Raypak Heat Pump RHP 33 User Guide

®
Raypak RHP Series  
Swimming Pool and  
Spa Heat Pump  
OWNER and  
INSTALLATION MANUAL  
Model RHP 33  
R
C
US  
I
S
T
9900276  
This manual should be maintained in legible condition and kept adjacent  
to the heat pump or in a safe place for future use.  
For additional information call: (03) 9757 3333  
The instructions in this manual are for the use of qualified individuals specially  
trained and experienced in the installation and maintenance of this type of  
equipment and related system components. Installation and service personnel  
are required by some states to be licensed.  
Persons not qualified must not attempt to install, service, or maintain this  
equipment.  
The Pool and Spa Heating Experts  
Effective Date: Dec 2004  
Replaces: All Previous Versions  
Part No.  
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RHP Series Swimming Pool and Spa Heat Pump  
OWNER and INSTALLATION MANUAL  
CONTENTS  
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
I. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
II. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
III. Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
IV. Controls and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
V. Initial Start-Up and Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
VI. Seasonal Start-Up or Annual Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
VII. Heat Pump Running Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
VIII. Summer Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
IX. Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
X. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
XI. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Plumbing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Heat Pump Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Control Panel Assembly Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Control Panel Cover Assembly Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Heat Pump Assembly Replacement Parts List - RHP 33 . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Limited Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY. . . . . . . . . . . . . . . . . . . . 16  
ii  
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Introduction  
WARNING  
This pool/spa heat pump is an electromechanical machine that incorporates  
a pressurised refrigerant gas in a sealed system. ONLY trained and qualified  
service personnel should attempt to install or service this equipment.  
Without proper training and knowledge of such equipment, any attempt to  
install or service the unit could result in serious injury or even death.  
This manual contains important information on the use, maintenance, chemistry requirements and  
installation of your new heat pump. Proper installation and operation of the unit will increase the  
benefits you receive from the unit.  
This heat pump is an extremely efficient, economical machine designed specifically for pool and  
spa heating. It is similar in design and operation to a typical residential air conditioning system.  
The heat pump employs a hermetic motor/compressor operating in a refrigeration cycle to extract  
heat from ambient air and deliver it to the circulating pool water.  
As with all pool/spa heat pumps, compared to other types of pool heat pumps such as gas,  
this heat pump has lower heating capacity on a KW/hr basis. As a result, it will be required  
to operate longer to accomplish the desired results. It may, at certain times, operate as much as 24  
hours per day. However, this should not be of concern to the owner, because the unit is designed  
to operate continuously. Even though it may operate continuously for many hours, it will still heat  
the pool with greater economy than other types of fossil fuel heaters.  
You are advised to put a pool cover over the pool at night and other non-use periods. This will  
keep evaporation, the cause of the greatest heat loss, to a minimum, and so greatly reduce overall  
pool heating costs. During warmer weather, the pool cover may be required only at night.  
I. Installation  
• The placement of the pool heat pump is very important to minimize installation costs while  
providing maximum efficiency of operation, and to allow adequate service access.  
• The unit is designed for outdoor installation and must not be installed in a totally enclosed  
area such as a shed or garage, unless ventilation is provided to ensure adequate air exchange  
for proper operation. Recirculation of cold discharge air back into the evaporator coil will  
greatly reduce the unit’s heating capacity and efficiency.  
• When installed in a geographical location where freezing temperatures can be encountered,  
the water circuit should be drained to prevent possible freeze-up damage. See Section IX,  
Freeze Protection.  
• The unit should be located as close as possible to the existing pool pump and filter to  
minimize water piping.  
• All models feature an "up-flow" discharge for quiet operation. Air is pulled up through the  
evaporator coil and discharged through the top grill. Allow at least 2.5m clearance above the  
unit for unrestricted air discharge. Do NOT install the unit under a porch or deck.  
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• Each side of the unit must be located at least 300mm from walls, pipes, or other obstructions  
for unrestricted air intake and service access.  
WARNING  
Do not install the unit within 1m of fossil fuel burning heaters. Air intake  
along the sides of this heat pump could disturb the combustion process  
of the unit, and could cause damage or personal injury.  
• Mount the unit on a level, sturdy base, preferably a concrete slab or blocks. The size of the  
base should be not less than 1m by 1m.  
