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Raypak P-1083, Installation & Operating Instructions Manual

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Raypak P-1083 Installation & Operating Instructions Manual Download Page 2

2

WATER CHEMISTRY

(Corrosive water voids all warranties)

For your health and the protection of your pool equipment, it is essential that your 

water be chemically balanced. The following levels must be used as a guide for bal-

anced water.

Recommended Level(s)

Fiberglass Pools Fiberglass Spas

Other Pool & Spa 

Types

Water Temp. (Deg. F)

68 to 88

89 to 104

68 to 104

pH

7.3 to 7.4

7.3 to 7.4

7.6 to 7.8

Total Alkalinity (PPM)

120 to 150

120 to 150

80 to 120

Calcium Hardness (PPM)

200 to 300

150 to 200

200 to 400

Salt (PPM)

6000 MAXIMUM

6000 MAXIMUM

6000 MAXIMUM

Free Chlorine (PPM)*

2 to 3

2 to 3

2 to 3

Total Dissolved Solids 

(PPM)

3000 MAXIMUM

3000 MAXIMUM

3000 MAXIMUM

* Free Chlorine MUST NOT EXCEED 5 PPM!

•    Occasional chemical shock dosing of the pool or spa water should not damage the 

heater providing the water is balanced.

•    Automatic chemical dosing devices and salt chlorinators are usually more efficient 

in heated water, unless controlled, they can lead to excessive chlorine level which 

can damage your heater, and which is not covered under warranty.

•    Further advice should be obtained from your pool or spa builder, accredited pool 

shop, or chemical supplier for the correct levels for your water.

Revision 21 reflects the following changes: 

Removed California Proposition 65 on page 4.

Summary of Contents for P-1083

Page 1: ...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 must be performed by a qualified installer service agency ...

Page 2: ... 6000 MAXIMUM Free Chlorine PPM 2 to 3 2 to 3 2 to 3 Total Dissolved Solids PPM 3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM Free Chlorine MUST NOT EXCEED 5 PPM Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water unless controlled they can ...

Page 3: ...e Controls 18 External Auxiliary Bypass Valve Where Required Models 926 1223 Only 18 Auxiliary Bypass Valve Adjustment 18 Electrical Wiring 19 Wiring Diagram Models 926 1223 with UG 20 Wiring Diagram Models 926 1826 with H Bypass 21 Wiring Diagram Models 2100 2500 22 Wiring Diagram Models 3001 4001 23 SERVICING 24 General Location Of Controls 24 Temperature Control 24 Pressure Switch 24 Pressure S...

Page 4: ...ll a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the heater free of combustible materials gasoline and other flam mable liquids and vapors Heater should never be...

Page 5: ...quirements of ANSI Z21 56 CSA 4 7 American National Standard for Gas Fired Pool Heaters Rated inputs are suitable for up to 2000 feet elevation For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level as high elevation reduces combustion performance INSTALLATION These instructions are intended for the use of qualified personnel only specifically trained and experienced in t...

Page 6: ...gh winds are frequent it may be nec essary to locate the heater a minimum of 3 from high vertical walls or install a wind break so the heater is not in direct wind current Indoor Heaters The design is certified for indoor installation when equipped with approved drafthood Locate the heater as close as practical to a chimney or gas vent Combustion Air Indoor Units Only The heater must have both com...

Page 7: ...p which com plies 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...

Page 8: ...sized to approach the minimum size as deter mined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 NFPA 54 For special venting applications that require reduced vent sizes or through the wall venting the optional D Series Power Vent can be used Consult the factory or your local Raypak representative Gas Supply Connections Per NFGC requirements gas piping must have a sediment ...

Page 9: ...1 10 15 35 40 85 120 250 500 3500 10 30 30 45 80 200 400 600 4001 5 20 25 35 65 160 300 400 Natural Gas 1000 BTU FT3 60 Specific Gravity 0 5 in WC Pressure Drop Propane Gas 2500 BTU FT3 1 53 Specific Gravity 0 6 in WC Pressure Drop Table B Maximum Equivalent Pipe Length Fig 6 Gas Pressure Test Points Venting of Diaphragm Gas Components Heaters with gastrain components that have dia phragms in thei...

Page 10: ... 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 he...

Page 11: ...ause very rapid corrosion to the heat exchanger in the heater Such damage is not covered under the warranty Unitherm Governor Operation The patented Unitherm Governor UG is a thermo static mixing valve specifically designed to maintain constant heater internal temperature between 105 and 115 F despite continually changing flow rates from the filter and changing pool temperatures This narrow range ...

Page 12: ... Front Mounted Loop Using Mounting Slots For heater models 1287 1336 1414 1468 1571 1631 1758 1826 2100 2500 3001 3500 4001 1 Remove the poolstat control cover by removing the two cover screws at the top See Fig 13 14 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 ...

Page 13: ...s Fig 16 Insert Clamps 3 Remove either the left or right knock out for wir ing on the poolstat control as shown in Fig 17 4 Attach appropriate conduit and connectors to the poolstat control 5 Attach wires to the poolstat wire terminals See Fig 18 6 Install poolstat control to the cover and fasten cover screws 7 Poolstat should be mounted level as shown in Fig 19 Fig 17 Remove Knockout Fig 18 Attac...

Page 14: ...22 are acceptable Follow clamp manufacturer s instructions CAUTION The inlet water temperature must be kept above 105 F Changes in system flow or valve position may require re adjustment of the flow settings Check the heater bypass settings after making adjustments Failure to maintain an inlet temperature above 105 F may result in damage to the heater Failure to comply with this instruction voids ...

