Raypak Low NOx Series Installation And Operation Manual Download Page 3

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CONTENTS

1. WARNINGS ............................................................. 4

Pay Attention to These Terms

.................................4

2. WATER CHEMISTRY .............................................

Automatic Chlorinators and Chemical Feeders

....... 5

3. BEFORE INSTALLATION ...................................... 6

Receiving equipment

...............................................6

Rating and certifications

..........................................6

Elevation

.................................................................6

Ambient Temperature Rating

..................................6

4. INSTALLATION ....................................................... 6

Installation Codes

...................................................

Clearances

..............................................................

Outdoor Heater Installation

.....................................

Combustion and Ventilation Air

...............................9

Vent Piping

............................................................

D-2 Power Vent Kit

................................................

Gas Supply Connections

.......................................

Flow Rates

............................................................

ProTek Shield Assembly

........................................

Unitherm Governor Operation

...............................

Internal Automatic Bypass Valve

...........................

External Auxiliary Bypass Valve

............................

Auxiliary Bypass Valve Adjustment

.......................

Pressure Relief Valve Installation

..........................

Plumbing Diagram

.................................................

Heat Exchanger Reversal

.....................................

5. ELECTRICAL WIRING ......................................... 19

Electrical Power Draw

...........................................20

Transformer Wiring

...............................................20

6. WIRING DIAGRAM ............................................... 21
7. CONTROLS ........................................................... 22

Control Panel Removal

.........................................22

Control Adjustments

.............................................22

Operation

..............................................................

Status and Diagnostics

.........................................25

Remote Control Installation and Operation

...........26

Remote Control Wiring

..........................................26

8. OPERATING INSTRUCTIONS ............................ 32

Before Start-Up

.....................................................

Start-Up Procedures

.............................................

9. MAINTENANCE AND CARE ............................... 34

Cold Weather Operation

.......................................

10. TROUBLESHOOTING ......................................... 35

Digital - Flow Chart

................................................

Control Logic - Flow Chart

....................................

11. REPLACEMENT PARTS ..................................... 38
12. ILLUSTRATED PARTS LIST .............................. 39

6000.592A_PoolSpa_LoNOx.indd 3

11/22/2019 10:44:36 AM

Summary of Contents for Low NOx Series

Page 1: ...ity of this or any other appliance To do so may result in an explosion or fire 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 ...

Page 2: ...rientation Flow rates See page 15 for flow rate values GAS Distance to regulator pipe lengths and gas inlet sizes See page 14 Required pressure for Natural Gas Min 5 WC Max 10 5 WC Sediment trap is required for all installations See page 13 WATER CHEMISTRY Water chemistry requirements See page 5 POWER Supply voltage See page 20 for acceptable input voltages VENTING Materials See pages 8 10 and 12 ...

Page 3: ... External Auxiliary Bypass Valve 16 Auxiliary Bypass Valve Adjustment 17 Pressure Relief Valve Installation 17 Plumbing Diagram 18 Heat Exchanger Reversal 19 5 ELECTRICAL WIRING 19 Electrical Power Draw 20 Transformer Wiring 20 6 WIRING DIAGRAM 21 7 CONTROLS 22 Control Panel Removal 22 Control Adjustments 22 Operation 23 Status and Diagnostics 25 Remote Control Installation and Operation 26 Remote...

Page 4: ... death or substantial property damage if ignored A ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could cause minor personal injury or product or property damage if ignored NOTE Indicates special ins...

Page 5: ...ause severe damage to your heater and associated equipment Maintain your water chemistry according to Table A If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and damaging the heater If the pH drops below 7 2 this will cause corrosion of the heat exchanger and severely damage the heater Heat exchanger da...

Page 6: ...o indoor or vice versa Elevation Rated inputs are suitable for up to 5 000 feet 1524 m elevation For elevations above 5 000 feet 1524 m consult the factory Ambient Temperature Rating Heater Components Electronic Ignition Heater 32 F to 175 F 35 C to 79 C Requires 120 or 240VAC 1 Ph 60 Hz Power Supply 4 INSTALLATION A AWARNING This unit contains refractory ceramic fiber RCF insulation in the combus...