• Completely isolate the base from the building foundation or wall to prevent sound or  
vibration transmission into the building. For this purpose, 4 black rubber sound isolation  
pads are included with the unit. These pads must be installed under the corners of the  
unit to reduce vibration and sound transmission to the base.  
• If the unit is installed in an area known for water accumulation during periods of heavy  
rainfall, its supporting base must be high enough to keep it completely free of standing water  
at all times.  
II. Electrical Connections  
The table below lists the typical electrical power requirements for your heat pump.  
Table 1: Typical System Electrical Power Requirements  
Model  
VIN - Phase - Hz  
240 - 1 - 50  
Min. circuit Ampacity (A) Max. breaker size (A)  
42.2 60  
RHP 33  
Refer to the unit rating plate below the control panel for precise power requirement for each unit,  
and for ampacity and over-current protection requirements. All wiring must be in accordance with  
the AS3000 Wiring Rules Section 7.2 Swimming Pools, latest edition, and all applicable state  
and local codes.  
The power supply connections to the unit are located behind the control panel. Remove the  
control panel to expose the electrical controls. Line voltage connections are made at the line  
voltage terminals of the compressor contactor. Refer to the Heat Pump Schematic (page 11) and  
the Control Panel Assembly Replacement Parts List (page 12).  
Conduit entrance to the unit is through a hole below the control panel.  
NOTE: Make certain all electrical connections to unit terminals are secure.  
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III. Water Connections  
CAUTION  
The heat pump inlet and outlet connections are NOT interchangeable.  
They must be connected as instructed below.  
1. Connect the heat pump in the return water line between the pool filter and the pool. See  
page 10, Plumbing Diagrams.  
2. Connect the filter outlet to the fitting marked WATER IN at the bottom front of the unit.  
3. Connect the fitting marked WATER OUT to the return piping to the pool. Unit inlet/outlet  
connection fittings are 50mm PVC slip couplers.  
Water connections from the heat pump to the main return line can be PVC pipe or flexible pipe  
approved for the purpose and, in either case, should be at least equal in size to the main pool  
circulation piping.  
4. In cold weather (freeze zone) areas, shutoff valves (ball or gate type) must be installed at the  
heat pump inlet and outlet to facilitate service and cold weather drain-down.  
5. When the water connections are complete, operate the pool pump and check the system for  
leaks.  
Automatic chemical feeders must not be installed upstream of the heat pump. Improper  
installation of erosion-type automatic chemical feeders can result in serious damage to, or  
premature failure of, the heat pump. A flow check valve will be required.  
IV. Controls and Indicator Lamps  
Your heat pump incorporates safety controls and indicators to ensure its safe, reliable operation.  
Water Pressure Switch: Prevents operation when the pump is OFF. The unit requires 35 Kpa  
minimum pressure.  
Water Temperature Control: Pool/spa water temperature is controlled by the heat pump  
thermostat on the unit control panel, which contains a switch and 2 thermostats, one for setting a  
spa temperature and the other for a swimming pool temperature. The switch can operate an  
optional external control system, or can switch between thermostats for pool or spa.  
NOTE: The heat pump will not run when the Remote position is selected  
and there is no remote control system attached.  
Defrost Switch: Prevents heat pump operation if ambient air temperature falls below a  
predetermined safe minimum (approximately 5.5°C).  
Delay Timer: Prevents compressor from short cycling, which could damage or destroy the  
hermetic motor/compressor. Upon water temperature control satisfaction, or other control circuit  
interruption, this solid state device will prevent compressor restart for approximately 5 minutes.  
Upon power failure or interruption, a 6 to 8 minute delay will also be initiated.  
Refrigerant Low Pressure Control: Stops the compressor if refrigerant suction (low side)  
pressure falls too low as a result of a malfunction or loss of charge.  
3
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Indicator Lamps: There are 6 indicator lamps located on the unit control panel:  
Control panel  
Indicator lamps  
When this  
lamp is lit,  
unit requires  
service.  
When any combination  
of these 5 lamps is lit,  
operation is normal.  
Power (amber lamp): When lit, indicates power is applied to the unit.  
Water Flow (green lamp): When lit, indicates normal water flow.  
Heat Demand (green lamp): When lit, indicates the actual water temperature is below the  
target water temperature.  
Compressor Delay Active (amber lamp): Under normal operation, when lit, indicates  
compressor anti-short cycle timer is active. The fan will run but the compressor will be  
OFF for 6 to 8 minutes.  
