Raypak Pool Spa Gas Heaters Installation Manual

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Raypak Pool & Spa Gas Heaters
Owner’s Guide and Installation Instructions
Residential & Premium Range
Models
Natural Gas
Propane
Residential Pool & Spa
Heater Models:
P0131NCO/OD
P0131PCO/OD
P0200A-N
P0200A-P
P0280A-N
P0280A-P
P0350A-N
P0350A-P
P0430A-N
P0430A-P
Premium Pool & Spa
Heater Models:
P0127NNO
P0127PNO
PC0280A-N
PC0280A-P
PC0430A-N
PC0430A-P
Please read this manual prior to installing this product. It contains all the necessary technical and installation information that will be required by the contractor to correctly install this system. An electronic copy of these Owner’s Guide and Installation Instructions can be downloaded from rheemthermal.com.au. This product must be installed in accordance with the installation instructions and in compliance with standards AS/NZS 5601.1, AS/NZS 3500.4, AS/NZS 3000, the relevant electrical authorities’ requirements and all local codes and regulatory requirements.
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CONTENTS
RHEEM WARRANTY (Australia Only) ......................................................................................................... 3
SAFETY AND WARNINGS ......................................................................................................................... 5
WHAT TO DO IF YOU SMELL GAS ........................................................................................................... 5
WATER TREATMENT ................................................................................................................................ 6
INSTALLATION INSTRUCTIONS ............................................................................................................... 7
PRECAUTIONS ........................................................................................................................................ 11
PERIODIC MAINTENANCE ...................................................................................................................... 12
COMMISSIONING .................................................................................................................................... 13
RESET BUTTON ...................................................................................................................................... 14
OPERATING INSTRUCTIONS.................................................................................................................. 16
PROGRAMMING OF POOL OR SPA HEATER CONTROLLER ............................................................... 18
ELECTRICAL CONNECTIONS ................................................................................................................. 20
DIMENSIONAL & TECHNICAL DATA ....................................................................................................... 21
WIRING DIAGRAMS ................................................................................................................................. 24
POOL HEATER OPERATION FLOW CHART ........................................................................................... 27
Date of installation:
Model No.
Serial No.
Installed by:
Purchased from:
This Owners Guide and Installation Instructions manual is provided with the necessary information for the proper installation, operation and maintenance of your Raypak pool or spa heater. Please review and follow these procedures carefully. Keep this manual in a safe and accessible place for easy reference in the future.
Warning: Upon completion of the installation and commissioning, leave this guide with the householder
or responsible officer.
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RHEEM WARRANTY (Australia Only)
Raypak Pool & Spa Heater Models: P0127, P0131, P0200A, P0280A, P0350A, P0430A, PC0280A & PC0430A
1. THE RHEEM WARRANTY – GENERAL
1.1 This warranty is given by Rheem Australia Pty Limited ABN 21 098 823 511 of 1 Alan Street, Rydalmere New South Wales.
1.2 Rheem offer a trained and qualified national service network who will repair or replace components at the address of the water heater subject to
the terms of the Rheem warranty. Rheem Service, in addition can provide preventative maintenance and advice on the operation of your water heater. The Rheem Service contact number is 131031 with Contact Centre personnel available 24 hours, 7 days a week to take your call and if necessary arrange a service call for during normal working hours Monday to Friday (hours subject to change).
1.3 For details about this warranty, you can contact us on 131 031 or by email at warrantyenquiry@rheem.com.au (not for service bookings).
1.4 The terms of this warranty are set out in section 2 and apply to Raypak pool & spa heaters manufactured after 1
st
October 2015.
1.5 If a subsequent version of this warranty is published, the terms of that warranty will apply to pool & spa heaters manufactured after the date specified
in the subsequent version.
1.6 The application of the Rheem warranty is dependent on payment for the Raypak pool or spa heater being made in accordance with Rheem’s
Standard Terms and Conditions of Sale.
2. TERMS OF THE RHEEM WARRANTY AND EXCLUSIONS TO IT
2.1 The decision of whether to repair or replace a faulty component is at Rheem’s sole discretion.
2.2 If you require a call out and we find that the fault is not covered by the Rheem warranty, you are responsible for our standard call out charge. If you
wish to have the relevant component repaired or replaced by Rheem that service will be at your cost.
2.3 Where a failed component is replaced under this warranty, the balance of the original warranty period will remain effective. The replacement does
not carry a new Rheem warranty.
