. 5: Gas Piping
CAUTION: The heater and its manual shut-off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 psig (3.45 KPA). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut-off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURIZED GAS VALVES ARE NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use open flame.
CAUTION: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.
A minimum of 7 in. WC and a maximum of 10.5 in. WC upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 11 in. WC and a maximum of 13 in. WC for propane gas.
Gas Pressure Regulator
The gas pressure regulator is preset and sealed at 4 in. WC for natural gas, and 11 in. WC for propane gas. Between the gas valve and the burners is a 1/8" pipe plug. The pressure at this point, taken with a manome­ter, should be about 3.7 in. WC natural gas and 10.5 in. WC propane gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise
, to increase pressure or counter-clockwise , to decrease pressure.
8
MANOMETER
GAS PRESSURE
T
ES T AT G AS
V
ALVE
GAS PRESSURE TEST
AT HEATER
M
ANUAL
SHUTOFF
V
ALVE
G
AS PRESSURE
TEST UPSTREAM
Fig. 6: Gas Pressure Test Points
Venting of Diaphragm Gas Components
Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.
Heaters with gastrain components that have diaphragms in their construction are supplied with a bleed line connection that must be connected to the outside atmosphere as required by the National Fuel
Model
No.
1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 4”
N P N P N P N P N P N P N P
Bleed Line Connection
Fig. 7: Bleed Line Connection
926/962 15 20 45 45 110 150 360 400
1083/1125 10 15 35 35 80 120 300 300
1178/1223 25 25 60 85 220 200
1287/1336 25 20 55 75 180 170 325 560
1414/1468 20 15 45 65 150 165 300 500
1571/1631 15 15 35 50 20 125 250 400
1758/1826 15 10 30 40 100 100 225 340
2100 10 10 25 30 80 75 175 260
2500 15 20 55 55 135 160 400 600
3001 10 15 35 40 85 120 250 500
3500 10 30 30 45 80 200 400 600
4001 5 20 25 35 65 160 300 400
Natural Gas, 1000 BTU/FT3.60 Specific Gravity @ 0.5 in. WC Pressure Drop Propane Gas, 2500 BTU/FT31.53 Specific Gravity @ 0.6 in. WC Pressure Drop
Table B: Maximum Equivalent Pipe Length
9
Water Connections
Location
Models 926-1223 With UG
The heater requires water flow and positive pressure to fire and operate properly. It must therefore be installed downstream of the discharge side of the filter pump. A typical installation is plumbed as follows:
1. The inlet side of the filter is plumbed directly to the discharge side of the filter pump;
2. The outlet side of the filter is then plumbed to the inlet of the heater; and
3. The outlet of the heater is plumbed to the return line to the pool or spa. The pump, filter and heater are thus plumbed in series.
low temperature piping. A fireman switch included in the time clock may be used for this purpose with instructions not to override this sequence manually. See wiring diagram section for electrical hookup loca­tion of the fireman switch in the electrical circuit.
NOTE: If piping is used into the heater, this piping (copper) must be anchored or screwed into the flange (metal) if operating pressures above 30 PSI are encountered.
All Models With H-Bypass or CWR
These heaters must be installed using primary/sec­ondary piping. For multiple-heater installations, use reverse-return logic to ensure equal duty cycles. Flow in the main line must be at least 120% of the heater flow. See pages 16-17.
CONTROLS
Heater must be located so that any water leaks will not damage the structure of adjacent area. High-tempera­ture plastic pipe (CPVC) may be connected directly into the heater, if local codes permit and if controls operate the pump for at least fifteen minutes after the heater is turned off.
CAUTION: NEVER install PVC directly into heater. Four feet of copper or high temperature pipe and two elbows are required between the heater and the PVC connections. See Fig. 8 below.
Flow Switch
This dual purpose control shuts off the boiler in the case of a pump failure or low water condition. It is mounted and wired in series to the main gas valve. Standard on all units except on UG models.
NOTE: Flow switch will not operate if flow is less than:
Models 926-1223 60 gpm Models 1287-1826 85 gpm Models 2100-4001 180 gpm
Fig. 8: Plumbing
When local codes permit the use of less than four feet of high-temperature piping or two elbows, provisions should be made to always shut the heater off a mini­mum of 15 minutes prior to pump shutdown in order to carry away residual heat and prevent damage to the
Fig. 9: Flow Switch
10
Water Pressure Switch
Unitherm Governor Operation
On Models 926-1223 built with a Unitherm Governor (UG), a water pressure switch is provided in the heater instead of a flow switch, to shut down the gas valves in the event the water supply to the heater is interrupt-
d. It is very important to verify that the switch
e electrically opens and shuts off the gas valve when water flow to the heater is interrupted.
Otherwise, rapid and severe damage to the heater will likely occur. (The water pressure switch should be checked and adjusted for proper operation by a quali­fied service person at the time of installation and periodically checked thereafter. Refer to pressure switch servicing instructions on page 24).
WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.
Automatic Chlorinators and 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 chlorine tablets or bromine sticks in the skimmer. High chemical concen­trations will result when the pump is not running (eg, overnight).
The patented Unitherm Governor (UG) is a thermosta­tic mixing valve specifically designed to maintain constant heater internal temperature between 105° and 115°F despite continually changing flow rates from
he filter and changing pool temperatures. This narrow
t range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time with an inlet temperature below 105°F. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scal­ing temperatures.
The Unitherm Governor is the default configuration on models 926 through 1223. Where installed, it is built into the inlet/outlet header. The larger sizes, models 1287 through 4001, do not have a UG option. Instead, they have an externally-mounted bypass pump that is designed to maintain the water entering the heater at the proper temperature to prevent condensation and scale. Thermometers are provided on the inlet and outlet to the heater.
Companion Flange Connections (Models 926-1223 with UG)
DO NOT use petroleum base assembly fluids (such as Petroleum Jelly or Lubricating Oil). If assembly lube is required use a silicone base such as Armoral etc.
Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off.
NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heater. Such damage is not covered under the warranty.
The inlet/outlet header flange accepts a 2" copper tube as a slip connection directly into the header. The flange is also threaded for a 2 NPT copper male adapter.
Fig. 10: Companion Flange Connections
(Models 926–1223 with UG)
11
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