Certikin MB055 Operating instructions

Natural Gas L.P.G.

MODEL:

MB055PEH MB055 MB105 MB155 MB185 MB265 MB405

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbour's phone. Follow the gas supplier's instructions.

Installation and service must be performed by a Corgi registered installer, service agency or the gas supplier.

MB055 MB105 MB155 MB185 - MB265 - MB405

Operating, Installation and

Servicing Instructions for

Pool & Spa Heaters

MB055PEH

MB055

MB105

MB155

MB185

MB265

MB405

M3556

Contents

2

2

2

3

4

4

4

5

5

5

6

6

6

27

28

28

28

27

27

27

27

23

23

25

25

26

29

29

29

15

16

16

20

8

11

11

14

36

36

38

40

42

30

30

32

34

PART ONE - OWNER'S OPERATING INSTRUCTIONS

SECTION 1 / START-UP PROCEDURES

Before Start-Up

Operating Instruction & Shut-Off Procedures

After Start-Up

SECTION 2 / CAUTION

SECTION 3 / MAINTENANCE & CARE PROCEDURE

Pool & Spa Water Chemistry

Cold Weather Operation

Winterizing the Pool & Spa Heater

PART TWO - INSTALLATION/SERVICE INSTRUCTIONS

SECTION 1 / RECEIVING EQUIPMENT

SECTION 2 / GENERAL SPECIFICATIONS

SECTION 3 / INSTALLATION INSTRUCTIONS

Outdoor Heaters

Indoor Heaters

Combustion Air

Gas Supply Connections

Plumbing For Water Connections

Left Side Water Connection Conversion

Electrical Wiring

SECTION 4 / SERVICING INSTRUCTIONS

General Location of Controls

Temperature Controls

Pressure Switch

High Limit

Pilot Safety

Burner Drawer Removal

Gas Valve Removal

Main Burner & Orifice Removal

Pilot Removal & Cleaning

Heat Exchanger Removal

Control Immersion Well Replacement

Tube Cleaning

Desooting Procedure

Combustion Chamber Removal

Unitherm Governor Replacement

SECTION 5 / TROUBLE SHOOTING GUIDE

Mechanical

Electrical IID Units 055, 105 & 155.

Electrical IID Units 185, 265 & 405.

SECTION 6 / REPLACEMENT PARTS

Replacement Parts List - 055



Replacement Parts List - 185, 265 & 405

1

01-10-98

PART ONE - OWNER'S OPERATING INSTRUCTIONS

FOR YOUR SAFETY - READ BEFORE OPERATING

WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS

EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING

PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

SECTION 1 / START-UP PROCEDURES

BEFORE START-UP

BURNERS

Clean air louvres of dust, lint and debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not obstruct the flow of combustion and ventilating air.

WATER

Water must be flowing through the heater during operation. Ensure that system is filled with water and the pump is operating.

055 105

105view.tif

155

8111.tif

2

185 - 265 - 405

405view.tif

01-10-98

CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters.

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY

RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

A. This appliance is equipped with an ignition device which automatically lights the pilot.

Do not try to light the pilot by hand.

B. BEFORE OPERATING Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

C.

D.

Use only your hand to push in or move the gas control lever. Never use tools. If the lever will not push in or move by hand, don't try to repair it, call a qualified service engineer. Force or attempted repair may result in a fire or explosion.

Do not use this appliance if any part has been under water. Immediately call a qualified service engineer to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

* WHAT TO DO IF YOU SMELL GAS

* Do not try to light any appliance.

Do not touch any electric switch;

Do not use any phone in your building.

* Immediately call your gas supplier from a neighbour's phone. Follow the gas suppli er's instructions.

* If you cannot reach your gas supplier, call the fire service.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot.

Do not try to light the pilot by hand.

5. Remove heater door panel.

6. Turn " OFF " gas supply to appliance.

7.

8.

9.

10.

11.

12.

Wait five ( 5 ) minutes to clear out any gas.

Then smell for gas, including near the floor.

If you smell gas STOP! Follow " B " in the safety information above on this label. If you don't smell gas, go to the next step.

Turn " ON " gas supply to appliance.

Replace heater door panel.

Turn on all electric power to the appliance.

Set the thermostat to the desired setting.

If the appliance will not operate, follow the instructions " To Turn Off Gas To Appliance " and call your service engineer or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn off all the electric power to the appli ance if service is to be performed.