Page 15: ...hecked regularly to prevent heater condensation The heater inlet temperature can be higher than 105 F without heater damage but operating at less than 105 F inlet can cause dam age from condensation NOTE Consult factory if target temperatures cannot be achieved Piping Configurations for Raytherm Commercial Pool Heaters Models 0926 thru 1223 with UG INTERNAL DIVERTING BYPASS SYSTEM UG 4 PIPE DIAMET...

Page 16: ...S MAX Models 926 1826 with H Bypass BLENDED WATER TEMPERATURE THERMOMETERATHEATERINLET HEATEROUTLETTEMPERATURE THERMOMETER HEATERTHERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATIONVALVESFORSERVICE TI To Tc Piping Configurations for Raytherm Commercial Pool Heaters ...

Page 17: ...LETTEMPERATURE THERMOMETER HEATERTHERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATIONVALVESFORSERVICE TI To Tc 4 PIPE DIAMETERS MAX 4 PIPE DIAMETERS MAX 4 PIPE DIAMETERS MAX Models 2100 thru 4001 with H Bypass Piping Configurations for Raytherm Commercial Pool Heaters ...

Page 18: ... valve This may be used with flow rates up to 100 gpm and adjusted as below Temperature Controls High Limits The pool heater is equipped with two high limits Both high limits the non adjustable auto reset high limit and adjustable manual reset high limit are attached to the outlet side of the in out header Poolstat The pool heater is equipped with a poolstat that is attached to the inlet side of t...

Page 19: ...rmed Heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 The heater draws less than 1 amp not includ ing the pump power when operating on either 120VAC or 240VAC power Fig 25 Low Water Cutoff Fig 26 High Low Gas Pressure Switch Model Without Lockout With Lockout N P N P ...

Page 20: ...20 Wiring Diagram Models 926 1223 with UG ...

Page 21: ...21 Wiring Diagram Models 926 1826 with H Bypass ...

Page 22: ...22 Wiring Diagram Models 2100 2500 ...

Page 23: ...23 Wiring Diagram Models 3001 4001 ...

Page 24: ...ter control to the OFF mode 3 Turn the filter pump on and confirm that the pres sure switch is closed use a multimeter to check If the pressure switch fails to close either the switch setting is too high or the filter pump is not supplying enough pressure 4 Turn the heater ON 5 Manually turn the pressure adjustment knob clock wise see Fig 30 until the heater shuts off A flat screw driver may be ne...

Page 25: ...t performs its own safety check and opens the main valve only after the pilot is proven to be lit START UP PROCEDURES Before Start Up Burners Clean main burners and air louvers of dust lint and debris Keep heater area clear and free from com bustibles flammable liquids and chemicals Do not obstruct the flow of combustion and ventilating air Water Water must be flowing through the heater Start Up L...

Page 26: ...valve should open and main burner should ignite after gas reaches the burner port INSPECTION PROCEDURES Burners Clean main burners and air louvers of dust lint and debris Keep heater area clear and free from combus tibles and flammable liquids Do not obstruct the flow of combustion and ventilating air Make visual check of burner and pilot flame Yellow flame indicates clogging of air openings Lifti...

Page 27: ...rally After reaming mount the wire brush in lieu of the auger and clean out the debris remaining in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhib ited de scale solvent Burner Drawer Removal 1 Shut off power and gas supply to the pool heater Disconnect union s and pilot tubing then loosen and remove burner hold down screws 2 Disconnect w...

Page 28: ...emove combustion chamber clips at the four corners of the heat exchanger 7 Lift heat exchanger straight up using caution not to damage refractory Heat Exchanger Reassembly 1 Heat exchanger header O rings should be replaced with new ones 2 Install inlet outlet and return water headers and install header retainer nuts and torque nuts even ly 3 Install the four 4 corner clips between tube sheets and ...

Page 29: ...hanger straight up and out Heat exchanger header o rings must be replaced with new ones The tube may be cut out with a hack saw or hammer and chisel adjacent to both tube sheets leav ing stubs in the tube sheets Then proceed to collapse stubs in the tube sheets with a chisel or screwdriver Use caution not to cut into the tube sheet Replacement tubes will have the fins stripped off longer on one en...

Page 30: ...nd open fuel gas passageways 2 Clean main burners and pilot burner of dust and lint 3 Inspect and operate all controls and gas valve 4 Make visual check of burner and pilot flame Flame pattern on main burner and pilot is indicat ed on page 26 Yellow flame means restriction of air openings Lifting or blowing flame indicates high gas pressure Low flame means low gas pressure 5 Clean room air intake ...

Page 31: ... low point of Governor piping or break connections and rotate inlet fittings 180 degrees to face downward Turn off manual main gas and main gas shut off 2 On units equipped with a UG models 926 1223 locate the pressure switch Disconnect the com pression fittings on both ends of the 1 8 copper tube and allow the tube to drain Remove the heat exchanger inspection panels on the right side of the heat...

Page 32: ...ects or debris clogging burnerintakeports Lowgaspressure Restrictedpilot Weakpilotgenerator Lowgaspressure Insects or debris clogging burnerintakeports Check movement by putting in hot water 110 F or higher If no move ment replace Locate the restriction and remove Flush system and clean Remove debris or blow out gas line Scale forming in heat exchanger clean heat exchanger and check pool pH and to...

Page 33: ...not take into account heat loss due to weather Reset time clock Cleanfilter Refer to installation instructions Inspect bypass for movement if no movement replace Replace if no movement when heated Replace well and maintain water chemistry properly Replace heat exchanger and main tain chemistry properly See pressure switch adjustment Replace refractory Determine cause of sooting and cor rect Liming...

Page 34: ... Vac across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control If okay replace gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even though operation is norma...

Page 35: ...35 ...

Page 36: ...36 www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A ...

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