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1. Optional Relay Optional Relay Low Voltage Raceway do not run high voltage wire in this compartment RS6 or RS8 RS8 oje ee ele ele System Power 5 Wire Nut to 120 VAC Power BE eee 01 4 12V Pint DI 1 Note Dip Switch 1 on pump must be in the ON position for this configuration L1 Black Note Filter Pump Relay must be connected to DI 4 for the Spa mode L2 Red or White feature to function properly 208 230V Power Source Earth Figure 9 21 22 3rd Party Controllers Wiring continued Wiring Diagram for Multiwave with PS165VSP Make sure that voltage selector switch is in 120V position Select Breaker to match wire size before applying power to Terminals 1 amp 2 and load requirement Observe maximum control circuit capacity loolfoollool a Single pole Breaker RECEIVER POWER SUPPLY NEUTRAL BUS EF 12V Pint DI 3 Note Dip Switch 1 on pump must be in the ON position for this configuration ASIE HE I L1 Black L2 Red or White Figure 10 um Power Source ee 3rd Party Controllers Wiring continued Wiring Diagram for IntelliTouch with PS165VSP CIRCUIT BOARDS STANDARD SPECIAL PURPOSE RELAY OUTPUTS2. A oco N OO OO A N A GO gt DESCRIPTION LID LOCK RING DARK GRAY LID CLEAR O RING LID 137 x 5mm BASKET WHITE ONE PIECE NUT UNION ABS UNION END 2 ABS O RING UNION 68 X 3 5mm CASING DRAIN CAP DARK GRAY 3 8 WITH GASKET CASING O RING DIFFUSER 90 x 5mm DIFFUSER IMPELLER 1 65 HP 124 5 0mm MECHANICAL SEAL 20mm COMPLETE O RING CASING 206 x 6mm SEAL HOUSING 49mm SCREW CASING 3 8 HEX SLOT M7 x 48mm SS LEGO SPACER FLANGE SCREW 3 8 16 X 2 SLOTTED SPANNER LID 33 Notes 2999999292 Rev 01 2013 v1
3. ELECTRIC HEATER oran TO GAS HEATER TERMINALS FOR ACTUATOR SOLAR BOOSTER PUMP FACTORY WIRING REMOTE CONTROL OPERATION OR 2 SPEED FILTER PUMP cron 12VAC 18VAC 24VAC TO FIREMAN S SWITCH CONNECTION Seale ACTIVATES WITH SPA MODE CAUTION VALVE DO NOT BYPASS INTERNAL HEATER ACTUATOR OPTIONAL THERMOSTAT HIGH LIMIT SWITCH AUX VALVE FILTER PUMP AND AUXILIARY RELAYS ie OR OTHER SAFETY DEVICES eee RELAY 1 FILTER PUMP Theat T ad T esl T VOLTAGE P BREAKERS ACTUATOR ib SYSTEM AUX 1 4 CLNR AUX 3 pe pev La VALVE AUX VALVE 17 3 SYSTEM AUX 1 6 CLNR AUX 4 EXPANSION i9 3 SYSTEM AUX 1 8 CLNR AUX 5 ACTUATOR OPTIONAL MODULE A ARHAR eee ee ENTAKE RE TURNIVLV A VLVB ELET SOLAR 2SPD SPA FILTER Aux1 aux2 AuXx3 AUX4 AUXS AUX6 AUX7 AUX 8 T VALVE ACTUATORS WIRES TO i 3 TRANSFORMER TELS PA PHONE NODULE 10K OHM THERMISTOR SENSORS KA WATER SENSOR PORTS i7 ano i p I7 mo 19 ONLY 4 SOLAR SENSOR USE EITHER ET AIR SENSOR OR BOTH BLK BLK 112131415715 TEMP SENSORS HAVE NO POLARITY RED BLK WIRES ARE INTERCHANGEABLE INDOOR CONTROL INDOOR CONTROL AND OR AND OR WIRING DIAGRAM RF TRANSCEIVER RF TRANSCEIVER AND OR AND OR IntelliTouch Models i5 i7 3 i973 i 10 SPA SIDE REM i 10 SPA SIDE REM iS4 SPA SIDE REMOTE 28 RELAYS 2 SPEED FILTER PUMP OPTI
4. sl r IS IN Inr TETE D 12V Pint 01 1 9 Earth S L1 Black L2 Red or White 208 230V Power Source D Figure 8 Dip Switch Settings Factory Set Optional Set 3rd Party Controllers Wiring Wiring Diagram for AquaLink RS with PS165VSP Return JVA Cleaner Solar Pump 38 ars o 05 gu g o One RE 5 gt essy 9992905 presses s O gt mar crmozmm ZZM E JVA 0000 000000 0000000000 4 3 2 1 654321 11987654321 To Controller To Remote To Sensors etc red term bar brown term bar green term bar JVA Sockets 24 VAC output Relay Sockets 24 VDC output OFF ON Aux 1 Cleaner 1 spd pump 2 spd pump Aux 3 Spa Spillover Cool Down Disabled See Manual See Manual Not Used Not Used See Manual See Manual Gas Heater HeatPump CONDOR CO no ck Battery 9 Volt Optional Relay Optional Relay RS6 or RS8 RS8
5. 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 For Use in Swimming and Wading Pools Spas Hot Tubs and Whirlpool Bathtub Applications Fittings Fittings restrict flow for best efficiency use fewest possible fittings but at least two 2 suction outlets Avoid fittings that could cause an air trap Pool cleaner suction fittings must conform to applicable International Association of Plumbing and Mechanical Officials IAPMO standards WARNING Risk of Electrical Shock or Electrocution This pool pump must be installed by a licensed or certified electrician or a qualified pool serviceman in accordance with the National Electrical Code and all applicable local codes and ordinances Improper installation will create an electric hazard which could result in death or serious injury to pool users installers or others due to electrical shock and may also cause damage to property WARNING epis ee Always disconnect power to the pool pump at the circuit breaker Cause death before servicing the pump Failure to do so could result in death or Disconnect power before serious injury to serviceman p
6. Wiring Connections 5 Service and Maintenance Routine Maintenance 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 because as the debris accumulates it will begin to block the flow of water through the pump Keep the basket clean and clear to improve the performance of the pump 4 Turn the lid s lock ring counter clockwise until it stops Carefully remove the lid and lock ring 5 Remove the basket and properly dispose of the debris into the trash and rinse out the basket Check basket for cracks if crack is found replace basket 6 Replace basket back into the pump align the basket properly with the suction pipe Then fill with water up to the suction pipe Clean clear cover lid o ring and sealing surface of the pump of any debris 7 Replace lid with locking ring Hand tighten the lid to make an air tight seal Do not use any tools to tighten the lid 2 28 Routine Maintenance continued 8 Verify that all valves have been returned to the proper position for normal operation Turn on the power to the pump Winterizing CAUTION The pump must be protected when freezing temper