3. Remove heater door panel.

4.

5.

Turn off gas supply to appliance.

Replace heater door panel.

CARE OF YOUR HEATER

This heater casing is Polyester powder on top of zinc coated steel to assist in resisting corrosion. It is recommended that periodically the casing is cleaned and sprayed with WD40 or similar liquid especially when installed outdoors. Exposed threads on manifolds will benefit from a light coating of grease. Outdoor tops are finished with a special black high temperature coating and as this is part of the flueing system, subject to high temperatures and the elements, can discolour and corrode over a period of time.

08-08-01

3

AFTER START-UP

SECTION 2/CAUTION

Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot.

WARNING: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control to the appliance.

VISUAL INSPECTION

With the heater on, remove the door and make a visual check of the pilot and burner.

The flame should be blue with a well-defined pattern.

4" MAX

100MM

MAIN BURNER FLAME flame.tif

Elevated water temperature can be hazardous, and the U. S. Consumer Product Safety Commission recommends the following guidelines:

1.

Spa or hot tub water temperatures should never exceed 40°C (104°F). A temperature of 38°C (100°F) is considered safe for a healthy adult. Special caution is suggested for young children.

2.

Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning.

3.

Pregnant Women Beware! Soaking in water over 39°C (102°F) can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain-damaged or deformed child. Pregnant women should stick to the 38°C (100°F) maximum rule.

4.

Before entering the spa or hot tub, users should check the water temperature with an accurate thermometer; spa or hot tub thermostats may err in regulating water temperatures by as much as 2°C (4°F).

5.

Persons with a medical history of heart disease, circulatory problems, diabetes, or blood pressure problems should obtain a physician's advice before using pools or hot tubs.

6.

Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines, or anticoagulant, should not use spas or hot tubs.

europilot2.tif

PILOT BURNER FLAME

A yellow or "floating" flame indicates restricted air openings or incorrect injector size. Should this occur, shut the heater off and contact your installer or gas supplier.

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to shut off the burners in the event that water supply to the heater is interrupted. It is very important to verify that the switch electrically opens and shuts off the gas valve when water flow to the heater is interrupted. Otherwise, rapid and severe damage is likely to occur to the heater. (The water pressure switch should be checked and adjusted for proper operation by a qualified service person at the time of installation checked thereafter.

SECTION 3/MAINTENANCE AND

CARE PROCEDURES

To be followed one month after start-up and then semi-annually. A full service by a competent person

(i.e. CORGI registered) should be conducted at least once a year.

1.

2.

Inspect top of heater and drafthood for soot,

(a sticky black substance around finned tubes and "V" baffles), and open flue gas passage ways. If soot is present, contact installer or service agent.

Inspect and operate all controls, gas valve and pressure relief valve.

WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.

03-06-99

4

3.

Make visual check of the burner and pilot flame. Flame pattern on the main burner and pilot is indicated in the previous illustration. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means

4.

low gas pressure. Should this occur, shut the heater off and contact your gas supplier or qualified service agency.

On indoor heaters, clean room intake openings to assure adequate flow of combustion and ventilation air.

COLD WEATHER OPERATION

MODERATE CLIMATE: Heater operation can continue during short term cold spells. When temperatures are below freezing, flow (continuous pump operation) must be maintained.

CAUTION : Do not use the heater to maintain water temperatures just above freezing or for freeze protection. When heater is used during freezing weather, care must be taken to avoid freeze ups.

Continuous pump operation is a must. Additional protection may be required. The heater is not warranted against freeze ups.

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

5.

Keep area around heater clear and free from combustible materials, gasoline and other flammable and corrosive vapours and liquids.

POOL & SPA WATER CHEMISTRY

COLD CLIMATE: Prolonged operation with water temperatures below 10°C (50°F) is not recommended. When starting the heater with pool temperatures below 10°C (50°F) operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 10°C (50°F) can seriously damage the heater, and is not covered by the warranty.

IMPORTANT!

These Heaters are not suitable for use on Salt Chlorinated pools. If this is intended please contact the Manufacturer.

For cold climate areas, please follow the winterizing procedures listed.

Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water pH between 7.4 and 7.8 and total alkalinity between 100 and 150 p.p.m. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and also damaging the heater.

If the pH drops below 7.2, the heater will be severely damaged. This will result in corrosion of the heat exchanger. warranty.