2.4 Where the pool or spa heater is installed outside the boundaries of a metropolitan area as defined by Rheem or further than 25 km from either a
regional Rheem branch office or an Accredited Rheem Service Agent's office, the cost of transport, insurance and travelling between the nearest branch office or Rheem Accredited Service Agent’s office and the installed site shall be the owner’s responsibility.
2.5 Where the pool or spa heater is installed in a position that does not allow safe or ready access, the cost of that access, including the cost of
additional materials handling and/or safety equipment, shall be the owner’s responsibility. In other words, the cost of dismantling or removing cupboards, doors or walls and the cost of any special equipment to bring the pool or spa heater to floor or ground level or to a serviceable position is not covered by this warranty.
2.6 This warranty only applies to the original and genuine Raypak pool & spa heater in its original installed location and any genuine Raypak
replacement parts.
2.7 The Rheem warranty does not cover faults that are a result of: a) Accidental damage to the pool or spa heater or any component (for example: (i) Acts of God such as floods, storms, fires, lightning strikes and
the like; and (ii) third party acts or omissions).
b) Misuse or abnormal use of the pool or spa heater. c) Installation not in accordance with the Owner’s Guide and Installation Instructions or with relevant statutory and local requirements in the State
or Territory in which the pool or spa heater is installed.
d) Connection at any time to a pool or spa that does not comply with the guidelines as outlined in the Owner’s Guide and Installation Instructions. e) Repairs, attempts to repair or modifications to the pool or spa heater by a person other than Rheem Service or a Rheem Accredited Service
Agent.
f) Faulty plumbing or faulty power supply. g) Failure to maintain the pool or spa heater in accordance with the Owner's Guide and Installation Instructions. h) Transport damage. i) Fair wear and tear from adverse conditions (for example, corrosion). j) Cosmetic defects
2.8 Subject to any statutory provisions to the contrary, this warranty excludes any and all claims for damage to furniture, carpet, walls, foundations or
any other consequential loss either directly or indirectly due to leakage from the pool or spa heater, or due to leakage from fittings and/ or pipe work of metal, plastic or other materials caused by water temperature, workmanship or other modes of failure
2.9 If the pool or spa heater is not sized in accordance with the guidelines in Raypak’s pool & spa heater literature, any resultant fault will not be
covered by Rheem's warranty.
2.10 The Rheem warranty is not applicable if the installation of the pool or spa heater is carried out by an installer not approved by Rheem or a person
who is considered qualified and qualified to do so in the opinion of Rheem.
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3. WHAT IS COVERED BY THE RHEEM WARRANTY FOR THE POOL & SPA HEATERS DETAILED IN THIS DOCUMENT
3.1 Rheem will repair or replace a faulty component of your pool or spa heater if it fails to operate in accordance with its specifications as follows:
Models
What components are
covered
The period in which the
fault must appear in order
to be covered
What coverage you receive
Residential P0131, P0200A,
P0280A, P0350A & P0430A
All components
Years 1 to 3
Repair and/or replacement of the faulty component,
free of charge, when installed at a Single Family
Dwelling for the purpose of heating a pool or spa
Premium (Light Commercial)
P0127, PC0280A & PC0430A
All components
Years 1 to 3
Repair and/or replacement of the faulty component,
free of charge
All above models
Labour
Year 1
Repair and/or replacement of the faulty component,
free of charge
Residential P0131, P0200A,
P0280A, P0350A & P0430A
All components
Months 1 to 6
Repair and/or replacement of the faulty component,
free of charge, when installed at other than a Single
Family Dwelling for the purpose of heating a pool or
spa
Labour
Months 1 to 6
Repair and/or replacement of the faulty component,
free of charge
4. ENTITLEMENT TO MAKE A CLAIM UNDER THIS WARRANTY
4.1 To be entitled to make a claim under this warranty you need to:
a). Be the owner of the pool or spa heater or have consent of the owner to act on their behalf b). Contact Rheem Service without undue delay after detection of the defect and in any event, within the applicable warranty period.
4.2 You are not entitled to make a claim under this warranty if your pool or spa heater:
a). Does not have its original serial numbers or rating labels. b). Is not installed in Australia.
5. HOW TO MAKE A CLAIM UNDER THIS WARRANTY
5.1 If you wish to make a claim under this warranty, you need to:
a). Contact Rheem on 131 031 and provide owner’s details, address of the pool or spa heater, a contact number and date of installation of the pool or spa heater or if that’s unavailable, the date of manufacture and serial number (from the rating label on the heater)
b). Rheem will arrange for the pool or spa heater to be tested and assessed on-site. c). If Rheem determines that you have a valid warranty claim, Rheem will repair or replace faulty parts and components and or the pool or spa
heater in accordance with this warranty.