Page 7: ...s from Combustible Surfaces When installed according to the listed minimum clearances from combustible construction the pool heater can still be serviced without removing permanent construction around the heater However for ease of servicing we recommend a clearance of at least 24 610 mm in the front and at least 18 457 mm on the water connection side This will enable the heater to be serviced in ...

Page 8: ...faces Heaters must not be installed under an overhang of less than three 3 0 9 m from the top of the heater Three 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 For U S installations the point from where the flue products exit the heater must be a minimum of 4 1 2 m below 4 1 2 m horizon...

Page 9: ...el Gas Code U S ANSI Z223 1 or Canada CAN CSA B149 and any local codes that may have jurisdiction The most common approach is the 2 opening method with combustion air opening no more than 12 from the floor and the ventilation opening no more than 12 from the ceiling For opening sizes using this method see below All Air from Inside the Building Each opening shall have a minimum net free area as not...

Page 10: ...st to unit 4 total 2 x 6 x 1 8 Pallet Anchor Bracket 4 Total Kit 011636 1 4 x 1 3 4 S S Tapcon Bolt and Washer Field Supplied NOTE Use hole closest to unit with washer overlapping edge of unit Min Edge Distance 6 152 mm Min Edge Distance 6 152 mm F10649 Model B in mm 207A 20 508 266L 267A 23 584 337A 26 660 399L 407A 29 737 Florida and Texas Building Code Wind Speed 150 mph 3 sec gust Exposure C F...

Page 11: ...2 219 99 238 108 19 8 6 399L 399 116 9 29 737 9 229 58 1 2 1486 14 5 368 12 1 2 318 3 4 2 237 108 N A 21 9 5 407A 256 116 Table G Heater Specifications and Dimensions Specifications and Dimensions Figure 8 Front View 20 1 2 521 mm 31 13 16 792 mm DRAFTHOOD B A J D C 7 3 4 197 mm F10647 INDOOR GAS CONNECTION 26 1 2 673 mm ELECTRICAL CONNECTION 28 711 mm 34 867 mm STACKLESS OUTDOOR TOP 4 3 8 111 mm ...

Page 12: ...at least 5 1 5 m in vertical height above the drafthood outlet The vent cap location shall have a minimum clearance of 4 1 2 m horizontally from and in no case below unless a 4 1 2 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Theweightoftheventstackorchimneymustnotrestonthe heater drafthood Support must be provided in compliance with applicabl...

Page 13: ... conditions must be provided for natural gas Gas Pressure Regulator The gas pressure regulator is preset at 3 1 in WC for natural gas The pressure at the gas valve taken with a manometer should be about 3 1 in WC natural gas If an adjustment is needed remove seal and turn adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure MANUAL SHUT OFF VALVE UNION F10639 4 ...

Page 14: ... 125 473 399L 407A 1 1 4 1 1 2 2 40 151 125 473 When flow rates exceed maximum GPM an external auxiliary bypass valve is required See external bypass valve section for details Table J Min Max Flow Rates F10638 1 Figure 15 Polymer Headers Water Flow F10637 1 Figure 16 Brass Headers ASME Water Flow Flow GPM lpm Pressure Drop Ft of Head m of Head 207A 266L 267A 337A 399L 407A 20 75 4 0 1 2 25 95 4 0 ...

Page 15: ...at will allow a standard ASME unit to comply with the code requirements ProTek Shield Assembly This heater is equipped with a ProTek Shield Assembly located under the inlet connection on polymer headers and in the ProTek Shield Adapter assembly shipped loose in the accessory carton for field installation on brass ASME headers This component provides protection to the heat exchanger against galvani...