Heat exchanger damage resulting from chemical imbalance is not covered by the

AUTOMATIC CHLORINATORS AND CHEMICAL

FEEDERS

WINTERIZING THE POOL & SPA HEATER

When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe the following step-by-step procedure:

1.

Turn off gas valve, manual gas valve, and electrical supply to the heater.

2.

Open drain cock located on the inlet/outlet header, (under water pipes). Remove drain plug from return header. Remove the heat exchanger inspection panels on the side opposite water piping to gain access to the plug on the return header.

All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (i.e. overnight).

Return Header

Drain

Plug

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical back-up into the heater when the pump is shut off.

plug.tif

185, 265 & 405 Models

NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heaters. Such damage is not covered under the warranty.

5

3.

Disconnect compression fittings from the pressure switch and return header that connects to the 1/4" copper tube and allow the tube to drain.

08-08-01

PART TWO - INSTALLATION/SERVICE INSTRUCTION

SECTION 1 / RECEIVING EQUIPMENT

WARNING:

This appliance must be installed and serviced by a CORGI registered installer.

On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the carton is damaged, a note should be made on the delivery note when signing for equipment. Remove the heater from the carton and if it is damaged, report the damage to the carrier immediately. Save the carton.

These items are shipped loose inside the carton with the 055 & 105 heater:

1. CPVC Adaptors (2)

2. Plastic Flange (1)

These items are shipped loose inside the carton with the 155, 185, 265 & 405 heater:

1. In/Out Flanges (2)

2. 1-1/2" Flange Gaskets (2)

3. 2" Flange Gaskets (2)

4. Flange Bolts (4)

5. 2" CPVC Adapters (2)

Be sure that you receive the number of packages indicated on the delivery note.

When ordering parts, you must specify model and serial number of heater. When ordering under warranty conditions, you must also specify date of installation.

It is recommended that this manual be reviewed thoroughly before installing your pool/spa heater. If there are any questions that this manual does not answer, please contact the supplier.

SECTION 2 / GENERAL SPECIFICATIONS

All heaters are inter-changeable and can be used either indoor or outdoors. The appropriate top designated for that type of use is required. If desired, the top can be changed at a later date to change from outdoor to indoor or vice versa.

WATER CONTENT Litre

(gal)

MAXIMUM WATER PRESSURE bar (psi)

MAXIMUM WATER FLOW TEMP

°C (°F)

ELECTRICAL SUPPLY

GENERAL SPECIFICATIONS

Model

055

Model

185

0.8

Model

(0.18) 105

1.9

(0.4)

Model

265

1.1

(0.3)

1.9

8 bar (125 psi)

Model

155

1.8

(0.4)

Model 2.6

(0.4) 405 (0.5)

45.0

(110)

230V 50Hz

FUSED AT 3A. POWER 100W

6

01-10-98

PERFORMANCE SPECIFICATIONS

GAS CATEGORY, TYPE, AND

SUPPLY PRESSURE.

II

2H3P

G20 @ 20 mbar (8 in. wg)

G31 @ 37 mbar (14.8 in. wg)

PERFORMANCE SPECIFICATIONS - NATURAL GAS

GAS TYPE AND SUPPLY PRESSURE G20 @ 20 mbar (8 in. wg)

MODEL

BURNER

PRESSURE mbar

(in. wg)

HEAT GROSS kW

INPUT (Btu/h)

NET kW

(Btu/h)

HEAT

OUTPUT kW

(Btu/h) m

3

/h GAS RATE

INJECTOR DIA.

mm

& (MARKING) gauge

NUMBER OF BURNERS

& INJECTORS

055

6.3

( 2.5 )

12.9

(44,000)

11.6

(39,600)

10.06

(34,300)

1.22

(50)

1.78

4

(50)

105

6.8

( 2.7 )

26.67

(91,000)

24.0

(81,900)

20.8

(71,000)

2.5

1.78

(49)

8

155

7.7

( 3.1 )

38.98

(133,000)

35.08

(119,700)

30.4

(103,700)

3.7

1.85

(50)

10

185

8.1

(3.2)

49.53

(169,000)

44.58

(152,100)

38.63

(131,820)

4.6

1.78

(50)

13

265

8.3

(3.3)

71.5

(244,000)

64.4

(219,600)

55.8

(190,300)

6.6

1.78

(50)

19

405

8.7

(3.5)

108.4

(370,000)

97.6

(333,000)

84.58

(288,600)

