Raypak PS165VSP, Installation, Operating And Service Manual

Page 1: ...Installation Operating and Service Manual PS165VSP Variable Speed Pool Pump Catalog No 6000 555 Effective 01 16 2013 Replaces NEW P N 241508 Rev 1 LISTED 31B4 ...

Page 2: ...umber For Service Call Safety Safety is emphasized throughout the user manual These are safety alert symbols They alert the user to potential personal injury hazards Obey all safety messages to avoid possible injury or death or damage to equipment CAUTION WARNING DANGER Manufactured for Raypak by Speck Pumps Jacksonville Florida USA 2012 2013 All Rights Reserved This document is subject to change ...

Page 3: ...se 16 Power Outage 16 Schedule Advance 17 Using an existing or new 24 hour timer 17 Optional PS165VSP RM Controller 17 Freeze Protection 18 Override 18 Communication 18 3rd Party Controllers Wiring 20 Heat Pump Pool Heater Connections Wiring 24 5 Service and Maintenance 27 Routine Maintenance 27 Winterizing 28 6 Troubleshooting 28 Fault LED 28 General Troubleshooting Problems 29 Blocked Impeller 2...

Page 4: ...lets WARNING Pump suction is hazardous and can trap and drown or disembowel bathers Do not use or operate swimming pools spas or hot tubs if a suction outlet cover is missing broken or loose The following guidelines provide information for pump installation that minimizes risk of injury to users of pools spas and hot tubs Entrapment Protection The pump suction system must provide protection agains...

Page 5: ... ASME A112 19 8 ANSI APSP 16 2011 the standard for Suction Fittings For Use in Swimming and Wading Pools Spas Hot Tubs and Whirlpool Bathtub Applications Testing and Certification Suction outlet covers must have been tested by a nationally recognized testing laboratory and found to comply with the latest published edition of ANSI ASME A112 19 8 ANSI APSP 16 2011 the standard for Suction Fittings F...

Page 6: ...tructed in or on the ground or in a building such that it cannot be readily disassembled for storage A storable pool is constructed so that it may be readily disassembled for storage and reassembled to its original integrity TO REDUCE THE RISK OF ELECTRICAL SHOCK connect ground wires to grounding screw located in the motor Use no smaller than a 12 AWG 3 3mm2 wire TO REDUCE THE RISK OF ELECTRICAL S...

Page 7: ...r Buttons Increases or decreases speed or duration of selected value STOP button Stops pump and programming START button Must be pressed to start the pump and programming 7 Figure 1 The PS165VSP Variable Speed control panel provides manual speed controls for the pump General Description continued 3 Installation Information Preparation Guide 1 Upon receipt of the pump check the carton for damage Op...

Page 8: ...ee circulation of air for cooling 6 Although the pump is designed for outdoor use it is recommended to protect the pump from direct sunlight and excessive moisture rain sprinklers etc 7 DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this pump DO NOT store pool chemicals near the pump 8 DO NOT remove any safety alert labels such as DANGER WARNING or CAUTION Kee...

Page 9: ... make sure that the control switch time clock or control system is installed in an accessible location so that in the event of an equipment failure or loose plumbing fitting the equipment can be easily turned off CAUTION The pump must be permanently connected to a dedicated electrical circuit No other equipment lights appliances or outlets may be connected to the pump circuit with the exception of...

Page 10: ...stallation The motor is designed to handle either a bare wire connection or a quick disconnect connection The quick disconnect tab is 0 250 For a direct wire connection the wire insulation should be stripped to a length of approximately 0 33 and the screw tightened to a torque of 10 in lb The terminals will handle wire up to 12 AWG in size There are two terminals labeled L1 and L2 See Figure 3 Att...

Page 11: ...to a pressure test These requirements are generally not intended to apply to the pool equipment However if the WARNING cannot be followed and pressure testing of the complete system must be done follow the following guidelines 1 RELEASE ALL AIR in the system before testing 2 Water pressure for the test must NOT EXCEED 35 PSI 3 Water temperature for the test must NOT EXCEED 100 F 38 C 4 Limit the t...

Page 12: ...left the filter close the filter pressure release valve If the pump is located above the water level of the pool remove the lid and fill the basket with water before starting the pump 2 Prior to replacing the lid check for debris around the lid o ring seat Debris around the lid o ring seat will make it difficult to prime the pump 3 Hand tighten the lid to make an air tight seal Do not use any tool...

