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PART 2 - SECTION I - INSTALLATION INSTRUCTIONS
PUMP SELECTION
The filtration pump must be sized to provide an
adequate water flow for the filtration system
and the heater. In some cases however, this
can cause a high back pressure which reduces
the filtration capacity and in this case it would
be more of on advantage to install an additional
pump for the heater only. This pump must be
installed on the inlet side.
DO NOT connect the pump to the heater outlet.
Some heater models incorporate their own By-
Pass Pump but this is used to control the
temperature of the water entering the heater to
prevent condensation and scale and will not be
suitable as the additional pump described above.
Refer to the Flow Rate chart following when
sizing the pump.
Where the water flow rate exceeds the
maximum shown in the chart, a by pass valve
must be installed to reduce the water flow
through the heater.
A pump run on timer must be fitted to remove
any residual heat from the boiler and prevent
any nuisance tripping of the high limit switch.
WATER FLOW RATES.
Model Water flow (l/sec)
min max
538 to 1292 4.5 7.5
1362 / 1412 1.9 3.2
1492 / 1552 2.2 3.5
1662 / 1722 2.5 4.1
1852 / 1922 2.8 4.4
2004 / 2214 3.2 5.0
2404 / 2634 3.8 5.9
2804 / 3164 4.7 7.2
3304 / 3694 5.6 8.4
3804 / 4224 6.2 9.4
We recommend that the pump be selected that
will deliver the maximum flow and the
installation of an external by-pass in all cases so
as to allow for the field adjustment if required.
IMPORTANT: When installing a new heater
to an old system, it is a Raypak
requirement that the system and its
equipment be inspected and if necessary,
drained and flushed out with clean fresh
water, before the new heater is
connected. Failure to do this may cause
blockages and/or heater damage which is
NOT COVERED BY WARRANTY and any
damage caused would result in extra
costs to repair etc.
IF THERE IS ANY DOUBTS ABOUT SYSTEM,
DRAIN AND FLUSH AS A PRECAUTION.
SYSTEM OVER TEMPERATURE
CUT OUT
The installation may require a "System -
Manual Reset High Limit", refer to AG601 and
other relevant codes.
AUTOMATIC CHEMICAL
DOSING EQUIPMENT
All automatic chemical dosing devices,
including salt chlorination, MUST be installed
downstream of the heater and in a manner that
will not allow the chemically dosed solution to
enter the heater before being thoroughly mixed
with the main pool or spa water.
PRESSURE RELIEF VALVE
The standard pressure relief valve supplied is
set to 410 kPa (60 PSI).
WATER SENSOR LOCATION
On models 1362 to 4224, where a By-Pass
pump is an integral part of the heater, the
water sensor of the Digital Thermostat is
supplied with the unit but it is not installed to
the pipework.
Please insert the sensor as shown in the
drawing below.
ELECTRICAL WIRING
The electrical power consumption of the
heaters is:
Models 538 - 1292 (No By-Pass Pump):
240 Volts AC, 50/60 Hz, 100 VA approx.
Models 1362 - 1922 (UPS 32-80B By-Pass Pump):
240 Volts AC, 50 Hz, 1.4 Amps approx.
Models 2004 - 3164 (UMT 50-30Z By-Pass Pump):
240 Volts AC, 50 Hz, 3.0 Amps approx.
Models3304 - 4224 (UMT 50-60Z By-Pass Pump):
240 Volts AC, 50 Hz, 3.0 Amps approx.
A normal 10 or 15 Amp, single phase power
circuit would be suitable.
Access to the electricals is achieved by
removing the cover of the control panel. (See
Location of Controls for different models.)
The heater must be properly earthed and
Raypak highly recommends the installation of
an RCD (Residual Current Device) for added
electrical safety. If the site is "electrically
noisy", a mains filter can be supplied at extra
cost, to eliminate failures.
THE HEATER MUST NOT BE ABLE TO
OPERATE WITHOUT THE CIRCULATING
WATER PUMP RUNNING.
The heater (240 Volts) power supply must be
"interlocked" via the auxiliary contacts of the
pump contactor (relay) etc or alternatively the
power supply for the pump and the heater
must operate off the same circuit and isolation
switch. (Parallel connection)
A Flow Switch is not regarded as an
interlock and must not be used as one.
Any other form of interlocking must be
approved by Raypak.
A pump run on timer is required so that at any
time that the heater is no longer required, the
heater shuts off and the pump continues for at
least ten (10) minutes.
A Raypak "economaster" is an optional extra
available at extra cost for all heaters.
For servicing purposes we suggest that the
isolation switch be installed as near as
practical to the heater.
If there is any control wiring etc which is not
isolated by this switch then a suitable warning
label must be affixed to the heater which will
also direct the service person to the isolation
switch for that particular wiring. E.G. More than
one isolation switch is required to turn off the
power supply, Extra switch(es) on switchboard
etc.
Caution: Do not locate cables in front of or
underneath the burner, please consult Raypak
for advice if unsure.
Where cables or conduit, trunking etc are to be
mounted on the heater casing, please keep at
least 10mm air gap from the heater casing to
eliminate possible overheating.
Do not locate cables etc where they will
restrict access covers, doors etc.
Where the clearance from the right hand side
of the heater (models 538 to 1922) is
restrictive, please notify Raypak at the time of
manufacture and we may be able to relocate
the control panel for a minimal extra cost, if
this is not possible then a field retrofit may be
the best solution. (At extra cost)
There are many variations to the types of
controls available and also RUN & FAIL indication
can be supplied. Ask Raypak what is available.