10.28

1.78

29

PERFORMANCE SPECIFICATIONS - PROPANE GAS

G31 @ 37 mbar (14.8 in. wg) GAS TYPE AND SUPPLY PRESSURE

MODEL

BURNER

PRESSURE

055

Easiheat mbar 23.8

(in. wg) (9.6)

055

19.0

( 7.6 )

105

21.5

( 8.6 )

HEAT GROSS kW

INPUT

14.1

(Btu/h) (48,000)

12.9

(44,000)

NET kW 13.0

11.9

(Btu/h) (44,500) (40,500)

HEAT

OUTPUT kW 11.0

10.06

(Btu/h) (37,400) (34,300) m

3

/h 0.50

0.47

GAS RATE

INJECTOR DIA.

mm

& (MARKING) gauge (57)

1.09

(57)

NUMBER OF BURNERS

& INJECTORS

4

26.67

(91,000)

24.54

(83,720)

20.8

(71,000)

0.97

1.09

8

(57)

155

28.5

( 11.4 )

38.98

(133,000)

35.86

(122,360)

30.4

(103,700)

1.43

1.09

(59)

10

185

29.4

(11.8)

49.53

(169,000)

45.57

(155,480)

38.63

(131,820)

1.82

1.06

(59)

13

265

29.3

(11.7)

71.5

(244,000)

65.8

(224,480)

55.8

(190,300)

2.57

1.06

(59)

19 29

405

30.0

(12.0)

108.4

(370,000)

99.8

(340,400)

84.58

(288,600)

4.04

1.06

13-08-03

U.K. & Ireland.

SECTION 3 / INSTALLATION

INSTRUCTIONS

IMPORTANT NOTICE

These instructions are intended for the use of qualified personnel only, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel must be CORGI registered.

Persons not qualified must not attempt to fix this equipment nor attempt repairs according to these instructions.

Models 185, 265 & 405

BS. 6891;

BS. 6644;

Installation of low pressure pipework.

Installation of Gas Fired Hot Water

Boilers 60kW to 2MW.

Water Supply.

CP 341;

British Gas Publications:

IM2; Purging Procedures on Non-domestic

IM5;

IM11;

Gas Installations.

Soundness Testing Procedures for

Industrial and Commercial Gas Installations.

Flues for Commercial and Industrial

Gas Fired Boilers and Air Heaters.

Model Water Byelaws.

WARNING:

Improper installation, adjustment, alteration, service or maintenance may damage the equipment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.

This appliance must be installed externally in open air

(without a flue) or indoors (with a suitable flue system) in a room separated from living rooms and provided with appropriate ventilation direct to the outside.

The appliance must be used only in accordance with these instructions. Incorrect use is dangerous and invalidates all warranties and Certification.

STATUTORY REQUIREMENTS

Gas Safety (Installation and Use)

Regulations, 1994

It is the law that all gas appliances are installed by competent persons in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with.

General Requirements

Conversion Instructions.

The heater is supplied in two versions,one for use with Natural Gas, G20 at 20 mbar inlet pressure, the other for Propane, G31 at 37 mbar. If it is necessary to convert the heater for use on the other gas the appropriate conversion kit must be purchased and fitted using the instructions provided.

NOTE: The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance.

The pan must not restrict combustion air flow.

The appliance must be installed by a competent person ie. CORGI registered in accordance with the relevant requirements of the Gas Safety Regulations, current I.E.E. Regulations, Model Water Byelaws,

Local Water Authority Byelaws and any relevant requirements of the local gas supplier, local authority and the relevant British Standard Codes of practice and Building Regulations. Manufacturers notes must not be taken in any way as overriding statutory obligations. Typical documents include:

BASE INSTALLATION

Heater must be mounted on a level base, such as cement slab, cement blocks or other non-combustible surface. An alternative method for providing a base for combustible floors is illustrated below.

Heaters must not be installed on carpeting.

Models 055, 105 & 155

BS. 5440:1 Flues (for gas appliances of rated input not exceeding 60 KW).

BS. 5440:2 Ventilation (for gas appliances of rated input not

BS. 5449

BS. 6798 exceeding 60KW).

Forced circulation hot water systems.

Installation of gas fired hot water boilers of rated input not exceeding 60 KW.

BS. 6891: Installation of low pressure pipework.

Health & Safety Document No. 635.

The Electricity at Work regulations, 1989.

CP341; Water Supply.