Defrost Active (red lamp): When lit, indicates unit is in defrost mode. Defrost mode occurs  
when ice starts to form on the outside coil. The fan will continue to run but the compressor  
will stay OFF (not heating) until weather conditions improve.  
Low Pressure (red lamp): When lit, indicates failure in the refrigeration circuit. When this  
lamp is ON, service is required. Call the number shown in the CONTACT INFORMATION  
at the front of this manual.  
V. Initial Start-Up and Check  
1. Verify that the Power lamp 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  
the figure.  
3. Turn the control switch to either Pool or Spa to turn the system ON and raise the thermostat  
setting above the current water temperature. At this time the 2 green lamps should illuminate.  
The fan and compressor should start up and run simultaneously.  
4
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NOTE: The heat pump will be OFF when the Remote  
position is selected on the Pool/Spa selector switch.  
Spa thermostat  
4.Allow the heat pump to operate for a few minutes to  
stabilize operating pressures and to allow various  
component temperatures to normalize.  
Pool/Spa selector  
switch  
5. Verify that the discharge air temperature is  
approximately 4°C - 6°C cooler than the air entering the  
unit.  
Pool thermostat  
VI. Seasonal Start-Up or Annual Check  
1. Remove leaves, pine needles, etc. from the evaporator coil. Clean the coil by spraying it with  
a mild solution of household liquid soap and water.  
2. Flush the coil with a garden hose; DO NOT use a high-pressure sprayer.  
3. Backwash or otherwise clean the pool filter. If necessary, clean the skimmer basket and pump  
strainer.  
4. Set the valves to assure proper water flow through the unit.  
5. Set the water temperature control to the desired temperature range for either pool or spa.  
6. Turn the control switch to either Pool or Spa. If the pool pump is running and the water is  
colder than the setting of the temperature control, the heat pump will start up and run. It will  
run until the desired water temperature is reached, or until the pool pump shuts OFF.  
NOTE: If the pool pump and heat pump shut OFF before the water temperature is  
raised to the desired level, you must lengthen the running time of both. To do this,  
reset the time clock dial for the longer running time, or manually operate the pump  
with the timer override switch. Since the pool heat pump capacity and efficiency are  
both greater at higher ambient air temperatures, run time should be set to take  
advantage of all daylight hours, when the air is generally warmer.  
VII. Heat Pump Running Time  
1. Determine the length of pump and heat pump operating time necessary for your particular  
requirements. Minimum run time should be the required hours to attain proper pool water  
filtration. Maximum run time obviously is 24 hours per day, or as required to reach desired  
pool temperature, and depends on such things as weather, pool size, covering, shading, etc.  
2. If cooler or warmer water is desired, simply adjust the water temperature control and/or the  
pump and heat pump operating time accordingly, until the desired water temperature is  
reached.  
NOTE: At the beginning of the heating season, or whenever the pool water  
temperature is to be raised several degrees, the pool pump and heat pump may  
need to operate continuously for several days. During summer months, only a few  
hours per day may be necessary, or none at all.  
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VIII. Summer Shutdown  
If you do not plan to use the pool heat pump during the summer months, secure and protect it  
as follows:  
1. From the control panel, turn the control switch to Remote (OFF).  
2. Turn the heat pump power switch to OFF.  
3. Leave the valves set the way they are unless additional circulation is required. DO NOT stop  
all flow through the heat pump.  
4. IMPORTANT: Remember to reset the valves before the next heating season, or the heat pump  
will not operate properly.  
IX. Freeze Protection  
If the pool heat pump is installed in a location subject to freezing conditions, it is important to  
protect the water circuit from freezing, just as should be done for the pump and filter.  
System Drain-Down  
1. Turn the heat pump circuit breaker or disconnect switch to OFF.  
2. From the control panel, turn the control switch to Remote (OFF).  
3. With the pool pump OFF, close the external shutoff valves and remove the internal drain plug.  
Use air pressure to remove water from the bypass assembly and heat exchanger.  
4. Leave the drains open until the unit is started in the spring.  
5. Cover the heat pump with a waterproof cover.  
Continuous Pump Operation  
It is also possible in some areas to prevent heat pump freeze damage by operating the pump  
continuously during freezing weather. However, this results in significantly higher pump  
operating cost. Further, if a sustained power failure occurs, the heat pump would have to be  
drained anyway, or freeze damage could result.  
