Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS Raypak Pool & Spa Heat Pump TM022 R Reevviissiioonn:: C C PPuubblliisshheedd:: M Maarrcchh 0066 Model RHP 33 TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by 1 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Safety Warning ....................................................................................................................4 Environmental......................................................................................................................4 Introduction ..........................................................................................................................4 General Description .........................................................................................
Evaporator Fan: (Procedure 14).....................................................................................36 Compressor and Evaporator Fan Capacitor: (Procedure 15) .........................................37 Water Temperature Sensor: (Procedure 16) ..................................................................37 Thermostat Adjustment POT spa: (Procedure 17) .........................................................37 Thermostat Adjustment POT pool: (Procedure 18) ...............................
Safety Warning The purpose of this Service Manual is to provide sufficient information to allow a person with the skills as required by the controlling Regulatory Authorities to carry out effective repairs to a Raypak pool and spa heat pump in the minimum of time. Safety precautions or areas where extra care should be observed when conducting tests outlined in this manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure.
Specifications Model RHP 33 Heat KW output (@ 26ºC air, 80% 33 relative humidity, 26ºC water) C.O.P 6.4 Voltage 240V 50Hz Amps 24 Electrical input KW 5.2 Water flow (litres per min)* 60 – 227 Degree of protection IPX4 Shipping weight (kgs) 150 Inlet and outlet water connections 50mm Refrigeration charge pressure min (Kpa) 1003 Refrigeration charge pressure max (Kpa) 2760 R22 Refrigerant charge (kg) 2.72 Superheat setting 8ºC Start winding - Red & Yellow: 2.7 ohms Compressor Run winding - Red & Blue: 1.
*Free Chlorine must not exceed 5ppm, however occasional chemical shock dosing of the pool or spa water should not damage the heater providing that the water is balanced to the above conditions. Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water. Unless controlled, they can lead to excessive chlorine levels that can damage the pool / spa heater. Excessive chemical content in a swimming pool or spa will damage the Heat Pump. DO NOT skimmer feed chemicals.
Start Up 1. Verify that the Power LED is ON and that the pool pump is running and circulating properly. 2. Verify that the control panel Spa-Remote-Pool switch is in the Remote (OFF) position; See figure on page 7. 3. Turn the control switch to either Pool or Spa to turn the system ON and raise the appropriate temperature dial above the current water temperature. At this time the two green LED’s (water flow and heat demand LED’s) should illuminate.
Boil Off – The action of a substance as it absorbs heat and changes state (evaporates) from a liquid to a vapour (gas). Give Up Heat – The action of a substance as it releases heat and changes state (condenses) from a vapour (gas) to a liquid. Components and their Function Spa and Pool Temperature Dials - Two adjustable dials (potentiometers) that allow a water temperature selection of 16 - 40ºC, one for Spa and one for Pool.
Thermal Expansion (TX) Valve - A valve, installed between the condenser and evaporator that controls (meters) the amount of refrigerant delivered to the evaporator. The TX valve has an external temperature sensor fitted to the suction line and increases or decreases the refrigerant flow to the evaporator depending on the detected suction line temperature. There is also a small diameter pipe fitted between the TX valve and the suction side of the evaporator designed to equalise the operating pressure.
Wiring Diagram TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by 10 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Refrigeration Sealed System Diagram Refrigerant Charge 1. Evacuate the unit to 300 microns and hold for 40 minutes. 2. Charge the unit with 2.72 kg of R22 refrigerant. 3. After the charge is in place the unit can be run. Note: Trickle charging is not possible due to the low pressure switch. Indication of correct refrigerant charge - Compressor current draw and system pressures are within the normal range and temperatures should be consistent with system pressure.
Plumbing Diagrams For systems with pumps of less than 1.5HP (1.1KW) (under 227 l/min) no external bypass is required. Connections are 50mm pipe slip. Plumb the Heat Pump after the filter and before the chlorinator. Ensure chlorinators and chemical dosing units are installed AFTER the Heat Pump. For systems with pumps of 1.5HP (1.1KW) or greater (over 227 l/min) an external bypass is required. Adjust the bypass valve to divert a minimum of 150 l/min through the Heat Pump. Connections are 50mm pipe slip.