7. a single drop of Loctite to the motor shaft threads 14 Install impeller by spinning it clockwise onto the motor shaft Continue to turn clockwise until the carbon and ceramic sides make contact and the seal spring slightly compresses 15 Install the diffuser by aligning the diffuser pin with the holes in the seal housing and pressing together 16 Make sure the diffuser and casing o rings are in place and free of debris Reassemble in reverse sliding the seal housing back into the casing 17 Tighten torque of 8 Nm or 70 8 in lb the ten 10 screws using a cross pattern from side to side and top to bottom CAUTION Do not over tighten or you will strip the casing threads 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 create dangerous electrical hazards which can cause high voltage to run through the electrical system This can cause property damage serious personal injury and or death Improper installation and or operation will void the warranty 1 Disconnect the wiring from the side of the motor Refer to the Electrical Installation 2 Remove the ten 10 screws holding the flange to the pump casing 3 Slide the motor and flange from the casing 4 Remove the diffuser by gently pulling the diffuser horizontally until the pins are clear from the seal
8. housing 5 Place a 5 16 Allen head wrench through the center hole of the fan cover and into the recess on the end of the motor shaft 6 While holding the motor shaft turn the impeller counter clockwise 7 After removal of the impeller the seal housing will slide easily off the motor shaft 8 Using a flathead screwdriver remove the four bolts and washers securing the flange to the motor 31 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 installation Product Specifications Dimensional Drawing 9 EL ul CV 46 8 JO Performance Curve 80 3450 RPM TOTAL HEAD IN FEET 0 20 40 60 80 100 120 140 160 GALLONS PER MINUTE B A and C represent average system curves for pools with the pipe diameter mentioned below 1 1 2 Pipe A 2 Pipe 2 1 2 Pipe Replacement Parts and Exploded View KIT NUMBER CALL OUT 1 1 QTY 014329F 014328F 014330F 014331F 014344F 014354F 014355F 014332F 014333F 014336F 014337F 014338F 014339F 014340F 014341F 014335F 014334F 014342F 014343F 014345F ON O oa A C DN N I
9. keep stored settings and time 18 Freeze Protection 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 return to the 24 hour based schedule NOTE The freeze protection function will NOT operate if the START button is not pressed This can be confirmed by verifying that the START LED is illuminated Override The pump is equipped with an OVERRIDE feature which can be engaged to temporarily run at higher or lower speeds between 600 to 3450 RPM Once override duration has elapsed the motor will automatically return to programmed schedule 1 Pressing the OVERRIDE key while the motor is running will cause the motor to start running in the OVERRIDE mode at the programmed Speed and Duration The active step LED for OVERRIDE will illuminate The speed and duration settings LED along with its respective bar graph LED of OVERRIDE shall blink back and forth at three 3 seconds 2 The UP DOWN arrows allow the user to configure Speed and Duration These settings can be changed while the motor is running These settings are stored each time the UP DOWN arrows are pressed NOT
10. suction outlets on any one 1 suction line must be at least three 3 feet center to center WARNING Entrapment Prevention continued The system must be built to include at least two 2 suction outlets drains connected to the pump whenever the pump is running However if two 2 main drains run into a single suction line the single suction line may be equipped with a valve that will shut off both main drains from the pump The system shall be constructed such that it shall not allow for separate or independent shutoff or isolation of each drain More than one 1 pump can be connected to a single suction line as long as the requirements above are met Water Velocity 7he maximum water velocity through the suction fitting or cover for any suction outlet must be 1 5 feet per second unless the outlet complies with the latest published edition of ANSI 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 In any case do not exceed the suction fitting s maximum designed flow rate If 10096 of the pump s flow comes from the main drain system the maximum water velocity in the pump suction hydraulic system must be six 6 feet per second or less even if one 1 main drain suction outlet is completely blocked The flow through the remaining main drain s must comply with the latest published edition of ANSI ASME A112 19 8
11. will be cancelled Note If power is lost during the Schedule Advance then the 24 hour schedule will automatically start when power is restored Using an Existing or New 24 hour timer to start the pump controller program The PS165VSP operates on a 24 hour cycle Once the controller is programmed it only requires the START button to be pressed to start the 24 hour cycle Once the START button is pressed power cycled such as a temporary power failure to the pump would result in the 24 hour cycle restarting at the beginning of STEP 1 Using or adding a 24 hour timer will allow you to start the 24 hour cycle at any time during the day Note The pump must be programmed and the Start Key pressed in order to operate Optional PS165VSP RM Controller This optional controller uses the RS485 connectors See Table 3 0 Note Verify 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 Duration 5 Ability to configure Freeze Protection temperature 6 Ability to view speed and power of the motor in real time 7 Ability to adjust motor speed in 25 RPM increments 8 Battery backup to