British Gas Publications:

IM2; Purging Procedures of Non-domestic Gas Installations

IM5, Soundness Testing Procedures for Industrial and

Commercial Gas Installations.

12" Min.

300mm base.tif

4" Min.

100mm

12" Min.

300mm

Sheet Metal

24 Gauge

0.7mm

8

Hollow concrete cinder block, align holes and leave ends open. Alternative method for providing a non-combustible base.

01-10-98

CLEARANCES

ALL HEATERS

For clearances from combustible surfaces, see the chart below.

For servicing, provide at least 600mm (24") in front of the heater for burner tray removal, and at least

450mm (18") on water connection side of the heater to inspect and delime the heat exchanger.

CLEARANCE FROM COMBUSTIBLE

MATERIAL (mm)

Plant Room Installation

Model Top

055 900 50

Back Right Left Front

150 150 Clear

105 900 50 150 150

155 1050 300 150 300

Clear

Clear

185-405 750 150 300 150 Clear

Heaters must not be installed under an overhang of less than 1.0m (3 feet) from the top of the heater.

Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters:

The point from where the flue products exit the heater must be a minimum of 1.25m (4 feet ) below, four (4) feet horizontally from or 0.3m (1 foot) above any door, window or gravity inlet to a building. The top surface of the heater shall be at least 1.0m (3 feet) above any forced air inlet, or intake ducts located within 3.0m (10 feet) horizontally.

Outdoor Installation

HIGH WIND CONDITIONS

(OUTDOOR HEATERS ONLY)

In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 1.0 m from high vertical walls, or install a wind break so the heater is not in direct wind current.

Model Top Back Right Left Front

055 Clear 50

105 Clear 50

150 150

150 150

155 Clear 300 150 150

185-405 Clear 150 150

Clear

Clear

Clear

150 Clear

1.25m

4'

Min

Forced Air

Inlet

1.25m

4' Min

1.0m 3' Min

3.0m

10'

Min.

clear.tif

9

1.25m

4'

Min

0.3m

1' Min

01-10-98

OUTDOOR HEATERS

These heaters are certified by British Gas plc for outdoor installation, when equipped with the approved tops designated for outdoor use.

105 & 155 Models

FLUE TERMINAL (Outdoor) Stackless Top Illustration

Top Vent

Opening

WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause water to spray through the cabinet louvres and into the heater. This could cause heavy internal rusting or damage some electrical components, and this would void the warranty.

It is recommended that the casing is cleaned and sprayed with WD40 or similar liquid, and exposed threads on the manifolds are lightly coated in grease, after assembly.

Heater with

Outdoor

Stackless Top

Heater Vent Opening

Jacket Top

185, 265 & 405 Models


1.

Insert tabs into keyhole (4 places).

FLUE CONNECTIONS AND DIMENSIONS

055 Models


1: Remove the (8) screws which fasten jacket top to heater.

2: Line up top vent opening over heater vent opening

3: Lower outdoor top onto unit lining up slots in outdoor top with screw holes in jacket top.

4: Reinstall (8) screws to secure jacket top and outdoor top to unit.

Press tab to locate tab1.tif

Pagoda Top

(Shipped

Loose with

Heater)

2.

Snap tabs into keyholes so as not to pull out.

055expl1.tif

10 tab2.tif

08-08-01

INDOOR HEATER

The design is also certified by British Gas plc for indoor installation when fitted with the appropriate draught diverter and a suitable flue system to outside.

Note that the heater must be in a room separated from living rooms and provided with appropriate ventilation direct to the outside.

055 Models

FLUE TERMINAL (Indoor) Draught Diverter

Illustration

Locate and assemble as shown. Secure with screws supplied in envelope inside carton.

Mounting

Screws

Draught

Diverter

185, 265 & 405 Models


Illustration

1.

Remove the louvred jacket top by removing four (4) No.10 flat head screws.

2.

If originally installed, remove "Pagoda" top from the louvered jacket top.

3.

Place the inner stack adapter panel over the flue collector inside the heater. Make sure the flanged side of the flue opening is up.

4.

Turn the stack (diverter) upside down and set it down bottom side up.

5.

Turn the jacket top panel (removed in step 1) down and place it through the stack.

6.

Attach the three (3) mounting brackets to the stack using the screws provided and the holes that are pre-drilled in the stack. Make sure the brackets are positioned with the flange near the top side of the stack (see illustration below).

Caution must be taken not to over tighten and strip the screw threads.

7.

