Raypak P-926, 1287-1758, P-1826, P-2100, P-4001 User Manual

...

INSTALLATION AND OPERA TING INSTRUCTIONS

RAYTHERM

COMMMERCIAL SWIMMING POOL HEATER

Models

P-926 to P-1826

CATALOG NO. 6200.51O Effective: 04-09-07 Replaces: 05-15-05

Models 1287-1758

and P-2100 to P-4001

Models 2100-4001

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of

this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• 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 a safe place for future reference.

P/N 240251 Rev. 16

Contents

SECTION 1: RECEIVING EQUIPMENT

SECTION 2: GENERAL SPECIFICATIONS

SECTION 3: INSTALLATION INSTRUCTIONS

Code Requirements

Base Installation

Clearances

Combustion Air

Venting Connections

Gas Supply Connections

Water connections

Controls

Wiring Diagrams

SECTION 4: SERVICING INSTRUCTIONS

General Location of Controls

Start-Up Procedures

Inspection Procedures

Servicing Procedures

Maintenance & Care

SECTION 5: TROUBLE SHOOTING

Mechanical

Electrical

SECTION 6: REPLACEMENT PARTS

WARRANTY

SECTION 1 / RECEIVING EQUIPMENT

On receipt of the equipment, visually check for external

IMPORTANT NOTICE

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 boiler 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

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.

Serial Number of boiler. 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

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.

representative.

Claims for shortages and damages must be filed with

CODE REQUIREMENTS

carrier by consignee. Permission to return goods must be factory authorized and are subject to a stocking charge.

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.

NOTE: 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.

SECTION 2 / GENERAL SPECIFICATIONS

Installation must be in accordance with local codes,

Models 962, 1125, 1223, 1336, 1468, 1631, 1826 & 2100 through 4001 are specifically designed for indoor

or, in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and National Electrical Code, ANSI/NFPA 70.

installation only. Models 926, 1083, 1178, 1287, 1414, 1571 & 1758 are specifically designed for outdoor instal-

BASE INSTALLATION

lation only. All heaters are standard with electronic ignition for both natural and propane applications. Heaters require 115V power supply. Control circuits operate at 24V, to be supplied by a 115V to 24V transformer.

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

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 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.

surface. An optional non-combustible base is available for Indoor Heater 962 through 1826. An alternative method for providing a base for combustible floors as illustrated below. Heaters may not be installed on

carpeting.

12"

inimum

HEATER

Minimu

SECTION 3 / INSTALLATION INSTRUCTIONS

Sheet Metal

CALIFORNIA PROPOSITION 65 WARNING:

This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Hollow concrete cinder block; align holes and leave

ends open. Alternative method for providing a non-com-

Minimum

bustible base.

24 Gauge

Fig. #8148

CLEARANCES

ALL HEATERS For clearances from combustible surfaces, see chart below. We require a minimal vertical clearance of three feet between the upper surface of the flue outlet to a noncombustible material.

MINIMUM CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

INDOOR HEATERS

Top - 24" *Vent - 6" Back - 24" Right Side - 24" Left Side - 24"

OUTDOOR HEATERS (926-1758)

Top - unobstructed Back - 24" Right side - 24" Left Side - 24"

For servicing provide a front clearance as shown below

Model 926/962-758/1826 - 24" Model 2100-4001 - 48"

*Vent includes factory supplied drafthood and does not include field supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into boiler.

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.

OUTDOOR HEATERS (MODELS 926-1758)

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 the heaters installed under overhangs with the use of gutters.

foot

Minimum

foot

Minimum

Forced Air Inlet

foot

Minimum

foot

Minimum

foot

Minimum

Fig. #8245

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 also certified for indoor installation when equipped with approved drafthood. Locate heater as close as practical to a chimney or gas vent.

COMBUSTION AIR (INDOOR UNITS ONLY)

The heater must have both combustion and ventilation air. Openings must not be obstructed. Minimum requirements are as follows:

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

1. Free combustion air 1 sq. in. per 1000 BTU

input within 12" of the floor.

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.

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

DRAFTHOOD (INDOOR) MODELS 962-1826

Locate and assemble as shown below. Secure with

screws supplied in envelope in carton.