12. 600 0 NOTE 0 is a programmable speed RPM and can be set for a specific duration Programmable Duration Settings Hours 24 22 20 18 16 14 12 10 8 6 4 2 0 Note Up to three separate speeds with duration may be set The sum of the three durations combined must not exceed 24 hours If the three combined exceed 24 hours the pump will keep the current step and re write the remaining two steps to zero User can change the program duration and speed of STEP 1 STEP 2 STEP 3 amp OVERRIDE keys Note Pump must be OFF for programming speed and duration of the STEP 1 2 3 keys Override speed and duration can be programmed when the motor is either OFF or running Four programmable buttons lay across the top 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 illuminate 3 Using the UP or DOWN arrows toggle to the desired speed The Bar graph will show the setting as you toggle up and down See Figure 4 shows the speed being set at 3100 RPM 4 Press the STEP 1 button again The LED above the duration column will be lit 5 Using the UP or DOWN arrows tog
13. A permanently installed pool is constructed 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 wire TO REDUCE THE RISK OF ELECTRICAL SHOCK a bonding connector is provided for bonding to metal water pipes metal rails or other metal within 5 feet of the swimming pool All local points should be bonded with a 8 AWG 8 4 wire SAVE THESE INSTRUCTIONS 2 General Description Raypak Professional PS165VSP Variable Speed The PS165VSP Variable Speed swimming pool pump is both environment friendly and cost efficient This Premium Efficiency Variable Speed Pump provides tremendous flexibility in motor speed and time settings The integrated electronic interface controls the speed settings between 600 and 3450 rpm and the start and stop times It is designed to maximize energy conservation optimize chemical usage and yet still be simplistic to use The PS165VSP is intended to run on the lowest speeds needed to maintain a healthy pool environment which in turn translates into money savings With speed settings of 3450 3100 2850 2600 2350 2100 1850 1600 1350 1100 850 600 and 0 it easily allows you to choose the most appropri
14. E When the OVERRIDE duration ends the motor resumes the 24 hour duration cycle and will start in the corresponding STEP The OVERRIDE duration will not affect the start or stop times of the 24 hour cycle NOTE Pressing Holding OVERRIDE key for more than three 3 seconds will cancel OVERRIDE mode NOTE During the OVERRIDE mode the motor will not start with the priming sequence NOTE Pressing STOP at any time turns the motor OFF and clears the start time for the 24 hour schedule Communication Control with Digital Inputs The user can run the motor at the programmed STEP 1 2 3 or OVERRIDE speeds by utilizing the four 4 digital inputs STEP 1 2 3 OVERRIDE are equivalent to Digital Input 1 2 3 or 4 respectively The controller is rated to accept digital inputs of 18V 30V AC 24V AC 20 and 9 30V DC 12 24 V DC 20 NOTE The motor will detect either a 50 60Hz for AC input or an active low signal for DC digital inputs The items below describe the functionality of the digital inputs See Figure 7 1 If the user provides any one of the 4 digital inputs then the DURATION LED will blink every one 1 second to indicate the Digital Input is functioning properly 2 The motor will illuminate the corresponding active step LED and the respective bar graph LED The START LED will be OFF when a digital input is present Communication continued NOTE There is no schedule for digital inputs The timing for each spee
15. Failure to follow warning notices and instructions may result in property damage personal injury or death ATTENTION INSTALLERS This manual contains important information about the installation operation and safe use of this product This manual should be given to the owner operator of this equipment 1 Raypak recommends in order to achieve better priming to install the pump as close to the pool as practical and run suction lines as direct as possible to reduce friction loss 2 It is recommended that a minimum length of straight pipe equivalent to five 5 times the pipe diameter be used between the pump suction inlet and any plumbing fittings elbows valves etc 3 Install the pump on a level solid foundation which provides a rigid and vibration free base Secure the pump to the base with screws or bolts to further reduce vibrations and stress on the plumbing 4 Protect the pump against flooding and excess moisture Select an area that will not flood when it rains DO NOT install the pump in a damp or non ventilated location 5 Keep the motor clean and provide free 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
16. Installation Operating and Service Manual PS165VSP Variable Speed Pool Pump F PIN APSP mirum The Association of eren PROFESSIONAL Catalog No 6000 555 Effective 01 16 2013 Replaces NEW P N 241508 Rev 1 Technical Support Address 7920 Interstate Court North Ft Myers FL 33917 Toll Free 1 877 213 3726 Website www raypak com Manufactured for Raypak by Speck Pumps Jacksonville Florida USA 2012 2013 All Rights Reserved This document is subject to change without notice 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 SAVE THESE INSTRUCTIONS 2999999292 Rev 01 2013 v1 Table of Contents Important Safety Instructions General Description Installation Information Preparation Guide Pump Location Pipe Sizing Plumbing Installation Bonding and Grounding Electrical Installation Pressure Testing Operation Start Up Guide e Energy Savings Optimization Programming Menu Structure Keypad Lock Motor Pause Power Outage Schedule Advance Using an existing or new 24 hour timer Optional PS165VSP RM Controller Freeze Protection Override Communication I 3rd Party Controllers Wiring Heat Pump Pool Heater Connections Wiring S