Page 13: ...EP 1 as determined for proper operation of the filtration system proper number of turns per day 5 STEP 2 and STEP 3 can be used and set for other equipment operation 6 OVERRIDE is used by the HPPH for heater operation Adjust the flow rate so that it is just sufficient for the unit to operate This is the lowest setting for heat pump operation and will result in the greatest energy savings 7 OVERRID...

Page 14: ... of the Keypad overlay See Figure 4 shows the speed being set at 3100 RPM The LED directly above each button when lit indicates it is in operation or active To create a custom schedule and change the factory defaults settings follow these steps 1 Place the pump in the stop position Press STOP Button 2 Press the STEP 1 button The LED above it will illuminate The LED above the SPEED column will illu...

Page 15: ...s above the SPEED and DURATION will flip back and forth every three seconds When lit the graph below will show the active programmed speed or duration in progress Note The START button must be pressed for the pump to operate The START LED will illuminate after the button has been pressed Note If the schedule times combined are less than 24 hours the remaining time for the 24 hour cycle will be fil...

Page 16: ...n different steps of the schedule The STEP currently being set will always take priority of any older settings Therefore the duration for the other two 2 STEPs not currently being set will be cleared to 0 hours and have to be programmed again by the user It is always a good idea to double check your programmed settings once you have completed the programming process Keypad Lock Setup 1 STEP 1 STEP...

Page 17: ...erify that Dip switch 1 is ON and Dip switch 5 is OFF Note The 12V and GND can also be used to supply 12V for the Digital Inputs when Dip switch 1 is ON The benefits of the PS165VSP RM 1 Ability to view fault codes and troubleshoot 2 Ability to set a pump running schedule based on a real time clock setting 3 Ability to remotely mount the PS165VSP RM 4 Ability to configure Prime Speed and Prime Dur...

Page 18: ... Override Freeze Protection will run the motor at 2600 RPM for eight 8 hours if the ambient temperature drops below 39 F Once this eight 8 hour duration has elapsed the motor control will check the ambient temperature again If the temperature is still below the 39 F threshold the motor will run for an additional eight 8 hours If the temperature is above the threshold the motor will automatically r...

Page 19: ...ital Inputs Therefore the serial commands as well as the Overlay Keypad inputs will be ignored when a digital input is present NOTE If more than one digital input switch is present then the motor will give priority to the highest number digital input Therefore OVERRIDE has highest priority followed by STEP 3 then STEP 2 then STEP 1 NOTE If no digital input is detected the motor will automatically ...

Page 20: ...k L2 Red or White Earth Earth 208 230V Power Source 20 3rd Party Controllers Wiring Figure 8 Note 12V from the RS485 can be wired to the Line In of each Aux Load Out will be the input for each digital signal Verify Dip switch 1 on pump is ON Wiring Diagram for ProLogic with PS165VSP ...

Page 21: ...B lue R ed N ot U sed B lack N ot U sed R ed B lack S ola r S ensor Low Vo ltag e H eate r F Pum p Aux 1 Aux 2 Aux 3 Relay Sockets 24 VDC output Aux 7 Aux 6 Aux 5 Aux 4 Relay Sockets 24 VDC output Relay Sockets 24 VDC output JVA Sockets 24 VAC output Battery 9Volt 1 2 3 4 5 6 7 8 Factory Set OFF Aux 1 1 spd pum p Aux 3 Cool Down See M anual Not Used See M anual Gas Heater Optional Set ON Cleaner 2...

Page 22: ...ontrollers Wiring continued Figure 10 Wiring Diagram for Multiwave with PS165VSP Make sure that voltage selector switch is in 120V position before applying power to Terminals 1 2 Select Breaker to match wire size and load requirement Observe maximum control circuit capacity Note Dip Switch 1 on pump must be in the ON position for this configuration ...

Page 23: ...I 2 DI 1 DI 3 DI 4 L1 Black L2 Red or White Earth Earth L1 Black L2 Red or White Earth Earth 208 230V Power Source 23 3rd Party Controllers Wiring continued Figure 11 Wiring Diagram for IntelliTouch with PS165VSP ...