5.2 Any expenses incurred in the making of a claim under this warranty will be borne by you.
6. THE AUSTRALIAN CONSUMER LAW
6.1 Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a
major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
6.2 The Rheem warranty (set out above) is in addition to any rights and remedies that you may have under the Australian Consumer Law.
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SAFETY AND WARNINGS
For your safety do not operate this appliance before reading this instruction booklet! 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 Rheem® Service agent. For your own safety only have this appliance installed by a qualified gas fitter who must issue you with a compliance certificate
when complete. Persons taking medications which induce drowsiness should not use spas. Persons with a medical history of heart disease circulatory or blood pressure problems, or diabetes should obtain their Doctor’s advice prior to using a spa.
SAFETY AND WARNINGS
This pool heater is only intended to be operated by persons who have the experience or the knowledge and the capabilities to do so.
This pool heater is not intended to be operated by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge. Children should be supervised to ensure they do not interfere with the pool heater.
The pool heater uses 240 Volt AC electrical power for operation of the control systems. The removal of the access cover(s) will expose 240 V wiring. They must only be removed by an authorised or qualified person.
DO NOT modify this pool heater.
DO NOT use or store flammable materials in or near this pool heater.
Flammable liquids (such as petrol), combustible materials (such as newspapers) and similar articles must be kept well away from the pool heater and the draught diverter or flue terminal.
DO NOT spray aerosols in the vicinity of the pool heater whilst it is operating. Gases from some aerosol sprays become corrosive when drawn into a flame.
DO NOT store swimming pool chemicals, household cleaners, etc., near the pool heater.
DO NOT place articles on or against this pool heater or in contact with the flue terminal. Ensure the flue terminal is not obstructed in any way at any time.
DO NOT use Propane / Butane gas mixtures in a Propane model. A Propane model is designed to operate on Propane only. The use of Propane / Butane mixture, such as automotive LPG fuel, in a Propane model is unsafe and can cause damage to the pool heater.
DO NOT operate with panels, covers or guards removed from the pool heater.
DO NOT enclose this pool heater (applies to external installations only).
DO NOT operate this appliance whilst a suction plate is fitted in the skimmer box for cleaning your pool. E.g.: With a vacuum
hose suction operated cleaning device
DO NOT use this appliance to heat water for drinking.
DO NOT enter water heated by this appliance without testing temperature first. Prolonged exposure to elevated water
temperatures may be hazardous to your health.
WHAT TO DO IF YOU SMELL GAS
DO NOT try to light this appliance.
DO NOT touch any electrical switch.
TURN OFF the gas supply at the meter immediately, contact a qualified gas fitter or Rheem Service.
NOTE: Some gases are heavier than air and it may be necessary to check for gas leaks at floor level.
Ceramic Fire tile refractory is used in this appliance. For a current Material Safety Data Sheet (MSDS) go to
www.morganthermalceramics.com\en-gb\datasheets\safety-datasheets and enter “MSDS 244” in the search. Ceramic Fire tile
refractory may produce smoke when the appliance is first started. Ensure area is well ventilated when lighting appliance. Avoid breathing fumes.
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WATER TREATMENT
IMPORTANT! CORROSIVE WATER VOIDS YOUR WARRANTY
This pool or spa heater must be installed in accordance with this advice to be covered by Rheem’s warranty. This pool or spa heater is manufactured to suit the water balance specified on the table below. However, there are some known water chemistries which can have detrimental effects on the pool or spa heater and its operation and/or life expectancy. This pool or spa heater must be installed in accordance with this advice to be covered by the Rheem warranty
For your health and the protection of your heater it is essential that your water quality is always chemically balanced. Only incorrect water balance will cause your heat exchanger to corrode. After corrosion occurs, subsequent water chemical tests may not reveal the water quality at the time that the damage occurred. Do not replace any corroded parts before bringing your water quality back into balance. The following table provides a guide to good water balance:
Fibreglass Pools
(less than 31C)
Fibreglass Spas
(more than 31C)
Other Pools &
Spas
pH
7.3 - 7.4
7.3 - 7.4
7.6 - 7.8
Total Alkalinity (PPM)
120 - 150
120 - 150
80 - 120
Calcium Hardness (PPM)
200 - 300
200 - 300
200 - 400
Salt (PPM)
6,000 MAX
6,000 MAX
6,000 MAX
Free Chlorine (PPM)*
2 - 3
2 - 3
2 - 3
Langelier Saturation Index
±0.3
±0.3
±0.3
* FREE CHLORINE MUST NOT EXCEED 4 PPM
* FREE BROMINE MUST NOT EXCEED 5 PPM
There are several factors that need to be considered in order to avoid damage to your heater.