Page 16: ... scaling temperatures F10725 GASKET UG PLUG UNITHERM GOVERNOR Figure 20 Unitherm Governor Polymer F10642 2 UG BYPASS ASSY UNITHERM GOVERNOR Figure 21 Unitherm Governor Brass Internal Automatic Bypass Valve In addition to the Unitherm Governor a built in automatic bypass valve is provided in the In Out header While the Unitherm Governor responds to the changes in water temperature in the heater the...

Page 17: ...tlet and run to a safe place of discharge Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve No shut off valve shall be installed between the relief valve and the drain line Valve lever should be tripped at least once a year to ensure that waterways are clear The heater requires water flow and positive pressure to ...

Page 18: ...NAL ENGINEER Figure 29 Single Pool Heater Installation THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER Figure 30 Multiple Pool Heater Installation ISOLATION VALVE PRESSURE RELIEF VALVE PUMP UNION CHECK VALVE BALL VALVE 6000 592A_PoolSpa_LoNOx indd 18 11 22 2019 10 44 44 AM ...

Page 19: ...osite sides For instructions on reversing the heat exchanger connections on ASME models call your factory representative 5 ELECTRICAL WIRING NOTE If it is necessary to replace any of the original wiring use 105 C wire or its equivalent and or 150 C wire or its equivalent like the original wiring A AWARNING Digital heaters are factory wired for 240 VAC 1Ph 60Hz power supply DO NOT attempt to operat...

Page 20: ...N WHITE WHITE WHITE GROUND Figure 32 120 VAC Wire Connection Models 240 VAC Wiring For 240 VAC input power to the unit connect the black wire to the L1 or hot leg of the power supply Connect the red wire to the L2 or second hot leg of the power supply There should be no connection to the white wires for 240 VAC operation Attach a wire nut to each white wire independently A AWARNING DO NOT attempt ...

Page 21: ...21 6 WIRING DIAGRAM 6000 592A_PoolSpa_LoNOx indd 21 11 22 2019 10 44 46 AM ...

Page 22: ...nel down until panel stops Do not force NOTE Caution must be used to not damage controls or wiring F10647 3 KNURLED SCREW Figure 36 Knurled Screw Location Control Adjustments The pool heater touchpad located on the upper front panel of the heater allows the user to select either POOL or SPA operation and to adjust the setpoint temperature The LCD display window indicates the mode OFF SPA POOL and ...

Page 23: ...y for 3 to 5 seconds The heater will continue to operate while in the Service Menu The first screen displayed is the Flame Strength indicator which indicates the pilot flame current using a bar graph and numerical display A signal of less than 4 bars indicates a weak flame signal and may require service Refer to the Troubleshooting section for possible causes and corrections Figure 40 Flame Streng...

Page 24: ...p one above to access the program screen Press the MODE button until SPA MAX TEMP appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The control can be set for a maximum of 107 F 42 C Pool Max Temp Pool Setpoint Maximum Adjustment Refer to step one above access into the program screen Press the MODE button until POOL MAX T...

Page 25: ...Time clock fireman switch circuit is open Low Temp Lockout Water temperature below 36 F 2 C Table N Heater Status Messages Active Faults The following conditions are displayed only while there is a demand for heat present Display Condition Water Sw Open Water pressure switch open Vent Field Sw 1 Vent spill switch field switch 1 open Hi Limit 1 Fault High limit 1 open Hi Limit 2 Fault High limit 2 ...

Page 26: ...Heating in the SPA Mode Remote Mode Figure 45 Remote Control Menu Remote Operation Activating the Remote To activate or deactivate the remote function 1 Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds The second line of the display will alternate even when the unit is off No Demand NOTE When in remote operation the keypad mode and temp buttons are disabled Figure 46 Remote Control ...

Page 27: ... Remote Interface Harness 7 Install the 7 Pin Remote Interface Harness to the P8 connector and turn power ON to the heater See Figure 48 For activation of the remote control see section on page 26 3 Wire Remote Control Using Three Position Switch Pool Off Spa or Low Off High This application assumes that both heating functions pool and spa are required 1 Turn on power to the heater 2 Push the MODE...

