INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Commercial Swimming Pool Heater Models P-926 to P-1826 L W & P-2100 to P-4001 WARNING: If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
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 balanced water. 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.
CONTENTS WATER CHEMISTRY 2 WARNINGS 4 Pay Attention to These Terms 4 RECEIVING EQUIPMENT 5 GENERAL SPECIFICATIONS 5 INSTALLATION 5 Code Requirements 5 Base Installation 5 Clearances 6 Combustion Air (Indoor Units Only) 6 Venting Connections 7 Gas Supply Connections 8 Water Connections 10 CONTROLS 10 Flow Switch 10 Water Pressure Switch 11 Automatic Chlorinators and Chemical Feeders 11 Unitherm Governor Operation 11 Companion Flange Connections (Models 926-1223) 11 Mounting the Poolstat Control with FrontMou
WARNINGS Pay Attention to These Terms DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
RECEIVING EQUIPMENT INSTALLATION On receipt of the equipment, visually check for external damage to the carton or the shipping crate. If the carton or shipping crate is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately. Remove the heater from the carton or shipping crate. Do NOT use the shipping base crate as an installation base.
Clearances All Heaters For clearances from combustible surfaces, see Table A below. We require a minimal vertical clearance of three feet between the upper surface of the flue outlet to a noncombustible material. Indoor Heaters Outdoor Heaters (926–1758) Heater Side Clearance (Inches) Heater Side Clearance (Inches) Top 24 Top 24 Back 24 Back 24 Right Side 24 Right Side 24 Left Side 24 Left Side 24 Vent* 6 Fig.
2. Free ventilation air 1 sq. in. per 1000 BTU input within 12" of the ceiling level. must have a minimum of 1/4 inch per foot rise and should be supported at not more than five foot intervals. Plumbers' tape, criss-crossed, will serve to space both horizontal and vertical piping. NOTE: If the room the heater is installed in is located against an outside wall and air openings communicate directly with the outdoors, the openings may be 1/4 the size specified above (ANSI Z223.
Gas Supply Connections At the time of removal of an existing heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket.
Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system. MANOMETER MANUAL SHUTOFF VALVE GAS PRESSURE TEST UPSTREAM GAS PRESSURE TEST AT GAS VALVE GAS PRESSURE TEST AT HEATER Fig.
Water Connections the time clock may be used for this purpose with instructions not to override this sequence manually. See wiring diagram section for electrical hookup location of the fireman switch in the electrical circuit. 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.
Water Pressure Switch Unitherm Governor Operation On Models 926-1223 built with a Unitherm Governor (UG), a water pressure switch is provided in the heater to shut down the gas valves in the event the water supply to the heater is interrupted. It is very important to verify that the switch electrically opens and shuts off the gas valve when water flow to the heater is interrupted.
Raypak recommends the installation of an air bleed vent at a suitable location (usually the highest point in the plumbing) to remove air from the piping system. These units should be available at your local wholesale supplier. Raypak does not provide this item. Pump 1-1/2" Slip Ball Valve Inlet/Outlet Header 2-1/2" Outlet 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.
3. Remove either the left or right “knock-out” for wiring on the poolstat control as shown in Fig. 17. Fig. 13: Poolstat Control Fig. 17: Remove Knockout 4. Attach appropriate conduit and connectors to the poolstat control. 5. Attach wires to the poolstat wire terminals. See Fig. 18. Fig. 14: Control Cover 2. Lace metal strapping or clamps, (NOT PROVIDED) through the ¾” slots on the cover and fasten securely to pipe as shown in Fig. 15 & 16. Do not over-tighten clamps. Fig. 18: Attach Wires 6.
Mounting Well into System Return Loop Pipe - FrontMounted Loop NOTE: For more detail on piping configurations for large systems, refer to the diagrams on pages 15, 16 & 17. 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. 20. Fig. 22: Installation with Weld O Lets NOTE: The drawings and instructions above show only one of several acceptable ways of installing the dry well into main system loop.
6. As the pool temperature rises to the desired temperature as controlled by the Pool aquastat, small adjustments to valves "A" and "B" will be required for optimum performance. Heater temperatures 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 damage from condensation. NOTE: Consult factory if target temperatures cannot be achieved.