Fig # 8165

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.

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 boiler drafthood. Support must be provided in compliance with applicable codes. The heater top and draft hood 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 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.

Models 2100-4001 have built-in drafthoods that must be properly vented to the outside.

VENT PIPING

WARNING:

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 draft hood 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 Chapter 10 of the National Fuel Gas Code, ANSI Z 223.1/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 should be supported at not more than five foot intervals. Plumbers' tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending 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.

10' OR LESS

2' MIN

VENT PIPE

DRAFT HOOD

HEATER

VENT CAP

2' MIN

5' MIN

Fig. #8119

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.

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.

GAS SUPPLY CONNECTIONS

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 accordance with local codes.

MANUAL SHUT HEATER GAS VALVE

OFF VALVE JACKET

GAS INLET

UNION SEDIMENT TRAP

FIG. #8090.0

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.

(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 re-sizing 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 Part 11 of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54.

For special venting applications that require reduced vent sizes and through the wall venting, the optional D Series Power Vent can be used. Consult the factory or your local Raypak representative.

NOTE: Do not use teflon tape on gas line pipe thread.

A flexible sealant is recommended.

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 counterclocwise , to decrease pressure.

GAS PRESSURE MANOMETER

TEST UPSTREAM MANUAL

SHUT-OFF

VALVE

GAS PRESSURE TEST

AT GAS VALVE GAS PRESSURE TEST

AT HEATER

PIPE SIZING FOR GAS CONNECTIONS

Fig. #8149.0

Bleed Line Connection

Fig. # 8185.2

WATER CONNECTIONS

LOCATION

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.

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 Models 926-1223, if local codes permit and if controls operate the pump for at least fifteen minutes after the heater is turned off.

VENTING OF DIAPHRAGM GAS COMPONENTS

Heaters have gas train 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 Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.

CAUTION (Models 926-1223): 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.

Fig. # 8129.0

When local codes permit the use of less than four feet high temperature piping or two elbows, provisions should be made to always shut the heater off a minimum of 15 minutes prior to pump shut down in order to carry away residual heat and prevent damage to the 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 (Models 926-1223): 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.

CONTROLS

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to shut down the gas valves in the event the water supply to the heater is interrupted. It is very important to verify that the switch 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 in Section 4 of this manual).

WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.

AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS

UNITHERM GOVERNOR OPERATION

The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105° to 115°F despite continually changing flow rates from the filter and changing pool temperatures. This narrow range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time below 100°F. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.

The Unitherm Governor is built into the inlet/outlet header on models 926 through 1223. The larger sizes, models 1287 through 4001, have an externally mounted bypass pump that is designed to maintain the water entering the heater at the proper temperature that will prevent condensation and scale. Thermometers are provided on the inlet and outlet to the heater.

COMPANION FLANGE CONNECTIONS (Models 926-1223)

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.

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.

MODELS 926 - 1223

INLET/OUTLET HEADER

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).

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.

FLANGE GASKET

OUTLET

INLET HEADER FLANGE

Fig. #8221.0

MODELS 1287/1336 - 1758/1826

1-1/2" Slip Ball Valve

2-1/2" Outlet

2-1/2" Inlet

MODELS 2100-4001

2" Slip Ball Valve

3" Outlet

Inlet/Outlet Header

Pump

Inlet/Outlet Header

Fig. #9200

3" Inlet

2 H.P. Pump

FLOW RATES/WATER CONNECTIONS

MODEL CONNECTION SIZE MIN GPM MAX GPM

926-1223 * 60 120 1287-1826 2-1/2" FPT Refer to flow rate table 2100-4001 3" FPT

LOOP* HEATER

FLOW FLOW

RATES RATES

MODELS (GPM) (GPM)

1287/1336 30-50 85 1414/1468 35-55 85 1571/1631 40-65 85 1758/1826 45-70 85

2100 50-80 180 2500 60-95 180 3001 75-115 180 3500 90-135 180 4001 100-150 180

*Loop is secondary piping to heater from main system.