17. ON FILTER PUMP Neleaiee AND MODEL 9 3 AUX 5 3 LOADP LINE 2 LOAD 1 LINE VOLTAGE LINE VOLTAGE LINE 1 A DITIONAL POWER RELAYS MODEL i7 3 AUX 5 6 e i e CEX X ejlgelsr NEISES Neleakele SOCKET ON P C BOARD HIGH LOW MOTOR TERMINALS 2 SPEED RELAY SPAR IN LN FE D 12V Pin L1 Black L2 Red or White 208 230V Figure 11 Power Source Earth 23 24 Heat Pump Pool Heater Connections Wiring The PS165VSP be connected directly to single phase or 3 phase Raypak Rheem Ruud Weatherking and Perfectemp Heat Pump Pool Heaters HPPH without the need for any external sequencer or control The HPPHs will provide an OVERRIDE signal to the pump whenever there is a Call for Heat at the HPPH if wired as shown in these instructions The pump will continue 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 Digital HPPH The P
18. RNING Entrapment Prevention DANGER DO NOT BLOCK SUCTION SUCTION HAZARD Can cause serious injury or death Do not use this pump for wading pools shallow pools or spas containing bottom 7 DANGER drains unless pump is connected to at least two 2 functioning suction outlets 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 v Hazardous suction loose Can trap hair or body parts causing severe The following guidelines provide information for pump installation injury or death that minimizes risk of injury to users of pools spas and hot tubs Do not block suction Entrapment Protection 7he pump suction system must provide A DANGER protection against the hazards of suction entrapment D Suction Outlet Covers All suction outlets must have correctly installed screw fastened covers in place All suction outlet drain covers must be maintained Drain covers must be listed certified to the latest published edition of ANSI ASME A112 19 8 ANSI APSP 16 2011 They must be replaced if cracked broken or missing Hazardous suction Can trap hair or body parts causing severe Number of Suction Outlets Per Pump Provide at least two 2 Injury oreste hydraulically balanced main drains with covers as suction for each circulating pump suction line centers of the main drains
19. S165VSP pump will also connect to all Analog HPPH models both R 410A and R 22 when connected as shown in these instructions e Li 4 1 JA O QG rn 1 el t bh ile E JE 1 IE oU CT CT es un E HMM m nmoE HVAC BTL BPM PH2 8D Figure 12 Digital HPPH Control Board Revision Heat Pump Pool Heater Connections Wiring continued Digital HPPH Wiring Connections 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 to connect to the HPPH control board at the terminals marked PUMP as noted below Use 18 AWG insulated stranded wire for these connections USE COPPER CONDUCTORS ONLY USE 75 C 600 V WIRE TORQUE SCREWS 40 IN LB 208 230V 1 PHASE 60Hz POWER SUPPLY VOLTAGE MONITOR INSERT B INSERT B 150 16 BL 000000000000 TRANSFORMER SPR1 FIELD CONNECTIONS TO RAYPAK PUMPS W P BR P BR P REMOTE CONTROL FIELD CONNECTIONS E O R Figure 13 Digital HPPH Wiring Connections 26 Heat Pump Pool Heater Connections Wiring Analog HPPH Wiring Connections Field wiring to Analog HPPH products will be accomplished by connecting directly to terminals 15 and 16 on the terminal strip located in the HPPH junction box as shown below in Figure 14 Use 18 AWG insula
20. akers at the power source Severe personal injury or death may occur if the pump starts while your hand is inside the pump 1 Turn off the pump Switch off the circuit breaker to the pump motor 2 Remove the pump lid and strainer basket 3 Look inside pump for debris Remove any debris found inside 4 Replace the strainer basket and lid 5 Switch on the circuit breaker to the pump motor 6 Turn on the pump see if the problem is resolved 7 f the impeller is still blocked with debris and it is not possible to remove the debris using Steps 2 4 the pump will need to be disassembled in order to access the inlet and outlet of the impeller Removal and Replacement of the Impeller and or Mechanical Seal WARNING Before servicing the pump switch off the circuit breakers at the power source Severe personal injury or death may occur if the pump starts while your hand is inside the pump 1 Turn 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 the pump casing Remove the pump casing o ring The impeller is connected to the motor shaft 5 Remove the diffuser by gently pulling t
21. ate speed for the maximum savings With pump parts made of 10096 recyclable plastic and engineering designed to significantly reduce greenhouse emissions it is sure to please the environmentally minded consumer General Description continued PROFESSIONAL Figure 1 The PS165VSP Variable Speed control panel provides manual speed controls for the pump Controls and LEDs Description LED Lights Active Step LEDs When lit indicates it is in operation or active Speed LED When lit Bar Graph displays speed Duration LED When lit Bar Graph displays duration in hours speed will run Bar Graph Shows current speed and duration hours of active programmed button or selected value during programming Must be pressed to start the pump and programming 3 Installation Information Preparation Guide 1 Upon receipt of the pump check the carton for damage Open the carton and check the pump for concealed damage such as cracks dents or a broken base If damage is found contact the shipper or distributor where the pump was purchased 2 Inspect the contents of the carton and verify that all parts are included See Section 7 Parts List and Exploded View for details Pump Location WARNING This product must be installed and serviced by a qualified pool professional and must conform to all national state and local codes Before installing this product read and follow all warning notices and instructions of this product