Automatic chemical dosing devices and chlorinators are usually more efficient in heated water and/or covered pools/spas. Unless controlled, they may lead to excessive chlorine levels which can damage your heater.
If the sanitising level in your pool/spa is too high, your test kit or that of your pool shop may not show the correct chlorine/bromine concentration.
If your salt chlorinator operates for extended periods whilst the pool is being heated and the weather is overcast or your pool is enclosed / covered, the chlorine may exceed the recommended levels.
The balance of your pool water depends on a combination of pH, total alkalinity, calcium hardness and temperature. Combined, these factors enable the Langelier Saturation Index to be calculated. It is essential these factors are maintained at the recommended levels so that the water is balanced and the sanitation of your pool will be optimal.
When adding acid to lower your pH, it must always be added in small quantities and spread uniformly over the entire pool surface. DO NOT add acid one litre at a time. Instead, add a cupful each day. DO NOT add acid into the skimmer box.
This may potentially lead to corrosion of your heat exchanger. Refer to “Periodic Maintenance” on page 12.
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INSTALLATION INSTRUCTIONS
Warning: This appliance must be installed in accordance with all local state and federal laws including the regulations of any government bodies and in complete accordance with these instructions. Where these instructions are contrary to the law or regulations of an appropriate government body those laws or regulations should take precedence subject to there being no compromise to safety.
BEFORE YOU COMMENCE INSTALLATION
1. Read these instructions in full.
2. Check that the pool or spa heater you have been supplied is suitable for the gas type that is available.
3. Ensure that your gas fitter checks that the gas supply pressure is between the minimum and maximum specified on the heater
data plate.
4. Confirm that the heater you have purchased is suitable for the location it is to be installed, i.e. Outdoor or Indoor.
5. Check that your pool system pump will provide water flow between the specified minimum and maximum flow rates required for
the heater to operate.
6. Remove packaging and timber base before installation.
7. Complete all details on the page 2 of this book.
PRODUCT APPLICATIONS
Raypak Residential pool & spa heaters are designed and built for installation in applications where the intention of its use is to heat a pool or spa of a single family dwelling. Its use in an application other than this may shorten its life. Residential heaters are not intended for installation in commercial applications such as multi residential apartments. For these applications a Raypak Commercialpool or spa heater (also referred to as “Premium”) pool or spa heater should be selected.
See WARRANTY & SERVICE sections in this book for details of the different Rheem warranties dependent on the heater type and its intended application.
HEATER LOCATION
The heater must be located so that any possible water leaks will not damage adjacent areas or structures. When such locations cannot be avoided it is recommended that a suitable safe tray be constructed and installed by your plumber. This must not restrict air required for combustion.
The heater must be located on a level non-combustible surface such as concrete. All packaging must be removed before installation.
OUTDOOR HEATERS
Raypak pool & spa heaters are built for outdoor installations as standard. The installation must conform to AS/NZS 5601.1 as a minimum. They must not be installed in any enclosed structure or under eaves, roof overhangs, or pool decks. Outdoor pool & spa heaters must be installed at least 1500mm from any window or room ventilation opening. They must also have no obstructions above the appliance.
If installing the heater on a raised base, the base must be non-combustible and contain no air openings or perforations. Drafts from below the heater can affect its operation.
High Wind Areas
Raypak pool & spa heaters are atmospherically vented and so may not function correctly in areas of sudden changing air pressure often caused by high or variable wind speeds. In some instances, it may be necessary to install either a Raypak High Wind Top or a Raypak Induced Draft Fan to ensure correct operation. These options should be discussed with Rheem before installation.
In areas of "constant extreme winds" or in areas where high winds frequently occur, it is necessary to locate the heater a minimum of one (1) metre from high vertical walls, or install a wind break so that the heater is not positioned and exposed in the direction of the prevailing winds.