Common Faults Unit is running but not heating When a complaint is lodged about the performance of a pool heating system there are a number of causes that should be checked and eliminated. In an attempt to pinpoint the most likely cause it is important to discuss with the customer their reasons for the complaint, the duration of the problem, any change in circumstances or usage and recent weather conditions.
General Fault Finding Chart Fault Diagnosis Is the complaint for pool heater not operating? YES 1 YES 2 YES 3 YES 4 NO Is the complaint for insufficient heating? NO Is the complaint for water too hot? NO Is the complaint for leaking pool heater? NO Noisy water heater 5 TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by 14 Service.
Fault Finding Chart 1 Pool Heater not operating 1 Warning: Terminals may be live, Personal Protective Equipment should be worn. Is 240 volts present at the terminal block? Test 1 YES 1.
Fault Finding Chart 1.1 Pool Heater not operating 1.1 Is the Spa/Remote/Pool switch on the correct setting? NO Turn Spa/Remote/Pool switch to correct setting NO Check pump operation. Check position of valves.
Fault Finding Chart 1.2 Pool Heater not operating 1.2 Test 5 Is there 240 VAC present at the transformer primary windings? NO Repair wiring between terminal block and transformer NO Replace transformer YES Test 6 Is there 24 VAC present at the transformer secondary windings? YES Test 7 Has the low voltage fuse blown? YES Replace 2A fuse cartridge Did the fuse blow again? YES 24V control circuit components will need to be checked individually.
Fault Finding Chart 1.3 Pool Heater not operating 1.3 Test 12 Is the evaporator fan running? NO Is the fan relay working? YES Heater operating YES Is the compressor running? NO Test 13 Is the fan motor NO resistance Note: Fan motor has an correct? internal over current cutout YES Replace fan relay Replace fan motor with auto reset. This is not repairable or replaceable. 2.1 NO YES Test 14 Is the capacitor working? Test 15 Is the defrost switch closed? NO Is the evaporator temp below 5.
Fault Finding Chart 1.4 Pool Heater not operating 1.4 Test 19 Is the Spa/Remote/Pool selector switch working? NO Replace Spa/Remote/ Pool selector switch NO Replace Heat Pump water sensor YES Test 20 Is the Heat Pump water sensor working? 1.5 Test 21 Is the Spa potentiometer working? YES Replace Spa potentiometer YES Replace control board NO Replace Pool potentiometer YES Replace control board YES Replace control board NO Repair or replace wiring 1.
Fault Finding Chart 2 Insufficient heating 2 Is the thermostat setting correct? NO Adjust thermostat dial. The thermostat setting must be higher than the actual water temperature NO Turn Spa/Remote/Pool switch to correct setting and ensure that valves are directing water from the selection made. ie.
Fault Finding Chart 3 Water too hot 3 Is the thermostat setting correct? NO Adjust thermostat dial. NO Turn Spa/Remote/Pool switch to correct setting and ensure that valves are directing water from the selection made. ie.
Fault Finding Chart 4 Leaking water heater 4 Is the leak intermittent? YES Leak is probably condensate draining from the evaporator. Normal operation YES Check union connections. Replace gasket if required YES Check inlet & outlet water pressure sensor hoses for leaks. Check water sensor seal for leaks. Check manifold hose & clamps. Check manifold for leak & replace if necessary YES Check manifold hose & clamps.
Fault Finding Chart 5 Noisy water heater 5 The unit is heating when the compressor is running Is the noise evident when the unit is not heating? YES Is the noise a humming sound? NO Is the noise mechanical or air related? NO Check for restrictions in pipe work, faulty valves or loose plumbing YES Check transformer AIR Normal noise level during operation is approx 65dB @ 1.5 metres YES Fan loose on motor shaft - Remove assembly and retighten.
Fault Finding Chart 6 Refrigeration circuit fault finding 6 Test 9 Did the low pressure switch open? Run Heat Pump. YES Test 23 Is the operating YES pressure low? NO Replace low pressure switch Test 24 Is the operating NO pressure high? Replace high pressure switch NO Test 8 Did the high pressure switch open? YES Leak in refrigerant system. Locate and repair NO Fit guages to high and low side of system and run Heat Pump.