22. atically start and run the programmed schedule This will ensure that the motor will re start in the case of a power outage Energy Savings Operation PS165VSP Pump Speed Optimization The PS165VSP pumps come with factory defaults of STEP 1 set for 1100 RPM for 12 hours duration and the OVERRIDE set for 3450 RPM for 2 hours duration The remainder of the 24 hour day the pump will be OFF These speeds and durations can be programmed on site for each specific pool installation to support specific pool parameters and equipment In order to maximize Energy Savings from pump operation follow the steps below to optimize the pool pump speeds to take full advantage of these savings opportunities 1 Push the OVERRIDE button directly from the pump control adjust the pump speed to determine the proper operation rpm of the pump for each device intended for use on the pool filter vacuum HPPH gas pool heater etc 2 Use the UP or DOWN buttons on the pump control to increase decrease the pump speed while in the OVERRIDE mode NOTE The light over the OVERRIDE button will be lit when in OVERRIDE mode 3 Record the lowest RPM that allows each pool device to work properly and save for future reference and use later in these instructions 4 STEP 1 is primarily used to circulate the pump for a sufficient period each day to ensure proper turn over of the pool water and filtration Adjust the pump speed and duration for STEP 1 as determined
23. atures are expected Allowing the pump to freeze will cause severe damage and void the warranty There are two options when winterizing the pump Option 1 1 Drain all the water from the pump system equipment and piping 2 Remove drain plugs Do not replace plugs Store the plugs in the empty strainer basket for winter 3 Keep the motor covered and dry Option 2 1 Drain all the water from the pump system equipment and piping 2 Remove the pump and motor from the plumbing and store indoors in a warm and dry location Note When the winter season is over the pump will need to be primed prior to start Refer to Section 4 Operation Start Up Guide CAUTION DO NOT run the pump dry If the pump is run dry the mechanical seal will be damaged and the pump will start to leak at the seal If this occurs the mechanical seal will need to be replaced ALWAYS maintain the proper water level in your pool Continued operation in this manner could cause a loss of pressure resulting in damage to the pump casing impeller and mechanical seal voiding warranty 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 cause high voltage to run through the electrical system This can cause property damage serious personal inj
24. d 3 will illuminate 2850 continuously indicating the keypad is unlocked Figure 6 Motor Pause Allows for temporary turn off of the motor 1 Press and hold the START button for three seconds while the motor is running The motor will turn off and the START and OVERRIDE LED s will blink 2 To resume running hold the START button for three seconds Power Outage If there is a power outage and the user does not press the STOP key upon power being restored the pump will automatically start and run the schedule starting with STEP 1 This feature ensures that the motor will re start in the event of a power outage The Priming sequence precedes STEP 1 programming is retained Schedule Advance The Schedule Advance Feature allows you to program the pump yet start the 24 hour cycle at a different time of day The following steps should be followed to set the Schedule Advance 1 With the motor stopped press the START Key and hold for more than three seconds The Start LED will blink The Duration LED and Bar Graph will illuminate 2 Press the UP or DOWN arrows to set the desired schedule cycle start time The schedule advance mode will automatically start after the desired delay time is selected This mode can be cancelled by pressing the STOP key Note During the Schedule Advance if a user presses the STEP 1 STEP 2 STEP 3 OVERRIDE or the START key the system will start the normal schedule and the Schedule Advance
25. d is controlled directly by the digital inputs NOTE The digital inputs have the highest priority amongst all the inputs i e Keypad Serial and Digital 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 start the 24 hour schedule if the START key was pressed prior to the application of the digital input Ul DIGITAL Automation System or INPUT CONNECTOR Solar System Controller J202 EXTERNAL SUPPLY Ferrans oe rire i External Supply Range 18 30V AC 24V 20 9 30V DC 12 24V DC 20 Figure 7 Table 3 0 Communication Connection Table RS485 Pin Wire Color Description J201 4 Isolated Ground 20 3rd Party Controllers Wiring Wiring Diagram for ProLogic with PS165VSP 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 Ier Tel EURE P ESTE ager n W WM
26. ervice and Maintenance Routine Maintenance Winterizing Troubleshooting Fault LED TEE General Troubleshooting Problems Blocked Impeller ewe as Removal and Replacement of the Impeller Motor Replacement Product Specifications Performance Curve amp Dimensional Drawing Replacement Parts and Exploded View O oo ON N 12 12 19 14 15 16 16 16 17 17 17 18 18 18 20 24 27 EZ 28 28 28 29 29 30 31 32 92 33 1 Important Safety Instructions READ THIS MANUAL CAREFULLY BEFORE USING THE PUMP READ AND FOLLOW ALL INSTRUCTIONS Important Notice This manual contains important information about the installation operation and safe use of this product This information should be given to the owner and or operator of this equipment WARNING This product must be installed and serviced by a qualified pool professional and must conform to all national state and local codes WARNING Before Installing this product read and follow all warning notices and instructions which are included Failure to follow safety warnings and instructions can result in severe injury death or property damage Call 1 877 213 3726 or visit www raypak com for additional copies of these instructions WARNING California Proposition 65 This product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WA
