Raypak PS165VSP Service Manual

Installation, Operating, and Service Manual

PS165VSP

Variable Speed Pool Pump

LISTED 31B4

Catalog No. 6000.555 Effective. 01/16/2013 Replaces: NEW P/N 241508 Rev 1

Technical Support

Address: 7920 Interstate Court

North Ft. Myers, FL. 33917

Toll Free: 1-877-213-3726

Website: www.raypak.com

This document is subject to change without notice.

Date of Installation:

Installed by:

Serial Number:

For Service Call:

Safety

Safety is emphasized throughout the user manual. These are safety alert symbols. They alert the user to potential personal injury hazards. Obey all safety messages to avoid possible injury or death or damage to equipment.

CAUTION

WARNING

DANGER

2999999292 - Rev 01/2013 v1

SAVE THESE INSTRUCTIONS!

Table of Contents

1 Important Safety Instructions 4

2 General Description 6

3 Installation Information 7

Preparation Guide . . . . . . . . . . . . . . . 7

Pump Location . . . . . . . . . . . . . . . . 8

Pipe Sizing . . . . . . . . . . . . . . . . . . 8

Plumbing Installation . . . . . . . . . . . . . . 9

Bonding and Grounding . . . . . . . . . . . . . 9

Electrical Installation . . . . . . . . . . . . . . 10

Pressure Testing . . . . . . . . . . . . . . . . 11

4 Operation 12

Start-Up Guide . . . . . . . . . . . . . . . . 12

Energy Savings Optimization . . . . . . . . . . . 13

Programming . . . . . . . . . . . . . . . . . 14

Menu Structure . . . . . . . . . . . . . . . . 15

Keypad Lock . . . . . . . . . . . . . . . . . 16

Motor Pause . . . . . . . . . . . . . . . . . 16

Power Outage . . . . . . . . . . . . . . . . . 16

Schedule Advance . . . . . . . . . . . . . . . 17

Using an existing or new 24 hour timer . . . . . . . 17

Optional PS165VSP-RM Controller . . . . . . . . 17

Freeze Protection . . . . . . . . . . . . . . . 18

Override . . . . . . . . . . . . . . . . . . . 18

Communication . . . . . . . . . . . . . . . . 18

3rd Party Controllers (Wiring) . . . . . . . . . . . 20

Heat Pump Pool Heater Connections (Wiring) . . . . 24

5 Service and Maintenance 27

Routine Maintenance . . . . . . . . . . . . . . 27

Winterizing . . . . . . . . . . . . . . . . . . 28

6 Troubleshooting 28

Fault LED . . . . . . . . . . . . . . . . . . 28

General Troubleshooting Problems . . . . . . . . 29

Blocked Impeller . . . . . . . . . . . . . . . . 29

Removal and Replacement of the Impeller . . . . . 30

Motor Replacement . . . . . . . . . . . . . . 31

7 32

Product Specifications

Performance Curve & Dimensional Drawing . . . . . 32

Replacement Parts and Exploded View . . . . . . . 33

1 Important Safety Instructions

READ THIS MANUAL CAREFULLY BEFORE USING THE PUMP

READ AND FOLLOW ALL INSTRUCTIONS!

Important Notice:

This manual contains important information about the installation, operation and safe use of this product. This information should be given to the owner and/or operator of this equipment.

WARNING: This product must be installed and serviced by a qualied pool professional, and must conform to all national, state, and local codes.

WARNING: Before Installing this product, read and follow all warning notices and instructions which are included. Failure to follow safety warnings and instructions can result in severe injury, death, or property damage. Call 1-877-213-3726 or visit www.raypak.com for additional copies of these instructions.

WARNING: California Proposition 65: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

WARNING - Entrapment Prevention

DANGER: DO NOT BLOCK SUCTION

SUCTION HAZARD. Can cause serious injury or death. Do not use

this pump for wading pools, shallow pools, or spas containing bottom drains, unless pump is connected to at least two (2) functioning suction outlets.

WARNING: Pump suction is hazardous and can trap and drown or disembowel bathers. Do not use or operate swimming pools, spas, or hot tubs if a suction outlet cover is missing, broken, or loose.

The following guidelines provide information for pump installation that minimizes risk of injury to users of pools, spas, and hot tubs:

Entrapment Protection: The pump suction system must provide protection against the hazards of suction entrapment.