Component Tests 1, 4, 5 & 6 Test 1 Test 4 Ensure power is isolated before Warning – ‘Live’ equipment Personal conducting test Protective Equipment should be worn Using a multimeter on the x1 resistance when conducting this test. scale, measure across the top (orange Using a multimeter on the AC voltage wire) and centre terminals (black wires) on scale, measure across Line 1 and Line 2 the water pressure switch. The reading on the compressor contactor.
Component Tests 7 - 10 Test 7 Ensure power conducting test is Test 8 isolated before Warning – ‘Live’ equipment Personal Protective Equipment should be worn when conducting this test. Using a multimeter on the x1 resistance Using a multimeter on the AC voltage scale, measure across the two fuse scale, measure across terminals 5 and 9 terminals. The reading should be less than on the terminal block. Normal voltage is 24 1 ohm. volts.
Component Tests 11 - 14 Test 11 Test 12 Warning – ‘Live’ equipment Personal Warning – ‘Live’ equipment Personal Protective Equipment should be worn Protective Equipment should be worn when conducting this test. when conducting this test. Using a multimeter on the AC voltage scale, Using a multimeter on the AC voltage measure across terminal 1 on the fan relay scale, measure across terminals E6 & and Line 2 on the compressor contactor. E11 on the control board. Normal voltage Normal voltage is 240 volts.
Component Tests 15 - 18 Test 15 Ensure power conducting test is isolated Test 16 Warning – ‘Live’ equipment Personal before Protective Equipment should be worn when conducting this test. Using a multimeter on the x1 resistance scale, measure across the two terminals on the defrost switch. The reading should be less than 1 ohm. Using a multimeter on the AC voltage scale, measure across the load terminal on the time delay switch and Line 2 on the compressor contactor. Normal voltage is 240 volts.
Component Tests 19 - 22 Test 19 Ensure power conducting test is isolated Test 20 before Ensure power conducting test Mark and disconnect switch wiring and using a multimeter on the x1 resistance scale, measure across switch terminals. The readings should be as follows.
Component Tests 23 - 26 Test 23 Ensure power conducting test is isolated Test 24 before Ensure power conducting test Disconnect the blue wire from terminal E10 on the control board and using a multimeter on the x1 resistance scale, measure across this blue wire and terminal 9 on the terminal strip. For pressures below 35kPa the reading should be infinity ohms and for pressures above 60kPa the reading should be less than 1 ohm.
Fault Finding Chart 7 Electrical insulation test 7 Disconnect the wiring to the compressor and megger between each compressor wire and earth Is the reading below 1 mega-ohm? YES Replace compressor Is the reading below 1 mega-ohm? YES Replace fan motor Is the reading below 1 mega-ohm? YES Replace transformer NO Check for pinched or damaged wiring touching the water heater chassis NO Disconnect the wiring to the fan motor and megger between each fan motor wire and earth NO Disconnect the wirin
2. Once satisfied, disconnect the active and neutral supply wires from the compressor contactor Line 1 and Line 2 terminals. 3. Short circuit the Line 1 and Line 2 terminals of the compressor contactor by inserting a wire bridge between these two terminals. 4. Connect megger leads to the Line 1 terminal of the compressor contactor and earth. 5. Operate megger. A reading above 1 mega-ohm should be obtained. 6.
4. Disconnect black wire from terminal 1 of fan relay and push through control panel grommet. 5. Cut cable ties holding fan wiring to back of control panel. 6. Remove 9 screws around top cover and lift out whole top cover assembly including fan and grill. 7. Reassemble in reverse order of above. Transformer: (Procedure 4) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1.
Personnel qualified and licensed to work with refrigerants may only carry out the following repair procedures to the sealed refrigeration system. The following procedures assume that all work conducted conforms to the refrigeration code of good practice. During repair the R22 refrigerant must be recovered, not vented to atmosphere. 1. Remove control panel cover and access panel (see procedures 1 & 2). 2.
Defrost Switch: (Procedure 9) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation. 1. Remove control panel cover and access panel (see procedures 1 & 2). 2.
The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation. Personnel qualified and licensed to work with refrigerants may only carry out the following repair procedures to the sealed refrigeration system. The following procedures assume that all work conducted conforms to the refrigeration code of good practice. During repair the R22 refrigerant must be recovered, not vented to atmosphere. 1.
