Raypak P-926, P-1826, P-2100, P-4001 Installation And Operating Instructions Manual
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Raypak P-926, P-1826, P-2100, P-4001 Installation And Operating Instructions Manual

Commercial swimming pool heater
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INSTALLATION
AND OPERATING
INSTRUCTIONS
RAYTHERM
COMMMERCIAL
SWIMMING POOL
HEATER
Models
P-926 to P-1826
and
P-2100 to P-4001
WARNING: If the information in these instructions is not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
— 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
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the
heater or in a safe place for future reference.
TM
CATALOG NO. 6200.51O
Effective:
04-09-07
Replaces:
05-15-05
Models 1287-1758
Models 2100-4001
P/N 240251 Rev. 16

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Summary of Contents for Raypak P-926, P-1826, P-2100, P-4001

  • Page 1 INSTALLATION AND OPERATING INSTRUCTIONS RAYTHERM COMMMERCIAL SWIMMING POOL HEATER Models P-926 to P-1826 P-2100 to P-4001 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. —...

  • Page 2: Table Of Contents

    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 &...

  • Page 3: Section 1: Receiving Equipment

    Raypak recommends that this manual be reviewed thoroughly before installing your Raypak Pool Heater. If there are any questions which this manual does not answer, please contact the factory or your local Raypak representative. Claims for shortages and damages must be filed with carrier by consignee.

  • Page 4: Clearances

    CLEARANCES ALL HEATERS For clearances from combustible surfaces, see chart below. We require a minimal vertical clearance of three feet between the upper surface of the flue outlet to a non- combustible material. MINIMUM CLEARANCES FROM COMBUSTIBLE CONSTRUCTION INDOOR HEATERS Top - 24"...

  • Page 5: Venting Connections

    VENTING CONNECTIONS DRAFTHOOD (INDOOR) MODELS 962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. Models 2100-4001 have built-in drafthoods that must be properly vented to the outside. VENT PIPING WARNING: Indoor heater requires a drafthood that must be connected to a vent pipe and properly vented to the outside.

  • Page 6: Gas Supply Connections

    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 of the heater gas controls, and a manual shut-off valve located outside the heater jacket.

  • Page 7: Water Connections

    GAS PRESSURE REGULATOR The gas pressure regulator is preset and sealed at 4 in. WC for natural gas, and 11 in. WC for propane gas. Between the gas valve and the burners is a 1/8" pipe plug. The pressure at this point, taken with a manometer, should be about 3.7 in.

  • Page 8: Controls

    When local codes permit the use of less than four feet high temperature piping or two elbows, provisions should be made to always shut the heater off a minimum of 15 minutes prior to pump shut down in order to carry away residual heat and prevent damage to the low temperature piping.
  • Page 9 MODELS 1287/1336 - 1758/1826 1-1/2" Slip Ball Valve 2-1/2" Outlet 2-1/2" Inlet MODELS 2100-4001 3" Outlet 2" Slip Ball Valve Inlet/Outlet Header MODEL CONNECTION SIZE 926-1223 1287-1826 2100-4001 MODELS 1287/1336 1414/1468 1571/1631 1758/1826 3" Inlet FLOW RATES/WATER CONNECTIONS MIN GPM 2-1/2"...
  • Page 10 Raypak recommends the installation of an air bleed vent at a suitable location (usually the highest point) to remove air from the piping system. These units should be available at your local wholesale supplier. Raypak does not provide this item.
  • Page 11 MOUNTING WELL INTO SYSTEM RETURN LOOP PIPE - FRONT-MOUNTED LOOP: Note: For more detail on piping configurations 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.
  • Page 12 2. Adjust Bypass Valve "A" 1/2 open and Balancing Valve "B" fully open. (See piping configuration page 11) 3. Fire your Raypak pool heater and adjust Bypass Valve "A" to obtain a heater inlet temperature approximately 100°F-105°F. Turning Valve A in the open direction will raise the heater inlet temperature and closing Valve "A"...
  • Page 13 PIPING CONFIGURATIONS FOR RAYTHERM COMMERCIAL POOL HEATERS Fig # 9268 Models 2100 thru 4001 BLENDED WATER TEMPERATURE (THERMOMETER AT HEATER INLET) HEATER OUTLET TEMPERATURE THERMOMETER HEATER THERMOSTAT RECOMMENDED FIELD INSTALLED ISOLATION VALVES FOR SERVICE Fig # 9269...
  • Page 14 EXTERNAL AUXILIARY BYPASS VALVE (Where Required) 926-1223 Models only An auxiliary bypass valve should be used when flow rates exceed 120 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.
  • Page 15 HIGH & LOW GAS PRESSURE SWITCHES Pressure switches sense either high or low gas pressure and automatically shut down burners if abnor- mal pressures exsist. Standard on Models 3001-4001. PRESSURE GAS MANIFOLD ELECTRICAL WIRING CAUTION: Label all wires prior to disconnection when servicing controls.

