Raypak Raytherm 1287-1758, 2100-4001 Installation And Operating Instructions Manual Download

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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

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Summary of Contents for Raytherm 1287-1758, 2100-4001

Page 1: ...a fire or explosion may result causing property damage personal injury or death 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: ...r Venting Connections Gas Supply Connections Water connections Controls WiringDiagrams SECTION 4 SERVICING INSTRUCTIONS General Location of Controls Start Up Procedures Inspection Procedures Servicing Procedures Maintenance Care SECTION 5 TROUBLE SHOOTING Mechanical Electrical SECTION6 REPLACEMENTPARTS WARRANTY 3 3 3 3 3 4 4 5 6 7 8 14 18 18 19 20 21 24 25 25 27 28 35 ...

Page 3: ... damage to the carton or the shipping crate If the carton or shipping crate is damaged make a note on the Bill of LadingandreportthedamagetotheCarrierimmediately Remove the boiler from the carton or shipping crate Do NOTuse 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 orderi...

Page 4: ...et louvers andintotheheater Thiscouldcauseheavyinternal rusting or damage some electrical components and this would void the warranty The point from where the flue products exit the heater must be a minimum of four 4 feet below four 4 feet horizontallyfromorone 1 footaboveanydoor window orgravityinlettoabuilding Thetopsurfaceoftheheater shall be at least three 3 feet above any forced air inlet or ...

Page 5: ...ter the following steps shall be followed with each appliance remaining connected to the common venting system placedinoperation whiletheotherappliancesremaining connected to the common venting system are not in operation VENTINGCONNECTIONS DRAFTHOOD INDOOR MODELS962 1826 Locate and assemble as shown below Secure with screws supplied in envelope in carton Models2100 4001havebuilt indrafthoodsthatm...

Page 6: ...on 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 Seri...

Page 7: ...on equipment flue or exhaust system 7 Bleed Line Connection Fig 8185 2 WATERCONNECTIONS 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...

Page 8: ... sticks in the skimmer High chemical concen trations 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...

Page 9: ...01 FLOWRATES WATERCONNECTIONS MODEL CONNECTIONSIZE 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 ...

Page 10: ...swillensurethattheheaterwillbeenergizedattherighttime Ifthemainwaterlineistoofarawayfromtheheater 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 ...

Page 11: ...onfigurations 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 NPT into the pipe as shown in Fig 9 4 Using a NPT tap and appropriate handle thread the tap into th...

Page 12: ...arly 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 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 confi...

Page 13: ...GCONFIGURATIONSFORRAYTHERMCOMMERCIALPOOLHEATERS Fig 9268 Fig 9269 BLENDED WATER TEMPERATURE THERMOMETERATHEATERINLET HEATEROUTLETTEMPERATURE THERMOMETER HEATERTHERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATIONVALVESFORSERVICE TI To Tc ...

Page 14: ...ss valve This may be used with flow rates up to 120 GPM and adjusted as below NOTE Sooting or liming caused by improper bypass adjustmentvoidsthewarranty BYPASSVALVE INLET OUTLET HEADER Fig 8223 0 OPEN POSITION CLOSED POSITION MANUAL BYPASS ADJUSTMENT Fig 8222 0 NOTE To avoid water damage or scalding due to valve operation drain pipe must be connected to valve outlet and run to a safe place of dis...

Page 15: ...the original wiring it must be replaced with 105 C wire or its equivalent ELECTRONIC IGNITION The intermittent ignition device conserves energy by automatically extinguishing the pilot when desired tem peratureisreached Whenadditionalheatisneeded the pilot re ignites electrically eliminating the fuel costs of maintaining a constant pilot To ensure safe operation the gas valve cannot open until the...

Page 16: ...16 WIRING DIAGRAM MODELS 926 1223 ...

Page 17: ...17 WIRING DIAGRAM MODELS1287 1826 ...

Page 18: ...WIRING DIAGRAM MODELS 2100 2500 18 ...

Page 19: ...WIRING DIAGRAM MODELS 3001 4001 19 ...

Page 20: ...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 enoughpressure 4 Turn the heater ON 5 Manually turn the pressure adjustment knob clock wiseuntiltheheatershutsoff Aflatscrewdrivermay be necessary if knob is too tight 6 Slowly turn the adjustment knob counter clockwise until the heater calls for heat again 7 Tu...

Page 21: ...enever the pilot flame is interrupted Pilot flame is automatically lit when the device is powered Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit 21 START UPPROCEDURES 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 obstru...

Page 22: ... valve should open and main burner should ignite after gas reaches the burner port 22 INSPECTIONPROCEDURES BURNERS Clean main burners and air louvers of dust lint and debris Keep boiler area clear and free from com bustibles 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 Li...

Page 23: ...eader side as shown without breaking pipe connections It is preferable however to remove both headers for better Fig 6049 23 visibility through the tubes and to be sure the ground up lime dust does not get into the system Note that you do not remove the top pan or the heat exchanger generally After reaming mount the wire brush in lieu of the auger and clean out the debris remaining in the tubes An...

Page 24: ...nboltmetalcombus tion chamber retainer from top and remove combustion chamberpanelsindividually REFRACTORY PANELS TOP VIEW Fig 8155 0 BURNER DRAWER REMOVAL 1 Shutoffpowerandgassupplytothepoolheater Dis connect union s and pilot tubing then loosen and removeburner holddownscrews 2 Disconnect wires at gas valve and slide burner drawer out GAS VALVE REMOVAL 1 Shut off gas supply to the pool heater Re...

Page 25: ...rippedofflongerononeend The long end is inserted into the opening of the tube sheet first thentheshortendisfittedthroughtheopposite tube sheet Ifthetubeendsbecomedentedorbent straighten at least four 4 inchesbackfromthetubeendby means of a tapered punch Insert tube roller into tube opening up to stop against tube then push center rod in until roller is tight Be careful to keep replacement tube squ...

Page 26: ...d void the warranty 7 Keep heater air clear and free from combustible materials and other flammable and corrosive vapors and liquids 8 Keepmovingpartslubricated 9 Manualoperationofpressure temperaturerelief valve at least once a year SPA WATER CHEMISTRY NOTE Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water pH between 7 2 and 7 8 and total alkal...

Page 27: ...vation Improperventing Insects 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 exchange...

Page 28: ... 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 Le...

Page 29: ...shuts off pilot gas if pilot fails to light To reset interrupt power to heater NOTE Before troubleshooting familiarize yourself with the start up and checkout procedure Check line voltage power low voltage transformer limit controller thermostat controller and wiring Pull ignition lead and check spark at module Spark Okay YES Check ignition cable ground wiring ceramic insulator and gap and correct...

Page 30: ... standard company warranties must be properly tagged with RAYPAK 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 the part will be returned in kind or equal substitution freight collect Credit will not be issued Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 30 ...

Page 31: ...MODELS 926 962 1083 1125 1178 1223 1287 1336 1414 1468 1571 1631 1758 1826 31 2 C ...

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Page 34: ...MODELS 2100 2500 3001 3500 4001 34 ...

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Page 37: ...ENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Ra...

Page 38: ...ak Inc 2151 Eastman Avenue Oxnard CA 913030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T 1G2 905 677 7999 FAX 905 677 8036 Litho in U S A www raypak com ...

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