Page 28: ...ultimeter to check If the pressure switch fails to close either the switch setting is too high or not enough pressure is being supplied by the filter pump 4 Turn the heater ON 5 Manually turn the pressure adjustment knob clockwise until the heater shuts off A flat screwdriver may be necessary if knob is too tight 6 Slowly turn the adjustment knob counter clockwise until the heater calls for heat a...

Page 29: ...moval 1 Shut off main electrical power switch to heater 2 Remove inlet outlet sheet metal access panel 3 Remove defective high limit and replace with the correct new high limit 4 Replace access panel Pilot Safety The heater employs a pilot safety which closes the main gas valve within 8 10ths of a second whenever the pilot flame is interrupted The pilot flame is automatically lit when the device i...

Page 30: ...ombustion blower to blower box 6 Reverse above procedure to reinstall Heat Exchanger Removal 1 Shut water gas and electricity off close valves and relieve pressure then remove relief valve Remove side access panels 2 Remove top jacket holding screws 3 Remove rear top panel 4 Remove screws mounting the rain shield to the rear panel Also remove the screws that mount the rain shield to the sway brace...

Page 31: ...ncy Particulate Air HEPA filtered vacuum to minimize airborne dust Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust Wear appropriate personal protective equipment including gloves safety glasses with side shields and appropriate NIOSH certified respiratory protection to avoid inhalation of airborne dust and airborne fiber part...

Page 32: ...gas supply fail to shut off turn off the manual gas control to the appliance Visual Inspection Flames can be observed through the opening below the plenum Flame color is blue and evenly spread on the top surface of the burner At least every three months a visual inspection should be made of the burners Water Pressure Switch A water pressure switch is provided in the heater to shut off the burners ...

Page 33: ...ny part of the control system and any gas control which has been under water 1 STOP Read the safety information above 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 5 Remove heater door panel 6 Turn gas control knob clockwise t...

Page 34: ...al 4 The pump may have lost its prime and be running dry Check the pressure on the filter If there is no pressure then you are not moving water or your gauge is broken Try to get the pump to run at its normal flow rate Cold Weather Operation Important Freeze Information MODERATE CLIMATE Heater operation can continue during short term cold spells When temperatures are between 0 F 18 C and 32 F 0 C ...

Page 35: ...e Adjust gas pressure Insects or debris clogging burner intake ports Clean burners Outer jacket very hot paint blistered Broken refractory caused by shipping damage or improper combustion Replace refractory panels Excessive sooting of heat exchanger Determine cause of sooting and correct Takes too long to heat pool or spa Under sized heater Calculate heating capacity of heater Htr output BTUH Pool...

Page 36: ...or on gas control Check for 24 VAC across PV MV PV terminals on PC board If voltage is okay replace gas control if not replace PC board NOTE If PC board goes into lockout reset system Lockout is used on L P G models Check for 24 VAC across MV MV PV terminals If no voltage replace module Check electrical connections between PC board and gas control If okay replace gas valve or gas control operator ...

Page 37: ...ce k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor Failure Inspect thermister wires and connector at Terminal P1 Check resistance value of the thermister Reference to chart below Replace thermister if not within 10 of values shown below If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Pressure switch Verify water flow and pres...

Page 38: ...warranties must be properly tagged with a return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty a like part or equal substitution will be returned freight collect Credit will not be issued MANUFACTURER 2151 Eastman Avenue Oxnard Ca 93030 6000 592A_PoolSpa_LoNOx indd ...