  • Page 16: Wiring Diagrams

    WIRING DIAGRAM MODELS 926 - 1223...
  • Page 17 WIRING DIAGRAM MODELS 1287-1826...
  • Page 18 WIRING DIAGRAM MODELS 2100-2500...
  • Page 19 WIRING DIAGRAM MODELS 3001-4001...

  • Page 20: Section 4: Servicing Instructions

    SECTION 4/ SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS MODELS 926-1826 Inlet/Outlet Header Unitherm Governor Hi-limit control/ Temp. Control Main Burner Gas Valve MODELS 2100-4001 Inlet/Outlet Header w/Bypass Pump Main Burner Manual On/Off Valve Gas Valve TEMPERATURE CONTROL The pool water temperature is controlled by the pool thermostat.

  • Page 21: Start-Up Procedures

    ADJUSTMENT KNOB PRESSURE SWITCH ADJUSTMENT RANGE HEAT EXCHANGER HEIGHT 5' Max NOTE: If heater is installed outside of the limits shown, a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater. TWO-SPEED PUMPS In some cases, the flow on the low speed is insuffi- cient to operate the heater.

  • Page 22: Inspection Procedures

    AFTER START-UP Pilot System Checkout Procedure 1.Turn on power to the ignition systems and turn gas supply off. 2.Check ignition module as follows: a.Set the thermostat above pool water temperature to turn heater on. b.Watch for continuous spark at the pilot burner. c.

  • Page 23: Servicing Procedures

    Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in non-inhib- ited de-scale solvent. RAYPAK TUBE CLEANING KIT Auger with Carbide Tip Fig. #6049 Wire Brush...
  • Page 24 BURNER DRAWER REMOVAL 1. Shut off power and gas supply to the pool heater. Dis- connect 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.
  • Page 25 IMMERSION WELL TUBE REPLACEMENT PROCEDURE On Raypak tube replacement may be affected without rolling, as a temporary means of repair, provided there are two or more tubes rolled into act as stays on left and right sides.

  • Page 26: Maintenance & Care

    MODELS 926-1223 UNITHERM GOVERNOR INLET/OUTLET HEADER OUTLET INLET GASKET UNITHERM GOVERNOR WITH POWER ELEMENT MODELS 1287-1826 (Models prior to Jan. '95) DOUBLE EXTERNAL U.G. MODELS 2100-4001 (Models prior to Jan. '95) EXTERNAL U.G. To test operation of Unitherm Governor, place in hot water and watch for movement against spring.

  • Page 27: Section 5: Trouble Shooting

    SECTION 5 / TROUBLESHOOTING GUIDE 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.
  • Page 28 Outer jacket very hot (paint blistered) Takes long time to heat pool or spa Liming Leaking at well. Leaking at heat exchanger. Gasket brittle and leaking- (overheated). *Broken refractory caused by shipping damage or improper combustion………………………….. Excessive sooting of heat exchanger…………………………...

  • Page 29: Electrical

    ELECTRICAL (ELECTRONIC IGNITION IID) IID Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL) SPARK ACROSS IGNITER/SENSOR GAP TURN GAS SUPPLY ON PILOT BURNER LIGHTS? SPARK STOPS WHEN PILOT IS LIT? MAIN BURNER LIGHTS?

  • Page 30: Section 6: Replacement Parts

    Any part returned for replacement under 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.
  • Page 31 MODELS: 926/962, 1083/1125, 1178/1223, 1287/1336, 1414/1468, 1571/1631, 1758/1826...
  • Page 34 MODELS: 2100, 2500, 3001, 3500, 4001...

  • Page 37: Warranty

    Raypak, Inc. (“Raypak”) warrants to the original owner that all parts of this heater 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. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner’s responsibility.
  • Page 38 Raypak, 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.

This manual is also suitable for:

Raytherm 1287-1758, 2100-4001

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