Turn the assembled stack and jacket top, right side up. The jacket top will be trapped between the brackets and the top of the stack.

Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position. Reinstall the four (4) No.10 flat head screws removed in step 1 above.

055expl2.tif

105 & 155 Models


Illustration

Screw Hole

Location

Locate and assemble as shown. Secure with screws supplied in envelope inside carton.

Draught

Diverter

3.25"

82.5mm

Mounting

Screws (8)

Draught

Diverter

Jacket Top Panel

(Part of Heater)

No.10 Screw (3)

Mounting Bracket (3)

Inner Stack

Adapter Panel

Flue Collector

(Part of Heater)

Jacket

Top term.tif

S8960

11

405term.tif

01-10-98

MODEL FLUE DIA

SPECIFICATIONS & DIMENSIONS 055 - 105 - 155

WATER CONNECTIONS

055

105

155 mm (in.)

100 (4)

127 (5)

152 (6)

1-1/2" NPT

1- 1/2" NPT

2" NPT

DIMENSIONS -

055 Model Only

130mm

(5 -

1/8

")

60mm

(2 -

3/8

")

SHIPPING WEIGHT kg (lbs)

APPLIANCE

31.8 (70)

DIVERTER

2.3 (5)

48 (105)

62 (135)

3.5 (8)

3.5 (8)

620mm

(24 -

1/2

")

455mm

(18")

325mm

(12 -

7/8

")

DIMENSIONS - 105 Model Only

190mm

(7 -

1/2

")

85mm

(3 -

3/8

")

475mm

(18 -

3/4

")

525mm

(20 -

3/4

")

Gas Connection

65mm

(2 -

1/2

") dim055.tif

825mm

(32 -

1/2

")

690mm

(27 -

1/4

")

1070mm

(42")

835mm

(32 -

7/8

")

610mm

(24")

65mm

(2 -

1/2

")

Gas

Connection

325mm

(12 -

3/4

")

510mm

(20")

12 dim105.tif

10-12-01

DIMENSIONS - 155 Model Only

220mm

(8 -

3/4

")

85mm

(3 -

3/8

")

900mm

(35 -

1/2

")

680mm

(26 -

3/4

")

770mm

(30 -

3/8

")

Gas

Connection

390mm

(15 -

3/8

")

610mm

(24")

1140mm

(44 -

7/8

")

370mm

(14 -

1/2

")

MODEL WIDTH

(A)

185

265 mm (in.)

464 (18 1/4 )

568 (22 3/8 )

405 743 (29 1/4 )

SPECIFICATIONS & DIMENSIONS 185 - 265 - 405

FLUE DIA mm (in.)

150 (6)

175 (7)

230 (9)

WATER

CONNECTIONS

2" NPT

2" NPT

2" NPT

SHIPPING WEIGHT

kg (lbs)

APPLIANCE

86.8 (191)

97 (214)

115 (253)

DIVERTER

5.5 (12)

7 (15)

9 (20)

86mm

(3

-3/8

")

191mm

(7

-1/2

")

(C)

INDOOR DRAUGHT

HOOD

185 1590MM (62 5/8 ")

265 1597mm (62 7/8 ")

(C)

Indoor

Draft

405 1570mm (65 3/8 ")

965mm

(38")

1015mm

(40")

673mm

(26 ½ ")

*540mm

(*21

-1/4

")

336mm

Gas Connection (13

-1/4

")

Dim405.tif

A 675mm (26

-1/2

")

*Electrical Connection On Left Side is 486mm (19

-1/8

")

10-12-01

13

VENTILATION REQUIREMENTS

The heater must have both ventilation and combustion air. Safe and efficient operation of the heater is vitally dependant upon a good supply of fresh air to the room in which the appliance is installed. Minimum requirements for net free air supply openings direct to outside air at both high and low level are detailed in the table at the bottom of this page.

The flue/chimney design should avoid the formation of excessive quantities of condensate and for this reason it is recommended that all chimneys are suitably insulated and lined.

The draught diverter supplied with the heater must be used.

Position grilles to avoid the risk of accidental blockage or flooding. Further guidance is given in

BS6644.

Drain points should be fitted at the bottom of all vertical flue sections. Drain pipes must be a minimum of 25mm (1 in) internal diameter and manufactured from acid condensate resistant material (eg stainless steel) and positioned so that pipe runs and discharge points are not subject to the effects of frost and that flue gases cannot leak into the room.