INDOOR HEATERS
Combustion / Ventilation Air
Indoor pool & spa heaters must only be installed in a protective enclosure or properly constructed room, with ventilation in accordance with AS/NZS 5601.1. Ventilation must be provided via two permanent openings, one at ceiling level and one at floor level. Minimum vent area must be in accordance with AS/NZS 5601.1. Minimum opening dimensions in the vent must be at least 6mm.
For indoor applications the pool or spa heater must have at least the minimum clearances specified in the table below on page 8. Increased clearances should be provided where possible to improve serviceability. If the pool or spa heater is not installed in accordance with the sufficient and safe space for ease of service around the unit, Rheem advises that the pool or spa heater will be disconnected and removed to enable servicing.
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Note: The following table details minimum acceptable clearances (mm) for serviceability and for indoor installations on non­combustible floors only:
Models P0127, P0200, P0280, P0350, P0430, PC0280, PC0430
Rear
Front
Water
Side
Non-Water
Side
Above
Non-Combustible Surfaces
150
750
600
150
1200
Combustible Surfaces
500
750
600
500
1200
Models P0131*
Rear
Front
Left
Right
Above
Non-Combustible Surfaces
300
750
300
300
1200
Combustible Surfaces
500
750
500
500
1200
*Model 131 suitable for outdoor installations only.
Note: For outdoor installation clearances please refer to AS/NZS5601.1:2013
Air supply to the room must not be affected by mechanical exhausts of other equipment such as bathroom or kitchen fans, spa blowers or air-conditioning equipment, etc.
FLUEING
Flueing must be in accordance with AS/NZS 5601.1. Only the correctly-sized Raypak draft diverter must be fixed to the heater and connected to a properly constructed flue, vented to atmosphere using approved fittings and cowl. Alteration to the Raypak draft hood or reduction in cross section of connected flueing will void the Rheem warranty.
Where standard flueing options cannot be implemented Rheem should be contacted for flueing advice.
Additional ductwork connected to the Raypak draft hood must be self-supporting and allow the removal of the Raypak pool or spa heater and draft hood without removal of the flue. The flue system beyond the Raypak draft hood must in no circumstances be supported by the heater.
Where practical, the flue should be run vertically. Lateral flueing is allowed but must rise a minimum of 20mm per 1m of lateral run and the total lateral run must not exceed 50% of the total flue height.
WARNING! Do not use an unlined masonry chimney as the
flue for this appliance.
Indoor Hood Conversion
To convert Model P0200 to P0430 and PC0280 to PC0430 heaters from outdoor configuration to indoor:
1. Remove all screws from the appliance top panel and discard sheet metal.
2. Fit the indoor flue “stack adaptor” supplied with the indoor conversion kit to the flue collector and screw in position.
3. Fit the “draft diverter” over the indoor flue “stack adaptor” spigot.
4. Ensure that all connections are secure and will not allow products of combustion to escape into the room.
To convert Model P0127 heaters from outdoor configuration to indoor:
1. Remove all 4 screws on the supports for the appliance’s top hood and discard hood.
2. Fit the indoor “draft diverter” to the flue collector and screw in position.
3. Ensure that all connections are secure and will not allow products of combustion to escape into the room.
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GAS SUPPLY
The gas supply pipe and gas meter must be sized so that both are capable of providing sufficient gas for all gas appliances on the site to operate at the same time. Insufficient gas supply will cause the heater to operate below its designed performance or not at all.
Correct pipe sizing for the gas fitting line should be obtained from AS/NZS 5601.1. During commissioning of the heater the burner pressure must be adjusted by the gas fitter to conform to the specifications provided on the Raypak pool or spa heater rating label ­located on the left hand side of the heater (refer to “. The heater and its gas line must be fully leak-tested prior to normal operation.
Note: It is more important than ever that when installing a new gas pool or spa heater, the commissioning must be carried out by a qualified plumber. Gas supply companies are increasingly supplying natural gas to new installations with 2.75kPa. This means if the gas pressure is not adjusted to the correct working pressure (see rating label) the heater will be over gassed and cause serious damage within minutes. This damage is not covered under the Rheem Warranty.
Warning: Excessive Gas Pressure will damage the gas valve and void the Rheem warranty.
HOW LONG WILL THE POOL & SPA HEATER LAST
Your pool & spa heater is supported by a manufacturer’s warranty (refer page 3). There are a number of factors that will affect the length of service the pool or spa heater will provide. These include but are not limited to the water chemistry, the water flow rate, service & maintenance program and usage pattern. Refer to Precautions on page 11 and Periodic Maintenance on page 12.
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