Suction Outlet Covers: All suction outlets must have correctly installed, screw-fastened covers in place. All suction outlet (drain) covers must be maintained. Drain covers must be listed/certied to the latest published edition of ANSI/ASME A112.19.8 (ANSI/APSP-16, 2011). They must be replaced if cracked, broken, or missing.

Number of Suction Outlets Per Pump: Provide at least two (2) hydraulically-balanced main drains, with covers, as suction for each circulating pump suction line. The centers of the main drains (suction outlets) on any one (1) suction line must be at least three (3) feet apart, center to center.

WARNING - Entrapment Prevention - continued

The system must be built to include at least two (2) suction outlets (drains) connected to the pump whenever the pump is running. However, if two (2) main drains run into a single suction line, the single suction line may be equipped with a valve that will shut off both main drains from the pump. The system shall be constructed such that it shall not allow for separate or independent shutoff or isolation of each drain.

More than one (1) pump can be connected to a single suction line as long as the requirements above are met.

Water Velocity: The maximum water velocity through the suction tting or cover for any suction outlet must be 1.5 feet per second, unless the outlet complies with the latest published edition of ANSI/ASME A112.19.8 (ANSI/APSP-16, 2011), the standard for Suction Fittings For Use in Swimming and Wading Pools, Spas, Hot Tubs, and Whirlpool Bathtub Applications. In any case, do not exceed the suction tting’s maximum designed ow rate.

If 100% of the pump’s ow comes from the main drain system, the maximum water velocity in the pump suction hydraulic system must be six (6) feet per second or less, even if one (1) main drain (suction outlet) is completely blocked. The ow through the remaining main drain(s) must comply with the latest published edition of ANSI/ASME A112.19.8 (ANSI/APSP-16, 2011), the standard for Suction Fittings For Use in Swimming and Wading Pools, Spas, Hot Tubs, and Whirlpool Bathtub Applications.

Testing and Certication: Suction outlet covers must have been tested by a nationally recognized testing laboratory and found to comply with the latest published edition of ANSI/ASME A112.19.8 (ANSI/ APSP-16, 2011), the standard for Suction Fittings For Use in Swimming and Wading Pools, Spas, Hot Tubs, and Whirlpool Bathtub Applications.

Fittings: Fittings restrict ow; for best efciency use fewest possible ttings (but at least two (2) suction outlets).

Avoid ttings that could cause an air trap.

Pool cleaner suction ttings must conform to applicable International Association of Plumbing and Mechanical Ofcials (IAPMO) standards.

WARNING - Risk of Electrical Shock or Electrocution

This pool pump must be installed by a licensed or certied electrician or a qualied pool serviceman in accordance with the National Electrical Code and all applicable local codes and ordinances. Improper installation will create an electric hazard which could result in death or serious injury to pool users, installers, or others due to electrical shock, and may also cause damage to property.

Always disconnect power to the pool pump at the circuit breaker before servicing the pump. Failure to do so could result in death or

serious injury to serviceman, pool users, or others due to electric shock.

Important Safety Instructions

When installing and using this electrical equipment, basic safety precautions should always be followed, including the following:

READ AND FOLLOW ALL INSTRUCTIONS

WARNING: To reduce the risk of injury, do not permit children to use this product unless they are closely

supervised at all times.

WARNING: Risk of Electrical Shock. Connect only to a grounding type receptacle protected by a groundfault circuit-interrupter (GFCI). Contact a qualied electrician if you cannot verify that the receptacle is protected by a GFCI.

The unit must be connected only to a supply circuit that is protected by a ground-fault circuit-interrupter (GFCI). Such a GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push the reset button. Power should be restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts power to the pump without the test button being pushed, a ground current is owing, indicating the possibility of an electric shock. Do not use this pump. Disconnect the pump and have the problem corrected by a qualied service representative before using.

CAUTION: This pump is for use with permanently installed pools and may also be used with hot tubs and spas if so marked. Do not use with storable pools. A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed so that it may be readily disassembled for storage and reassembled to its original integrity.

TO REDUCE THE RISK OF ELECTRICAL SHOCK, connect ground wires to grounding screw located in the motor. Use no smaller than a #12 AWG (3.3mm2) wire.

TO REDUCE THE RISK OF ELECTRICAL SHOCK, a bonding connector is provided for bonding to metal water pipes, metal rails, or other metal within 5 feet of the swimming pool. All local points should be bonded with a #8 AWG (8.4mm2) wire.

SAVE THESE INSTRUCTIONS.

