Instruction/ maintenance manual of the product P-4001 Raypak
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INST ALLA TION & OPERA TING INSTR UCTIONS CA T ALOG NO. 6200.51P Effective: 05-24-10 Replaces: 04-09-07 P/N 240251 Rev . 17 WARNING: If these instructions are not followed exactly , a fire or explosion may result causing property damage, personal injury or death.
2 W A TER CHEMISTR Y (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 bal- anced water . Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool & Spa T ypes W ater T emp.
CONTENTS 3 WA TER CHEMISTR Y 2 WARNINGS 4 Pay Attention to These T erms 4 RECEIVING EQUIPMENT 5 GENERAL SPECIFICA TIONS 5 INST ALLA TION 5 Code Requirements 5 Base Installation 5 Clearances 6 Combusti.
4 D ANGER: I ndicates the presence of immediate hazards which will cause severe person- al 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.
5 RECEIVING EQUIPMENT On receipt of the equipment, visually check for exter- nal 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 .
6 Clearances All Heaters F or clearances from combustible surfaces, see T able A below . We require a minimal vertical clearance of three feet between the upper surface of the flue outlet to a noncombustible material.
7 2 . Free ventilation air 1 sq. in. per 1000 BTU input within 12" of the ceiling level . V enting Connections Drafthood (Indoor) Models 962-1826 Locate and assemble as shown in Fig. 3. Secure with screws supplied in envelope in carton. Models 2100-4001 have built-in drafthoods that must be properly vented to the outside.
8 At the time of removal of an existing heater , the follow- ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remain- ing connected to the common venting system are not in operation.
9 MANOMETER GAS PRESSURE TEST AT GAS V AL VE GAS PRESSURE TEST A T HEA TER MANUAL SHUTOFF V AL VE GAS PRESSURE TEST UPSTREAM Model No. 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 4” N P N P N P N P N .
the time clock may be used for this purpose with instructions not to override this sequence manually . See wiring diagram section for electrical hookup loca- tion of the fireman switch in the electrical circuit. CONTR OLS Flow Switc h This dual purpose control shuts off the boiler in the case of a pump failure or low water condition.
11 Wa ter Pressur e Switch 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 sup- ply to the heater is interrupted.
12 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 whole- sale supplier . Raypak does not provide this item.
13 2. Lace metal strapping or clamps, (NOT PROVID- ED) through the ¾” slots on the cover and fasten securely to pipe as shown in Fig. 15 & 16. Do not over-tighten clamps. Fig. 13: Poolstat Control Fig. 14: Control Cover Fig. 15: Hose Clamp Slots Fig.
14 T o adjust the temperature: 1. Both isolation valves must be fully open. 2. Adjust Bypass V alve "A" 1/2 open and Balancing V alve "B" fully open. (See piping configuration page 15, 16 & 17) 3. Fire your Raypak pool heater and adjust Bypass V alve "A" to obtain a heater inlet temperature approximately 105°F .
15 6. As the pool temperature rises to the desired tem- perature 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.
16 BLENDED WATER TEM PERATURE (THERMOMET ER AT H EAT ER I NLET) HEATER O UTLET TEMPERATURE THERMOMETER HEAT ER THERMOSTAT RECOMME NDED FIE LD INSTA L LED I SOLA TION VALVES FOR SERVICE T I T o T c Pip.
17 BLENDED WATER TEM PERATURE (THERMOMET ER AT H EAT ER I NLET) HEATER O UTLET TEMPERATURE THERMOMETER HEAT ER THERMOSTAT RECOMME NDED FIE LD INSTA L LED I SOLA TION VALVES FOR SERVICE T I T o T c Mod.
18 Exter nal Auxiliar y Bypass V alve (Wher e Required) 926-1223 Models Only A n 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).
19 Low W ater Cutoff Automatically shuts down burner whenever water level drops below probe. A 3 to 5 second time delay prevents premature lockout due to temporary condi- t ions such as power failure or air pockets.
20 W iring Dia g r am—Models 926–1223.
21 W iring Dia g r am—Models 1287–1826.
22 W iring Dia g r am—Models 2100–2500.
23 W iring Dia g r am—Models 3001–4001.
24 SER VICING General Location Of Contr ols Models 926-1826 Models 2100-4001 T emperature Contr ol The pool water temperature is controlled by the pool t hermostat.
25 Tw o-Speed Pumps In some cases, the flow on the low speed is insufficient to operate the heater . This is apparent when the pres- sure switch cannot be further adjusted or if the heater makes banging noises. In these cases, the pump must be run at high speed when heating the water .
26 After Star t-Up Pilot System Check out Pr ocedur e 1 . T urn on power to the ignition systems and turn gas supply off. 2. Check ignition module as follows: a. Set the thermostat above pool water tempera- ture to turn heater on. b. W atch for continuous spark at the pilot burner .
27 SER VICING PR OCEDURES T ube Cleaning Pr ocedur e (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.
28 Main Bur ner and Orifice R emo val 1 . Remove screws and burner hold down bracket. NOTE: If the heat exchanger is sooted badly , the b urner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts.
29 Combustion Chamber R emo val T o remove the combustion chamber you must first have removed the heat exchanger . Unbolt metal com- bustion chamber retainer from top and remove combustion chamber panels individually . Control Well R eplacement Remove top, sensing bulb and clip.
30 4. T ake garden hose and wash heat exchanger , mak- ing 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. Unither m Go ver nor R eplacement 1.
31 W interizing Y our 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 .
32 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.
33 Outer jacket very hot ( paint blistered) * Broken refractory caused by shipping damage or i mproper combustion………………………….. E xcessive sooting of heat exchanger…………………………... C alcu la te tem perature in ° F/hr…….
34 NOTE: Before trou ble shooting, f amilia rize y ours elf wi th the s tar t-up and c heckout procedure. Check line voltage p owe r, low v olt age t ransformer, li mit c ontrolle r, t hermostat (controller) and wiring. Pull ignition lead and c heck spark at module.
35 RA YTHERM COMMERCIAL SWIMMING POOL HEA TERS LIMITED WARRANTY RA YTHERM TYPE P SIZES 0926-4001 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this boiler w.
36 w w w.ray pa k .co m Raypak, Inc., 2151 Eastman A venue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A..
An important point after buying a device Raypak P-4001 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Raypak P-4001 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Raypak P-4001 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Raypak P-4001 you will learn all the available features of the product, as well as information on its operation. The information that you get Raypak P-4001 will certainly help you make a decision on the purchase.
If you already are a holder of Raypak P-4001, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Raypak P-4001.
However, one of the most important roles played by the user manual is to help in solving problems with Raypak P-4001. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Raypak P-4001 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