Piping Configurations for Raytherm Commercial Pool Heaters 4 PIPE DIAMETERS MAX. 4 PIPE DIAMETERS MAX. 4 PIPE DIAMETERS MAX.
Piping Configurations for Raytherm Commercial Pool Heaters 4 PIPE DIAMETERS MAX. 4 PIPE DIAMETERS MAX. 4 PIPE DIAMETERS MAX.
External Auxiliary Bypass Valve (Where Required) 926-1223 Models Only Bypass Valve An auxiliary bypass valve should be used when flow rates exceed 100 gpm (usually a high performance pump size larger than two HP will exceed this flow rate). This valve is required to complement the function of the automatic bypass valve, particularly when starting the heater in winter or early spring when the spa or pool temperature is below 55°F.
Low Water Cutoff Electrical Wiring Automatically shuts down burner whenever water level drops below probe. A 3 to 5 second time delay prevents premature lockout due to temporary conditions such as power failure or air pockets. Standard on Cal Code heaters. DANGER - SHOCK HAZARD - Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. CAUTION: Label all wires prior to disconnection when servicing controls.
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 Temperature Control General Location Of Controls The pool water temperature is controlled by the pool thermostat. The heater water temperature high limit is controlled by the manual reset high limit. Models 926-1826 Pressure Switch Inlet/Outlet Header Pressure Switch Unitherm Governor Electrical Conn. Hi-limit control/ T e mp .
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 combustibles, flammable liquids, and chemicals. Do not obstruct the flow of combustion and ventilating air. ADJUSTMENT KNOB Water Fig. 30: Pressure Switch Adjustment Range Water must be flowing through the heater. Start-Up 5’ Max CAUTION: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting heater in confined areas.
INSPECTION PROCEDURES After Start-Up Pilot System Checkout Procedure Burners 1. Turn on power to the ignition systems and turn gas supply off. Clean main burners and air louvers of dust, lint and debris. Keep heater area clear and free from combustibles 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. Lifting or blowing flame indicates high gas pressure.
SERVICING PROCEDURES Burner Drawer Removal Tube Cleaning Procedure (Typical) Establish a regular inspection schedule, the frequency depending on the local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. 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 wires at gas valve and slide burner drawer out. Gas Valve Removal 1.
Main Burner and Orifice Removal Heat Exchanger Reassembly 1. Heat exchanger header O-rings should be replaced with new ones. 1. Remove screws and burner hold down bracket. NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts. 2. Install inlet-outlet and return water headers and install header retainer nuts and torque nuts evenly. 2.
Combustion Chamber Removal canopy and flue collector off (on models 926-1826, remove the canopy hold-down brackets). Remove "V" baffles over tube(s) to be replaced. If no pipe unions have been provided, use the header as a union, remove the flange nuts off the inlet-outlet header, break gas connection and slide heater away from piping, allowing room to work. Pull wedge clips out of control wells and remove sensing bulbs. Remove flange nuts from the return header and remove header.
MAINTENANCE AND CARE 4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid excessive water against refractory). 5. Reassemble; when heater is fired, some steam will form from wet refractory. This is normal. To be followed one month after initial start-up and then quarterly. NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is steam cleaning at a local car wash. DO NOT WIRE BRUSH! 1.
Winterizing Your Heater When heaters installed outdoors in freezing climate areas are to be shut down for the winter, please observe the following step-by-step procedure: 1. Remove the drain plug or open the drain cock located on the inlet-outlet header. On larger 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.
TROUBLESHOOTING IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
Outer jacket very hot (paint blistered) Takes long time to heat pool or spa *Broken refractory caused by shipping damage or improper combustion………………………….. Excessive sooting of heat exchanger…………………………... Calculate temperature in °F/hr……... Filter not running long enough…….... Dirty filter…………………………….. Gas line or meter undersized……….................................. Replace refractory panels. Determine cause of sooting & correct. Heat rise (°F/hr.) = Htr.output Pool gallonage x 8.
ELECTRICAL (ELECTRONIC IGNITION IID) IID WARNING: HIGH VOLTAGE. technicians ONLY. Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL) YES SPARK ACROSS IGNITER/SENSOR GAP YES For qualified NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if the pilot fails to light. To reset, interrupt power to the heater.
RAYTHERM COMMERCIAL SWIMMING POOL HEATERS LIMITED WARRANTY RAYTHERM TYPE P SIZES 0926-4001 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