27. f the pump is located below the water level of the pool open the filter pressure valve to prime the pump with water Once all the air has 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 tools to tighten the lid hand tighten only Make sure all valves are open and the unions are tight 4 Restore power to the system 5 Pressing the START key will start the motor based on the factory default schedule See Table 2 0 Table 2 0 Factory Default Schedule Button Speed RPM Duration Hours Note Motor will always run the PRIMING sequence when starting from 0 speed Stop position or OFF power The factory priming settings are 3450 RPM for 3 minutes 6 Self Priming Pump Open the filter pressure relief valve until all air has escaped and then close 7 If the pump does not prime and all instructions to this point have been followed check for a suction leak Repeat steps 2 7 8 For technical assistance call Technical Support at 1 877 213 3726 Start Up Guide continued NOTE If power goes off to the motor and the user did not press the STOP key then the motor will autom
28. 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 OVERRIDE may also be used for other pool service tasks If it is adjusted for any other purpose please remember to readjust when completed to the preset value as the HPPH uses this RPM for proper heating cooling operation 8 Once all pump speeds have been determined you can adjust the programs in the pump accordingly See the Programming Section on page 14 NOTE It is best to use a speed slightly above the minimum speed determined in the steps above to ensure proper operation under dirty filter or clogged strainer baskets etc Example if the heater operation requires a setting of 1600 RPM use 1850 RPM This still maximizes pump energy cost savings but also reduces the probability of nuisance issues with the pool equipment not operating properly because of insufficient water flow 14 Programming Operates on a 24 hour cycle that begins from the time the START button is pushed To start the cycle at a specific time See the Schedule Advance Section on page 17 Programmable Speed Settings 3450 3100 2850 2600 2350 2100 1850 1600 1350 1100 850
29. gle to the desired duration that you want this speed to run in hours The Bar graph will show the setting as you toggle up and down See Figure 5 shows the duration being set at 10 hours 6 Press any of the other STEP or the OVERRIDE button to save these settings for STEP 1 7 To exit the system and not save these settings press the STOP button 8 Press STEP 2 STEP 3 or OVERRIDE key Repeat steps 3 6 to program the corresponding speed and duration for each button Programming continued ACTIVE send send send ACTIVE send send send POWER O POWER FAULT FAULT Figure 4 Figure 5 Restore Factory Defaults Press and hold the STOP and OVERRIDE key for 3 seconds When the reset has been recognized the Bar graph will blink three times Menu Structure 1 STEP 1 Set Schedule a Speed and Duration 2 STEP 2 Set Schedule a Speed and Duration 3 STEP 3 Set Schedule a Speed and Duration 4 OVERRIDE Settings a Speed and Duration 5 START Press START to run the pump based on the programmed 24 hour schedule The schedule is based on a 24 hour cycle and will repeat each day of the week During operation the LED lights 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 ha
30. he diffuser the diffuser is the cover over the impeller horizontally until the pins clear the seal housing Ceramic Ring Rubber Collar 6 Place a 5 16 Allen head wrench through the center e hole of the fan cover and into the recess on the end of hd Shaft motor shaft 7 While holding the motor shaft turn the impeller counter AE Suraces clockwise _ Figure 16 8 Gently pull the mechanical seal from the impeller shaft noting the way it was originally installed CAUTION Do not damage the ceramic or carbon surfaces of the seal If the surfaces are damaged leaks will occur 9 Using water with a small amount of dish soap brush the impeller shaft for ease of assembly Pump Seal Housing Removal and Replacement of the Impeller and or Mechanical Seal continued 10 With the carbon side up push the mechanical seal onto the impeller shaft and wipe carbon surface with a clean cloth CAUTION Do not use grease or lube to install seal It will damage the seal and cause failure 11 The ceramic side of the seal can be pushed out from the rear of the seal housing Please note its position before removing 12 Using water only wet the ceramic side of the seal and using your thumbs push into the seal housing Clean surface with a clean cloth 13 Wipe the motor shaft of all debris Re install the seal housing and apply
31. labels such as DANGER WARNING or CAUTION Keep safety labels in good condition and replace any missing or damaged labels 9 Provide access for future services by leaving a clear area around the pump Allow plenty of space above the pump to remove lid and basket for cleaning WARNING Some Safety Vacuum Release System SVRS devices are not compatible with the installation of check valves If the pool has an SVRS device be sure to confirm that it will continue to safely operate when the check valves are installed NOTE In Canada the pump must be located a minimum of three 3 meters approximately ten 10 feet from the water CSA 22 1 Pipe Sizing NOTE All pipe sizes are able to withstand the pressures the pump will deliver but not necessarily the flow If the pipe is too small for the pump or is elevated above water the maximum gallons per minute GPM may not be delivered If this happens the pump will develop a pocket of air cavitation that makes noise This may shorten the life of the pump SUCTION amp DISCHARGE When the pump is located up to fifty 50 feet from the pool the recommended minimum pipe size for both the suction and discharge is 2 Pipe Sizing continued For better efficiency and less restriction use as few fittings elbows tees valves etc as possible Suction line diameter must be equal or be greater than the discharge line diameter Suction and discharge lines should be independently suppor
