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CONTENTS

WATER CHEMISTRY

WARNINGS

Pay Attention to These Terms

RECEIVING EQUIPMENT

GENERAL

SPECIFICATIONS

INSTALLATION

Code Requirements

Base Installation

Clearances

Combustion Air (Indoor Units Only)

Venting Connections

Gas Supply Connections

Water Connections

CONTROLS

Flow Switch

Water Pressure Switch

Automatic Chlorinators and Chemical

Feeders

Unitherm Governor Operation

Companion Flange Connections

(Models 926-1223)

Mounting the Poolstat Control with Front-

Mounted Loop Using Mounting Slots

Mounting Well into System Return Loop

Pipe - Front-Mounted Loop

Piping Configurations for Raytherm

Commercial Pool Heaters (926-1223)

Piping Configurations for Raytherm

Commercial Pool Heaters (1287-1826) 16

Piping Configurations for Raytherm

Commercial Pool Heaters (2100-4001) 17

Temperature Controls

External Auxiliary Bypass Valve (Where

Required) Models 926-1223 Only

Auxiliary Bypass Valve Adjustment

Electrical Wiring

Wiring Diagram—Models 926–1223

Wiring Diagram—Models 1287–1826

Wiring Diagram—Models 2100–2500

Wiring Diagram—Models 3001–4001

SERVICING

General Location Of Controls

Temperature Control

Pressure Switch

Pressure Switch Adjustment

Two-Speed Pumps

Pilot Safety

START-UP PROCEDURES

Before Start-Up

Start-Up

After Start-Up

INSPECTION PROCEDURES

Burners

CONTROLS

SERVICING PROCEDURES

Tube Cleaning Procedure (Typical)

Heat Exchanger Reassembly

Burner Drawer Removal

Gas Valve Removal

Main Burner and Orifice Removal

Pilot Removal and Cleaning

Heat Exchanger Removal

Combustion Chamber Removal

Control Well Replacement

Tube Replacement Procedure

Procedure For Cleaning Flue Gas

Passageways

Unitherm Governor Replacement

MAINTENANCE AND CARE

Winterizing Your Heater

TROUBLESHOOTING

WARRANTY

Содержание Raytherm P-1826

Страница 1: ... 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 or...

Страница 2: ...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 Rev 17 reflects the followin...

Страница 3: ...ature 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 20 Wiring Diagram Models 1287 1826 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 Switch Adjustment ...

Страница 4: ...t 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 covered or have any blockage to the flow of fresh air to the heater WARNING C...

Страница 5: ...he requirements of ANSI Z21 56 CSA 4 7 American National Standard for Gas Fired Pool Heaters Rated inputs suitable for up to 2000 feet elevation For eleva tions above 2000 feet reduce input 4 for each 1000 feet above sea level as high elevation reduces com bustion performance INSTALLATION These instructions are intended for the use of qualified personnel only specifically trained and experienced i...

Страница 6: ...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 also certified for indoor installation when equipped with approved drafthood Locate heater as close as practical to a chimney or gas vent Combustion Air Indoor Units Only The heater must have both combustion and ventilation ...

Страница 7: ...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 location shall have a minimum clearance of 4 feet horizontally from and in no case above or below u...

Страница 8: ...ould be re sized to approach the minimum size as determined using the appropriate tables in 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 Series Power Vent can be used Consult the factory or your local Raypak representative Gas Supply Connections Gas piping must have a sediment trap ahead ...

Страница 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 gas train components that have diaphragms in thei...

Страница 10: ...s Heater must be located so that any water leaks will not damage the structure of adjacent area High tempera ture plastic pipe CPVC may be connected directly into the heater Models 926 1223 if local codes permit and if controls operate the pump for at least fifteen minutes after the heater is turned off When local codes permit the use of less than four feet high temperature piping or two elbows pr...

Страница 11: ...ustment will cause 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 thermosta tic 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...

Страница 12: ...ts 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 damage the heater Uncontrolled flow to...

Страница 13: ...ts Fig 16 Insert Clamps 3 Remove either the left or right knock out for wiring 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...

Страница 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 ...

Страница 15: ...should be checked 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 ...

Страница 16: ...TER TEMPERATURE THERMOMETERATHEATERINLET HEATEROUTLETTEMPERATURE THERMOMETER HEATERTHERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATIONVALVESFORSERVICE TI To Tc Piping Configurations for Raytherm Commercial Pool Heaters ...

Страница 17: ...TURE THERMOMETERATHEATERINLET HEATEROUTLETTEMPERATURE THERMOMETER HEATERTHERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATIONVALVESFORSERVICE TI To Tc Models 2100 thru 4001 Piping Configurations for Raytherm Commercial Pool Heaters ...

Страница 18: ... with flow rates up to 120 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 Pool Stat The pool heater is equipped with a pool thermostat that is attached to the inlet side of the in out heade...

Страница 19: ...sure safe operation the gas valve cannot open until the pilot relights and is confirmed 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 Fig 25 Low Water Cutoff Fig 26 High Low Gas Pressure Switch Model Without Lockout With Lockout N P N P 926 1826 Standard N A Option...

Страница 20: ...20 Wiring Diagram Models 926 1223 ...

Страница 21: ...21 Wiring Diagram Models 1287 1826 ...

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

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

Страница 24: ...t 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 until the heater shuts off A flat screw driver may be necessary if knob is too tight 6 Slowly turn the adjustment knob counter clock wis...

Страница 25: ...ammable liquids and chemicals Do not obstruct the flow of combustion and ventilating air Water Water must be flowing through the heater Start Up Lighting Instructions 1 Close all gas valves Turn off electric power supply wait 5 minutes 2 Open manual pilot valve Turn on electric power pilot is automatically lighted 3 Open main gas valve 4 Set temperature controls to desired temperature To Shut Down...

Страница 26: ...gas 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 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 L...

Страница 27: ...e heat exchanger generally 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 ...

Страница 28: ...emove combustion chamber clips at the four cor ners 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...

Страница 29: ... Lift heat exchanger 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 lo...

Страница 30: ...n quarterly 1 Inspect top of heater and draft hood for soot and 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 press...

Страница 31: ...heaters with external Unitherm Governor s and piping locate plug at 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 Disconnect compression 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 heater to gai...

Страница 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...

Страница 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...

Страница 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...

Страница 35: ...t for any failed part The failed part must first be returned to Raypak if request ed 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 Raypak will apply any such warranty as may be provided to...

Страница 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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