Page 24: ...ue to operate at this OVERRIDE speed until the HPPH thermostat has been satisfied NOTE This direct wiring is ONLY available for R 410A Digital HPPH models produced after August 2010 The HPPH control board revisions PH2 8 and PH2 8D are the only revisions that provide this connectivity Verify the HPPH control board revision as shown in Figure 12 before attempting to connect this pump to an existing...

Page 25: ... 23 24 3 9 7 10 8 6 15 16 BL R R R 5 4 BK BK SPR1 SPR2 BK BK Y Y BK BL BL PD AC F1 F2 F3 12 0 12 WS DS AS PS FR REV P S FLO LP HP COMP PUMP P O O R BL BL W BK BR P R R R RS R R T C S P HPS LPS WPS REMOTE CONTROL FIELD CONNECTIONS 25 Field wiring to Digital HPPH products will be accomplished by connecting directly to the HPPH control board as shown below in Figure 13 A spade connection is required ...

Page 26: ...2 3 BL 1 2 3 4 5 6 7 8 9 10 11 12 T T 5 1 8 9 4 13 12 11 10 14 7 5 6 2 3 HPS WPS LPS F A C B D Delay Timer E 24 Volts AC DEFROST SWITCH T P POT 1 POT 2 24 VAC HOT 24 VAC COM C SEN SEN BK BL TEMP CONTROL BOARD N O N C WATER SENSOR P BK T BK BL R 21 22 23 24 15 16 C S P REMOTE CONTROL FIELD CONNECTIONS 26 Field wiring to Analog HPPH products will be accomplished by connecting directly to terminals 1...

Page 27: ...ection page 13 This pump requires little or no service other than reasonable care and periodic cleaning of the strainer basket 1 Inspect the pump basket for debris by looking through the clear pump lid 2 Turn off the power to the pump If the pump is located below the water level close isolation valves on the suction and discharge sides of the pump to prevent back flow of water 3 Remove any debris ...

Page 28: ... cause a loss of pressure resulting in damage to the pump casing impeller and mechanical seal voiding warranty Winterizing 6 Troubleshooting Fault LED WARNING The pump must be serviced by a professional service technician qualified in pool spa installation The following procedures must be followed exactly Improper installation and or operation can create dangerous electrical hazards which can caus...

Page 29: ...g at terminal With power off turn shaft It should spin freely If not disassemble and repair Verify that the Dip switches are in the correct position 3 Motor Runs then Stops A Over temperature fault B Over current fault Check the back of the motor is free from dirt and debris Motor will automatically restart after one minute 4 Motor is noisy A Debris in contact with fan B Debris in strainer basket ...

Page 30: ...urn off the pump Switch off the circuit breaker to the pump motor If you are not replacing the motor do not disconnect the electrical wiring 2 Turn off any valves to prevent pool water from reaching the pump Drain water from the pump by loosening the unions or removing the drain plugs 3 Remove the ten 10 screws connecting the pump casing to the flange 4 Pull the motor seal housing flange out from ...

Page 31: ...tern from side to side and top to bottom CAUTION Do not over tighten or you will strip the casing threads Removal and Replacement of the Impeller and or Mechanical Seal continued Motor Replacement WARNING The pump must be serviced by a professional service technician qualified in pool spa installation The following procedures must be followed exactly Improper installation and or operation can crea...

Page 32: ... represent average system curves for pools with the pipe diameter mentioned below B 1 1 2 Pipe A 2 Pipe C 2 1 2 Pipe 32 Motor Replacement continued 9 Remove the motor flange from the face of the old motor and install on the new motor 10 Clean the surfaces of the seal Refer to the Removal and Replacement of the Impeller and or Mechanical Seal Section page 30 31 steps 9 17 Reverse the process for in...

Page 33: ...4331F 4 1 BASKET WHITE ONE PIECE 014332F 8 1 CASING 014333F 9 1 DRAIN CAP DARK GRAY 3 8 WITH GASKET CASING 014334F 17 3 LEGO SPACER 014335F 16 10 SCREW CASING 3 8 HEX SLOT M7 x 48mm SS 014336F 10 1 O RING DIFFUSER 90 x 5mm 014337F 11 12 1 DIFFUSER 014338F 1 IMPELLER 1 65 HP 124 5 0mm 014339F 13 1 MECHANICAL SEAL 20mm COMPLETE 014340F 14 1 O RING CASING 206 x 6mm 014341F 15 1 SEAL HOUSING 49mm 0143...

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