32. ng for this product Electrical Specifications 1 Voltage 208 230 VAC 60 Hz Single Phase 2 Max Amps 11 3 Speed Range 600 3450 4 Controller 208 230 Vrms Single Phase 5 Ambient 50 C 6 NEMA Type 3R Figure 2 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 Ib The terminals will handle wire up to 12 AWG in size There are two terminals labeled L1 and L2 See Figure 3 Attach the power leads to these terminals Attach the black lead to L1 and the red or white lead to L2 See Table 1 0 The top rear of the controller has a single screw Loosen this screw and lift cover to expose the terminal area Table 1 0 Pin Wire Color Description _ Electrical Installation continued HO UO Note All Dip switches should be in the L2 RED OR WHITE OFF position when external controllers are not being used Figure 3 CAUTION Voltage at the pump MUST NOT vary by more than 10 of nameplate voltage Components may overheat causing overload tripping and reduced component life Consult your power company if this condition exists Note Use only liquid tight fittings to protect the electronics and motor Pressure Test WARNING 7o minimize the risk of severe inju
33. o a gas supply line To avoid dangerous or fatal electrical shock turn OFF power to the pump before working on electrical connections 1 The motor frame must be grounded to a reliable grounding point using a solid copper conductor No 8 AWG or larger In Canada No 6 AWG or larger must be used If the pump is installed within five 5 feet of the inside walls of the swimming pool spa or hot tub the motor frame must be bonded to all metal parts of the swimming pool spa or hot tub structure and to all electrical equipment metal conduit and metal piping within five 5 feet of the inside walls of the swimming pool spa or hot tub 2 Bond the motor using the provided external lug WARNING n order to avoid the risk of property damage severe personal injury and or death 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 devices that may be required to operate simultaneously with the pump such as a chlorinating device or heater Electrical Installation WARNING electrical wiring must conform to the local NEC guidelines A licensed qualified electrician should complete the wiri
34. ool users or others due to electric shock working on pump or motor Important Safety Instructions When installing and using this electrical equipment basic safety precautions should always be followed including the following READ AND FOLLOW ALL INSTRUCTIONS WARNING reduce the risk of injury do not permit children to use this product unless they are closely supervised at all times WARNING Risk of Electrical Shock Connect only to a grounding type receptacle protected by a ground fault circuit interrupter GFCI Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI The unit must be connected only to a supply circuit that is protected by a ground fault circuit interrupter GFCI Such a GFCI should be provided by the installer and should be tested on a routine basis To test the GFCI push the test button The should interrupt power Push the reset button Power should be restored If the GFCI fails to operate in this manner the GFCI is defective If the GFCI interrupts power to the pump without the test button being pushed a ground current is flowing indicating the possibility of an electric shock Do not use this pump Disconnect the pump and have the problem corrected by a qualified service representative before using CAUTION 7his pump is for use with permanently installed pools and may also be used with hot tubs and spas if so marked Do not use with storable pools
35. ry or death the filter and or pump should not be subjected to the piping system pressurization test Local codes may require the pool piping system to be subjected 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 test to 24 hours After the test visually check the system to be sure it is ready for operation DO NOT USE COMPRESSED AIR TO PRESSURE TEST OR CHECK FOR LEAKS 11 12 4 Operation Start Up Guide CAUTION Never run the pump without water Running the pump dry for any length of time can cause severe damage to both the pump and the motor and will void the warranty If this is a new pool installation make sure all piping is clear of construction debris and has been properly pressure tested The filter should be checked for proper installation verifying that all connections and clamps are secure according to the manufacturer s recommendations WARNING 7o avoid risk of property damage severe personal injury or death verify that all power is turned off before starting this procedure 1 Depending on the location of the pump do one of the following I
36. s been pressed Note If the schedule times combined are less than 24 hours the remaining time for the 24 hour cycle will be filled with the motor stopped 16 Menu Structure continued Schedule Table Use these tables to enter a personalized operating schedule By writing down the planned schedule it will make the programming process easier and will help the user to remember the user s settings in case the programming is inadvertently lost The User Interface will not allow the user to program an overlap between 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 STEPI STEP 2 STEP3 OVERRIDE Sesmw Keypad Lock The Keypad has a key lockout feature to prevent unwanted changes to the settings To lock the keys hold down the STEP 1 2 and 3 buttons all at the same time for more than 3 seconds The active step LEDs for STEP 1 2 and 3 will blink for 30 seconds indicating that the keypad is locked See Figure 6 SETTING The user can unlock the keys by holding down the MAS POWER same buttons for more than 3 seconds The active step LEDs for STEP 1 2 an