Fig. #9270

Raypak recommends the installation of an air bleed vent at a suitable location (usually the highest point) to remove air from the piping system. These units should be available at your local wholesale supplier. Raypak does not provide this item.

CAUTION:

Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation. Improper flow control can damage the heater. Uncontrolled flow (too high) or restricted flow (too low) can

seriously affect heater operation. Follow these instructions to make sure your heater is properly installed.

Models 1287 through 4001 are equipped with an external pump and bypass arrangement that blends outlet water with the inlet to increase the inlet water temperature, thereby reducing the likelihood of condensation forming on the heat exchanger. The pump also serves to circulate water through the heater from the main system piping.

To complete the installation of the pool heater, the pool thermostat needs to be installed in the main return water line. This will ensure that the heater will be energized at the right time. If the main water line is too far away from the heater and the capillary bulb will not reach it, locate the pool thermostat adjacent to the main line and run wires back to the heater. Follow the instructions listed below to install the pool stat.

MOUNTING THE POOLSTAT CONTROL WITH FRONT-MOUNTED LOOP USING MOUNTING SLOTS

For heater models:

1287, 1336, 1414, 1468, 1571, 1631, 1758, 1826, 2100, 2500, 3001, 3500, 4001. Note: For more detail on piping, see figures 9268 and 9269.

1. Remove the poolstat control cover by removing the two cover screws at the top. See Figs. 1 & 2.

2. Lace metal strapping or clamps, (NOT PROVIDED) through the ¾” slots on the cover and fasten securely to pipe as shown in Figs. 3 & 4. NOTE: Do not over-tighten clamps.

3. Remove either the left or right “knock-out” for wiring on the poolstat control as shown in Fig. 5.

4. Attach appropriate conduit and connectors to the poolstat control.

5. Attach wires to the poolstat wire terminals. See Fig.6.

6. Install poolstat control to the cover and fasten cover screws.

7. Poolstat should be mounted level as shown in Fig. 7.

Fig. 3: Hose Clamp Slots

Fig. 4

Fig. 1: Poolstat Control

Fig. 2: Control Cover

Fig. 5 Fig. 6 Fig. 7

MOUNTING WELL INTO SYSTEM RETURN LOOP PIPE - FRONT-MOUNTED LOOP:

Note: For more detail on piping configurations for large systems, see figures 9268 and 9269.

1. Locate and mark an area on the main system return loop pipe where the well is always exposed to the water circulating back from the pool. See Fig. 8.

2. Shut off water and drain any water from the pipe as necessary.

3. Drill a 23/32" diameter hole (½” NPT) into the pipe as shown in Fig. 9.

4. Using a ½” NPT tap and appropriate handle, thread the tap into the pipe.

5. Apply pipe dope as necessary to male threads of well and insert into threaded hole.

Note: Do not over-tighten well.

Fig. 8

Fig. 10

Fig. 9

Note: The drawings and instructions above show only one of several acceptable ways of installing the dry well into main system loop. The use of saddle clamps and “Weld O Lets” (shown in Fig. 10) are acceptable. Follow clamp manufacturer’s instructions.

To adjust the temperature:

1. Both isolation valves must be fully open.

2. Adjust Bypass Valve "A" 1/2 open and Balancing Valve "B" fully open. (See piping configuration page 11)

3. Fire your Raypak pool heater and adjust Bypass Valve "A" to obtain a heater inlet temperature approximately 100°F-105°F. Turning Valve A in the open direction will raise the heater inlet temperature and closing Valve "A" will lower the heater inlet temperature.

4. If the heater inlet temperature remains less than 100°F and Valve "A" is fully open, leave Valve "A" fully open and throttle Valve "B" until the heater inlet temperature rises to within the range of 100°F-105°F.

5. The resultant heater outlet temperature should be in the range of 120-130°F.

6. As the pool temperature rises to the desired temperature as controlled by the Pool aquastat, small adjustments to valves "A" and "B" will be required for optimum performance. Heater temperatures should be checked regularly to prevent heater condensation. The heater inlet temperature can be higher than 100°F without heater damage but operating at less than 100°F inlet can cause damage from condensation.

Note: Consult factory if target temperatures cannot be achieved.

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