2 General Description

Raypak Professional PS165VSP - Variable Speed

The PS165VSP - Variable Speed swimming pool pump is both environment friendly and cost efcient. This Premium Efciency Variable Speed Pump provides tremendous exibility in motor speed and time settings. The integrated electronic interface controls the speed settings between 600 and 3450 rpm and the start and stop times. It is designed to maximize energy conservation, optimize chemical usage, and yet still be simplistic to use. The PS165VSP is intended to run on the lowest speeds needed to maintain a healthy pool environment, which in turn translates into money savings. With speed settings of 3450, 3100, 2850, 2600, 2350, 2100, 1850, 1600, 1350, 1100, 850, 600, and 0, it easily allows you to choose the most appropriate speed for the maximum savings. With pump parts made of 100% recyclable plastic and engineering designed to signicantly reduce greenhouse emissions, it is sure to please the environmentally minded consumer.

General Description - continued

Figure 1

The PS165VSP - Variable Speed control panel provides manual speed controls for the pump.

Controls and LEDs Description

LED Lights (Active Step LEDs) When lit, indicates it is in operation or active.

Speed LED When lit, Bar Graph displays speed.

Duration LED When lit, Bar Graph displays duration in hours speed will run.

Bar Graph Shows current speed and duration (hours) of active programmed button

or selected value during programming.

Programming Buttons Four programmable buttons, to be set for speed and length of time.

Power LED Indicates unit has power.

Fault LED Indicates the unit has a fault error.

+/- Buttons Increases or decreases speed or duration of selected value.

STOP button Stops pump and programming.

START button Must be pressed to start the pump and programming.

3 Installation Information

Preparation Guide

1. Upon receipt of the pump, check the carton for damage. Open the carton and check the pump for concealed damage, such as cracks, dents, or a broken base. If damage is found, contact the shipper or distributor where the pump was purchased.

2. Inspect the contents of the carton and verify that all parts are included. See Section 7, Parts List and

Exploded View for details.

Pump Location

WARNING: This product must be installed and serviced by a qualied pool professional, and must

conform to all national, state, and local codes. Before installing this product, read and follow all warning notices and instructions of this product. Failure to follow warning notices and instructions may result in property damage, personal injury, or death.

ATTENTION INSTALLERS: This manual contains important information about the installation, operation, and safe use of this product. This manual should be given to the owner/operator of this equipment.

1. Raypak recommends in order to achieve better priming, to install the pump as close to the pool as practical and run suction lines as direct as possible to reduce friction loss.

2. It is recommended that a minimum length of straight pipe, equivalent to ve (5) times the pipe diameter be used between the pump suction inlet and any plumbing ttings (elbows, valves, etc.).

3. Install the pump on a level, solid foundation which provides a rigid and vibration-free base. Secure the pump to the base with screws or bolts to further reduce vibrations and stress on the plumbing.

4. Protect the pump against ooding and excess moisture. Select an area that will not ood when it rains. DO NOT install the pump in a damp or non-ventilated location.

5. Keep the motor clean and provide free circulation of air for cooling.

6. Although the pump is designed for outdoor use, it is recommended to protect the pump from direct sunlight and excessive moisture (rain, sprinklers, etc.).

7. DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this pump. DO NOT store pool chemicals near the pump.

8. DO NOT remove any safety alert labels such as DANGER, WARNING, or CAUTION. Keep safety labels in good condition and replace any missing or damaged labels.

9. Provide access for future services by leaving a clear area around the pump. Allow plenty of space above the pump to remove lid and basket for cleaning.

WARNING: Some Safety Vacuum Release System (SVRS) devices are not compatible with the installation of check valves. If the pool has an SVRS device, be sure to conrm that it will continue to safely operate when the check valves are installed.

NOTE: In Canada, the pump must be located a minimum of three (3) meters (approximately ten (10) feet) from the water (CSA C22.1).

Pipe Sizing

NOTE: All pipe sizes are able to withstand the pressures the pump will deliver, but not necessarily the ow. If the pipe is too small for the pump, or is elevated above water, the maximum gallons per minute (GPM) may not be delivered. If this happens, the pump will develop a pocket of air (cavitation) that makes noise. This may shorten the life of the pump.

SUCTION & DISCHARGE:

When the pump is located up to fty (50) feet from the pool, the recommended minimum pipe size for both the suction and discharge is 2”.

Pipe Sizing - continued

For better efciency and less restriction, use as few ttings (elbows, tees, valves, etc.) as possible.

Suction line diameter must be equal or be greater than the discharge line diameter.

Suction and discharge lines should be independently supported at a point near the pump to avoid strains being placed on the pump.