37. ted at a point near the pump to avoid strains being placed on the pump NOTE If more than ten 10 suction fittings are needed the pipe size must be increased Plumbing Installation When installing the pump care should be taken to see the suction line is below water level to a point immediately beneath and in front of the pump to ensure quick priming via a flooded suction line The height between the pump and water level should not be more than five 5 feet If the pump is located below water level isolation valves must be installed on both sides of the pump to prevent the back flow of pool water during any routine or required servicing The PS165VSP Variable Speed comes equipped with unions on both the suction and discharge ports This feature simplifies installation and service and eliminates the possibility of leaks at the threaded adaptors Before starting the pump for the first time remove the see through lid Turn lid ring counter clockwise to remove Fill strainer tank with water until it is level with the suction inlet Replace lid making sure the o ring is in place and not damaged Screw down hand tight Every new installation must be pressure tested according to local codes See the Pressure Testing Section on page 11 Bonding and Grounding WARNING Ground and bond the pump before connecting to electrical power supply Failure to ground and bond the pump can cause serious or fatal electrical shock hazard DO NOT ground t
38. ted stranded wire for these connections USE COPPER CONDUCTORS ONLY USE 75 C 600 V WIRE TORQUE SCREWS 40 IN LB COMPRESSOR 5 208 230V 1 PHASE 60Hz POWER SUPPLY SPA REMOTE POOL SWITCH SHOWN IN POOL POSITION WATER SENSOR AL Z o 5 GY I 622 R 6 oe S R BL DEFROST zs BKIGY SWITCH 24 2 D Y LL BK R FIELD CONNECTIONS TO RAYPAK PUMPS 24 Volts AC Ww Figure 14 Analog HPPH Wiring Connections Heat Pump Pool Heater Connections Wiring continued Wiring Connections to the PS165VSP Pump Connect the 18AWG wires from the HPPH to the PS165VSP pump as show and described below It does not matter which wire is connected to the IO 4 terminal or the IGND terminal for these 24 VAC connections While the 24 VAC connections are polarity sensitive the digital inputs on the VSP pump are floating and look for a differential voltage from IO 4 to IGND Therefore the wiring does not matter for an AC input signal but will matter for a DC input signal However connections to the Analog and Digital HPPH are 24 VAC signals and so this is not an issue The factory default speed setting for this OVERRIDE signal is 3450 RPM This is to ensure sufficient water flow to ensure proper operation of the HPPH If optimization of this pump speed is desired as an energy savings measure Refer to the Energy Savings Operation PS165VSP Pump Speed Optimization Section page 13 Figure 15 PS165VSP
39. ult B Over current fault A Debris in contact with fan B Debris in strainer basket C Loose mounting A Dirty filter B Suction Leak Make sure strainer tank is full of water Open all valves in system Clean skimmer and strainer tank Open pump and check for clogging of impeller Check voltage at motor If low pump will not come up to speed Check that all power switches are on Be sure fuse or circuit breaker is properly set Time set properly Check motor wiring 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 Check the back of the motor is free from dirt and debris Motor will automatically restart after one minute Check that the back of the motor is free from dirt and debris Clean strainer basket Check that the mounting bolts are tight Back wash filter when filter pressure is high or clean cartridges See Problem 1 WARNING Before servicing the pump switch off the circuit breakers at the power source Severe personal injury or death may occur if the pump starts while your hand is inside the pump 1 Turn off the pump Switch off the circuit breaker to the pump motor 2 Remove the pump lid and strainer basket 3 Look inside pump for debris Remove any debris found inside 29 30 Blocked Impeller continued WARNING Before servicing the pump switch off the circuit bre
40. ury and or death Improper installation and or operation will void the warranty The fault LED will be solidly on if there is a fault in the controller portion of the electronics This can include over temperature over current over under voltage or an open phase of the motor The fault LED will blink if a fault has been detected in the user interface The motor reads the fault status every seven seconds The motor will stop and remain off when a fault is present Once the fault is cleared if the motor was previously running it will automatically resume running the normal schedule During the fault condition the Bar graph LEDs will turn off However the power LED and active STEP LED will remain illuminated When a fault is present only the STOP key will function Once the fault is cleared the fault LED will turn off automatically General Pump Troubleshooting Make sure see through lid and o rings are clean and properly positioned Hand tighten see through lid Tighten all pipes and fittings on suction side of pump Be sure water in pool is high enough to flow through skimmer 1 Pump will not prime 2 Motor Fails to Start 3 Motor Runs then Stops 4 Motor is noisy 5 Low flow Blocked Impeller A Suction air leak B No water in pump C Closed valves or blocked lines D Low voltage to motor A No power to motor B Pump jammed C Controller Dip switches not config ured properly A Over temperature fa
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