X. Maintenance  
The following maintenance procedures are designed to keep your heat pump operating at a high  
level of reliability. Maintenance should be performed on a periodic basis to prevent system  
failures and performance degradation.  
A. Air Coil Cleaning - Efficient system operation depends on free circulation of air through the  
thin and tightly-spaced fins of the evaporator coils. The evaporator should be cleaned whenever  
it has a buildup of dirt or debris.  
Shut OFF electricity to the heat pump.  
WARNING  
1.  
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To clean the fins, spray with a garden hose. But avoid high water  
pressure, which will bend and damage the fins.  
CAUTION  
2.  
B. Cabinet Care (optional) - The cabinet is designed for outdoor use and requires little care.  
However, you can clean it if you wish.  
Shut OFF electricity to the heat pump.  
WARNING  
1.  
2. Wash the cabinet with soap and water.  
C. Condensate Drainage - The heat pump extracts humidity from the air as it passes through the  
coil, similar to the way a cold drink outside “sweats” on a hot day. This condensate drains from  
the bottom of the unit.  
1. Routinely check to be sure the condensate drain holes in the base of the unit are not plugged  
with dirt or debris.  
NOTE: Owners often suspect that the heat pump is leaking when in fact it is  
condensate that is draining. To check that the liquid is condensate and not  
leakage from the heat pump, either:  
a. Use the pool chemistry test kit to confirm there is no chlorine in the condensate. Or,  
b. Shut the heat pump OFF and leave the filter pump running to see if the water disappears.  
If the water disappears, it would confirm the water to be condensate.  
XI. Troubleshooting  
If your heat pump does not operate, or simply does not heat your pool water, the indicator lamps  
on the front control panel (see page 4) can provide valuable clues as to what is wrong, and may  
even indicate precisely what the problem is. Always observe these lamps before calling a service  
representative. By reporting on the telephone which lamps are ON and OFF, the service rep may  
be able to solve the problem without the expense of a service call.  
A. UNIT IS RUNNING, BUT NOT HEATING  
• Is the ejected air from the unit 4° to 6° cooler than incoming air? If so, the unit is extracting  
heat from the air and transferring it to the pool.  
• Are the evaporator and internal copper pipes “sweating”? This is also evidence of heat  
removal from the air. When the air is cool with low humidity, “sweating” may not be  
evident.  
• How long has the heater been operating? During initial pool heating in cold weather, it may  
require a week to elevate the pool temperature to a comfortable level. Normally, it takes  
about 4 days.  
• How many hours per day is the unit operating? Remember that the heat pump only  
operates while the pool pump is running. Set the pool system time clock to permit  
24 hour per day  
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operation. After the desired temperature is reached, return the system to normal operation.  
• Is airflow through the unit being obstructed? Restrictions such as shrubbery, tall grass, dirty  
coils, or any other obstruction to airflow will reduce performance.  
• Is the pool blanket/cover being used? Unblanketed pools can lose up to 6° per night  
compared to 2 degrees or less when a blanket is used. Without a blanket, the total heat  
gained during the day can be lost overnight.  
• Are rapid heat losses occurring in some other way, such as high wind, waterfalls, spa  
spillage, bubblers, rainfall, flow through solar panels at nights, or a high water table?  
• Is water flow through the unit adequate? Check the system for obstructions, such as a  
clogged filter pump strainer or a dirty filter.  
B. UNIT IS NOT RUNNING  
Power lamp ON? If not, the power switch may be shut OFF or circuit  
• Is the control panel  
breaker tripped. Reset the power by switching it OFF, then back ON.  
Verify that the circuit breaker is set and operating properly before calling for service.  
• Is the thermostat setting correct? Verify that the temperature has been properly set on the  
thermostat, and that it is higher than the current water temperature.  
• Have you waited 6 minutes for the time delay? After the unit has been running and then shut  
OFF for any reason, there is a 6-minutes timed cycle before operation can begin again.  
• Is the Water Flow lamp OFF? This lamp will turn OFF if not enough water is flowing  
through the heater. Improperly positioned valves or a dirty filter could decrease the flow of  
water required for efficient operation. When the Water Flow lamp is ON, proper flow is  
present. If this lamp is OFF, but you can feel normal flow at the pool returns, check the water  
valves or settings.  
• Is the Defrost Active lamp OFF? If this lamp is ON, the fan will be running but not the  
compressor. The unit is waiting for the frost to melt or the air temperature to rise before  
heating is resumed.  