Page 39: ... 3 V 1 V 2 V 9 M I S I3 S 2 S 5 HP 4 HP 7 HP 6 HP I2 S 6 HP I5 HP 3 HP 7 S 4 S 17 HM 11 S 4 C 6 M 8 S 8 M 7 M 3 S 3 B 4 B 1 G 10 S 1 B 2 B 2 M 3 J 10 M 6 B 5 B 7 C 1 J 4 S 5 S 6 S 9 M 1 R 2 R 2 J 13 M 4 V 12 M 8 B 6000 592A_PoolSpa_LoNOx indd 39 11 22 2019 10 44 56 AM ...

Page 40: ... 17 M FOR UNITS WITH ASME BRASS HEADERS FROM 12 2019 FOR UNITS WITH ASME CAST IRON HEADERS PRIOR TO 12 2019 16 HM 15 HM 12 HM 9 HM 10 HM 2 C 6 M 11 HM 8 HM OPTIONAL 1 M 3 C 6 C 5 HM 17 HM 14 HM 13 HM 2 HM 4 HM 7 HM 3 HM 6 HM 2 S 9 S 4 S 18 HM 19 HM 21 HM 20 HM 19 HM 6000 592A_PoolSpa_LoNOx indd 40 11 22 2019 10 44 59 AM ...

Page 41: ...1 M 22 M TEXAS CODE OPTION PRIOR TO 12 2019 1 M 19 HP 3 M OPTIONAL 18 HP 17 HP 20 HP 13 HP 2 HP 16 HP 11 HP 12 HP 14 HP 8 HP 6 C 1 C 10 HP 16 HP 12 HP 2 HP 13 HP 14 HP 17 HP 18 HP 8 HP 6 C 19 HP 19 HP 11 HP 1 M 1 C 15 HP 6 M OPTIONAL 1 P 2 P 4 P 6 P IID LOW NOx PILOT 6000 592A_PoolSpa_LoNOx indd 41 11 22 2019 10 45 01 AM ...

Page 42: ... 006827F 006827F 006827F Inlet Outlet Header Includes 6 HP Units manufactured from 10 2019 017965F 017965F 017965F 017965F Units manufactured from 7 2013 thru 9 2019 014648F 014648F 014648F 014648F 3 HP Return Header Includes 6 HP 015095F 015095F 015095F 015095F 4 HP Tube Bundle Copper 010059F 010060F 010061F 010062F Tube Bundle Cupronickel Units manufactured from 7 2013 014930F 014931F 014932F 01...

Page 43: ...9 010055F 006733F 010057F 010058F Tube Bundle Cupronickel ASME Units manufactured from 12 2019 017978F 017979F 017980F 017981F Units manufactured prior to 12 2019 010368F 010369F 010370F 010371F 5 HM Baffle 010038F 005261F 010040F 010041F 6 HM Stud Bolt Kit Units manufactured from 12 2019 017982F 017982F 017982F 017982F Units manufactured prior to 12 2019 007870F 007870F 007870F 007870F 7 HM Heade...

Page 44: ...48F 11 M Touch up Paint Green 750125 750125 750125 750125 Dark Gray 750126 750126 750126 750126 Cool Dark Gray 750256 750256 750256 750256 Warm Dark Gray 750258 750258 750258 750258 12 M Tie Down Bracket Optional 011636 011636 011636 011636 13 M Roll Out Switch 250ºF Optional 011745F 011745F 011745F 011745F Roll Out Switch 250ºF Upgrade 011733F 011733F 011733F 011733F 14 M Texas Code Option ASME O...

Page 45: ...311F 010311F 010311F 010311F Access Panel Set ASME Access Panel Set 3 Pcs for BR Header 017967F 017967F 017967F 017967F Access Panel Set 3 Pcs for CI Header prior to 12 2019 010312F 010312F 010312F 010312F 5 S Jacket Side Panel Right 010313F 010313F 010313F 010313F 6 S Jacket Side Panel Left 010314F 010314F 010314F 010314F 7 S Jacket Rear Panel 2 Pcs 010315F 010316F 010317F 010318F 8 S Poolstat Co...

Page 46: ...6000 592A_PoolSpa_LoNOx indd 46 11 22 2019 10 45 01 AM ...

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