3. Remove fan blade by undoing bolt on retaining boss. Pay attention to the distance from bottom of boss to end of shaft for when reassembling. 4. Disconnect fan motor wiring from fan relay, capacitor and earth connection, cut cable ties and feed wiring through control panel grommet. 5. Remove 6 screws around outside of fan grill and lift out fan and grill together whilst feeding cables through conduit hole in top cover. 6. Remove four dome nuts holding fan to grill. 7.
6. Reassemble in reverse order of above ensuring potentiometer locating pin aligns with locating hole in control panel cover. Thermostat Adjustment POT pool: (Procedure 18) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Remove control panel cover (see procedure 1). 2.
3. Remove the top cover (see procedure 3). 4. Remove the three corner supports by removing 2 bottom screws on each support. 5. Gently remove the defrost thermostat probe from foil surround on left hand side of evaporator. 6. Remove 3 screws on left hand side of control panel and 1 screw on bottom left hand side of water inlet connector. 7. Remove tape holding TX probe to evaporator suction line and remove probe. 8. Recover R22 refrigerant. 9.
13. Reassemble in reverse order of above. Cut pipe work will need to be joined and rebrazed. 14. Pressurise system to 3000kPa and conduct a leak test. 15. Evacuate system to 300 microns for a period of at least 40 minutes. 16. Recharge system with R22. Refer to “Specifications” table on page 5. Water Manifold Assembly: (Procedure 22) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock.
8. Evacuate system to 300 microns for a period of at least 40 minutes. 9. Recharge system with R22. Refer to “refrigerant charge” on page 11. 10. If installing a new TX valve it will need to be adjusted. See the procedure on page 41. Receiver Filter Drier: (Procedure 24) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. The fan motor may commence operation without warning.
R22 Saturated Temperature Chart ºC - 60 - 56 - 52 - 48 - 44 - 38 - 36 - 34 - 32 - 30 kPa - 64 - 55 - 43 - 30 - 15 4 14 25 36 49 ºC - 28 - 26 - 24 - 22 - 20 - 18 - 16 - 14 - 12 - 10 kPa 62 76 92 108 125 143 163 184 205 229 ºC -8 -6 -4 -2 0 2 4 6 8 10 kPa 253 279 306 334 365 396 429 464 501 539 ºC 12 14 16 18 20 24 28 32 36 40 kPa 579 621 665 711 759 808 915 1029 1154 1288 ºC 42 44 46 48 50 52 54 56 58 60 kPa 1432 1508 1587 1669 1753 1841 1931 2025 2122 2325 ºC 36 37 38 39 40 41 42 43 44 45 46 47 O
Exploded Views and Parts Lists Control Panel Assembly Exploded View & Replacement Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Description Part No.
Control Panel Cover Assembly Exploded View & Replacement Parts List Item 1 2 3 4 5 6 7 8 Description Control Panel Cover Thermostat Adjustment POT Spa-Remote-Pool Selector Switch Type A403 Selector Switch Knob Label Control Panel LED Green LED Red LED Amber TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by Part No. 8130152 100-107 100-106 5610001 8410017 5310001 5310003 5310002 44 Service.
Exploded View Heat Pump Assembly TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by 45 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List Heat Pump Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ** ** ** ** ** Description Part No.
Raypak Heat Pump Water Heater Warranty – Australia Only WARRANTY CONDITIONS 1. 2. 3. 4. This warranty is applicable only to heat pump pool heaters manufactured from 1st October 2004. The pool heater must be installed in accordance with the Raypak heat pump pool heater installation instructions, supplied with the pool heater, and in accordance with all relevant statutory and local requirements of the State in which the pool heater is installed.
Document Revision History Document Number: Title: Raypak Pool and Spa Heat Pump Revision A B C Details of change Service Instructions issued for Raypak Heat Pump. Correction to fault finding chart 1.4 Additional part numbers added. TM022 Raypak RHP 33 Pool and Spa Heat Pump Service Instructions REV C D.O.I: 14/03/2006 This document is stored and maintained electronically by TM022 D.O.I. 08/05 09/05 03/06 48 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.