NOTE: If more than ten (10) suction ttings are needed, the pipe size must be increased.

Plumbing Installation

When installing the pump, care should be taken to see the suction line is below water level to a point immediately beneath and in front of the pump to ensure quick priming via a ooded suction line. The height between the pump and water level should not be more than ve (5) feet.

If the pump is located below water level, isolation valves must be installed on both sides of the pump to prevent the back ow of pool water during any routine or required servicing. The PS165VSP - Variable Speed comes equipped with unions on both the suction and discharge ports. This feature simplies installation and service and eliminates the possibility of leaks at the threaded adaptors.

Before starting the pump for the rst time, remove the see-through lid. (Turn lid ring counter clockwise to remove.) Fill strainer tank with water until it is level with the suction inlet. Replace lid, making sure the o-ring is in place and not damaged. Screw down, hand tight.

Every new installation must be pressure tested according to local codes. See the Pressure Testing Section on page 11.

Bonding and Grounding

WARNING: Ground and bond the pump before connecting to electrical power supply. Failure to ground

and bond the pump can cause serious or fatal electrical shock hazard. DO NOT ground to a gas supply line. To avoid dangerous or fatal electrical shock, turn OFF power to the pump before working on electrical connections.

1. The motor frame must be grounded to a reliable grounding point using a solid copper conductor, No. 8 AWG or larger. In Canada, No. 6 AWG or larger must be used. If the pump is installed within ve (5) feet of the inside walls of the swimming pool, spa, or hot tub, the motor frame must be bonded to all metal parts of the swimming pool, spa, or hot tub structure and to all electrical equipment, metal conduit, and metal piping within ve (5) feet of the inside walls of the swimming pool, spa, or hot tub.

2. Bond the motor using the provided external lug.

WARNING: In order to avoid the risk of property damage, severe personal injury, and/or death, make sure that the control switch, time clock, or control system is installed in an accessible location, so that in the event of an equipment failure or loose plumbing tting, the equipment can be easily turned off.

CAUTION: The pump must be permanently connected to a dedicated electrical circuit. No other equipment, lights, appliances, or outlets may be connected to the pump circuit, with the exception of devices that may be required to operate simultaneously with the pump, such as a chlorinating device or heater.

Electrical Installation

WARNING: All electrical wiring must conform to the local NEC guidelines. A licensed, qualied

electrician should complete the wiring for this product.

Electrical Specications

1. Voltage: 208-230 VAC, 60 Hz, Single Phase

2. Max Amps: 11

3. Speed Range: 600 - 3450

4. Controller: 208-230 Vrms, Single Phase

5. Ambient: 50o C

6. NEMA Type 3R

Figure 2

The motor is designed to handle either a bare wire connection or a quick disconnect connection. The quick disconnect tab is 0.250”. For a direct wire connection, the wire insulation should be stripped to a length of approximately 0.33” and the screw tightened to a torque of 10 in-lb. The terminals will handle wire up to 12 AWG in size.

There are two terminals labeled L1 and L2. (See Figure 3) Attach the power leads to these terminals. Attach the black lead to L1 and the red or white lead to L2. (See Table 1.0) The top rear of the controller has a single screw. Loosen this screw and lift cover to expose the terminal area.

Table 1.0

Pin# Wire Color Description

L1 Black Hot 1

L2 Red or White Hot 2

GRD Green Ground

Electrical Installation - continued

Off

1 2 3 4 5

Note: All Dip switches should be in the OFF position when external controllers are not being used.

Figure 3

CAUTION: Voltage at the pump MUST NOT vary by more than +/- 10% of nameplate voltage. Components may overheat, causing overload tripping and reduced component life. Consult your power company if this condition exists.

Note: Use only liquid tight ttings to protect the electronics and motor.

Pressure Test

WARNING: To minimize the risk of severe injury or death, the lter and/or pump should not be subjected

to the piping system pressurization test.

Local codes may require the pool piping system to be subjected to a pressure test. These requirements are generally not intended to apply to the pool equipment.

However, if the WARNING cannot be followed and pressure testing of the complete system must be done, follow the following guidelines:

1. RELEASE ALL AIR in the system before testing.

2. Water pressure for the test must NOT EXCEED 35 PSI.

3. Water temperature for the test must NOT EXCEED 100° F (38° C).

4. Limit the test to 24 hours. After the test, visually check the system to be sure it is ready for operation.

DO NOT USE COMPRESSED AIR TO PRESSURE TEST OR CHECK FOR LEAKS.

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