• Is the Heat Demand lamp ON? If not, then the thermostat setting is not higher than the  
temperature of the pool water. Raise the thermostat setting.  
• Is the Low Pressure lamp ON? If this lamp is ON, there is a problem with the unit that will  
require service. Turn the unit OFF and call the number shown in the CONTACT  
INFORMATION at the beginning of this manual.  
SERVICE CALL REQUESTS  
Determine if the problem is:  
• Warranty Service (within 5 years of installation)  
• Non Warranty Service (beyond 5 years of installation)  
• Maintenance-related (power supply, water flow, or pool system time clock adjustment)  
NOTE: The MANUFACTURER IS NOT RESPONSIBLE for maintenance adjustments.  
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POWER SUPPLY  
Verify that all circuit breakers are reset and working properly.  
• If the Power lamp on the control panel still does not light, contact the installing dealer,  
since it may be a power problem requiring an electrician.  
WATER FLOW  
Verify that the filter is clean to provide good flow.  
Verify that the valves are properly positioned.  
• If the Water Flow lamp on the control panel still does not light, and water is circulating  
in the pool or spa, contact the installing dealer to adjust the valves.  
TIME CLOCK ADJUSTMENT  
Verify that the time clock is set to permit the heater to run long enough to heat properly.  
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Plumbing Diagrams  
Water In  
(from pool  
or Spa)  
Water Out  
(to pool  
or Spa)  
Filter  
For systems with pumps of less than 2 HP(1.5Kw) (under 300 l/min), no external  
bypass is required. Connections are 50 mm pipe slip. Plumb the heat  
pump after the filter and before any chlorinators.  
Water In  
(from pool  
or Spa)  
Water Out  
(to pool  
Filter  
or Spa)  
For systems with pumps of 2 HP (1.5Kw) or greater (over 300 l/min), an external  
bypass is required. Adjust the bypass valve to divert a minimum of 150 l/min  
gpm through the heat pump. Connections are 50mm pipe slip. Plumb  
the heat pump after the filter and before any chlorinators.  
10  
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Heat Pump Schematic  
E4  
E5  
E6  
Pink  
Coil  
Coil  
11  
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Control Panel Assembly Replacement Parts List  
1
12  
4
7
13  
11  
11  
9
6
15  
3
16  
10  
14  
5
8
ITEM QTY DESCRIPTION  
PART No.  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
1
1
1
1
1
1
1
1
1
1
2
4
2
1
1
1
Control Panel  
Contactor Compressor  
Fan Relay  
Control Board 24Volt  
Thermostat  
Transformer  
Timer IMC 203  
Capacitor  
Pressure Switch Water  
Fuse Block  
Bushing Heyco 2184  
Stand-off RLCBSR1  
Terminal Strip  
Clamp Capacitor 04  
Ground Lug  
2
Fuse 2A Type 3AG  
12  
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Control Panel Cover Assembly Replacement Parts List  
4
5
4
4
Front  
1
6
6
7
8
8
7
2
3
2
1
Back  
ITEM QTY DESCRIPTION  
PART No.  
1
2
3
4
5
6
7
8
1
2
1
3
1
2
2
2
Control Panel Cover  
POT  
Switch Type A403  
Knob  
Label Control Panel  
Lamp Green  
Lamp Red  
Lamp Amber  
RHP Control Panel Cover  
13  
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Heat Pump Assembly Replacement Parts List - RHP 33  
11  
ITEM QTY  
DESCRIPTION  
PART No.  
1
2
3
4
5
6
7
8
1
1
1
1
1
1
3
1
2
1
1
1
1
1
1
1
1
1
1
Assembly Base  
Evaporator Coil  
Access Panel  
Power Input Panel  
Cover, Top  
Compressor, Scroll  
Corner Support  
Heat Exchanger  
Retainer, Screen  
Control Panel Cover  
Fan Guard  
Fan Blade  
Fan Motor  
Water Manifold Assembly  
Conduit, Fan  
Coil Guard  
13  
12  
15  
5
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
*
*
9
Control Panel Assembly  
Expansion Valve  
Filter Dryer BFK-165 S  
*See assembly drawing in this manual  
18  
7
2
16  
7
3
9
14  
7
17  
19  
6
10  
8
4
Model RHP 33  
1
14  
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15  
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16  
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