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

Any terminal fitted must be of a type acceptable to

British Gas plc.

NOTE: The design is also certified by British Gas plc for indoor installation when fitted with appropriate manufacturer's draught diverter and a suitable flue system to outside. The heater must be in a room separated from living rooms and provided with appropriate ventilation direct to outside. It must not be installed in a cupboard or compartment which is directly connected to a living space.

As part of commissioning, the flue must be satisfactory when tested for flue flow and spillage as detailed in BS5440 Part 1.

FLUE SYSTEM

WARNING:

Indoor boilers require a draught diverter that must be connected to a flue pipe and properly flued to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.

To ensure safe and satisfactory operation of the heater, the flue system must be capable of the complete evacuation of flue products at all times. The effective height of the flue terminal above the draught diverter must ensure sufficient buoyancy to overcome the resistance of the bends and horizontal runs of the flue pipe. The number of bends and length of horizontal run must be kept to a minimum to reduce resistance.

Flue.pcx

The chimney must terminate in a downdraught free zone.

Compliance with the recom-

Model Input Plant Room (cm

²

)

ref. BS5440 for models under 60kW ref. BS6644 for models over 60kW mendations made in BS 6644;

British Gas publication IM11

"Flues for Commercial and

Industrial Gas fired boilers and air heaters" and the "Third

Edition of the 1956 Clean Air Act memorandum" should be strictly observed where applicable.

055

105

155

185

265

405

(kW)

13

27

39

50

72

108

High

117

243

351

450

-

-

Inside

Low

234

486

702

900

-

-

High

59

122

176

225

297

378

Outside

Low

117

243

351

450

600

756

18-11-02

14

GAS SUPPLY CONNECTIONS

Gas piping must have a manual shut-off valve located outside the heater jacket. All gas piping should be tested after installation in accordance with local codes.

Honeywell Gas Valve

Burner Pressure

Adjustment

CAUTION: The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 150mbar (2.2psi). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line.

FAILURE TO FOLLOW THIS PROCEDURE MAY

DAMAGE THE GAS VALVE. OVER PRESSURED

GAS VALVES ARE NOT COVERED BY WAR-

RANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation.

Use soapy water for leak test. DO NOT use open flame.

Vr8600.tif

NOTE: Do not use PTFE tape on the gas line pipe thread. A Flexible sealant is recommended.

A minimum of 17 mbar (6.8”) WG and a maximum of

25 mbar (10”) W.G.upstream pressure under load, and no load conditions are provided for natural gas or a minimum of 25 mbar (10”) W.G.and a maximum of

45 mbar (18”) W.G for propane gas.

PIPE SIZING FOR GAS CONNECTIONS

MAXIMUM EQUIVALENT PIPE LENGTH METRES

GAS PRESSURE REGULATOR

The gas pressure regulator is preset in the factory.

If an adjustment is needed, remove cap and turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

Turn to page 7 for burner pressure and other relevant performance specifications.

MODEL

055

105

N - NATURAL GAS @ 1.0 mbar PRESSURE DROP

P - L.P.G. @ 2.5 mbar PRESSURE DROP

10mm

N P

15mm

N P

22mm

N P

28mm

N

6 12

3

15

5

155

185

20

10.5

8

>24

>24

36

29

265

405

4.5

18 14.5

8.5

7

15

18-11-02

PLUMBING FOR WATER CONNECTIONS

LEFT SIDE WATER CONNECTION CONVERSION

185, 265 & 405 Models Only

Dis-assembly:

1.

Remove the jacket top, upper side panels, right and left side access panel (see figure 1).

2.

Remove rain shield front and side panel assembly as follows: (see figure 2).

a) Remove front screws attaching rain shield to the vertical surface behind the control compartment.

b) Remove four (4) screws attaching the rain shield to the rear vertical support panel.

c) Remove front and side rain shield panels, leaving the back shield in place.

3.

Remove the flue collector housing

(see figure 3).

4.

Disconnect wires to high limit and AGS (Auto matic Gas Shut-off) limit switches in return and inlet/outlet header castings (see figure 4).

5.

Remove pressure switch as follows:

(see figure 4).

a) Disconnect wires to pressure switch.

b) Disconnect tube fitting from header casting.

c) Remove pressure switch with tubing through the front of the heater.

6.

Remove thermostat temperature sensor

(see figure 4).

Jacket Top

Panel fig1.tif

Upper Side

Panel

Figure 2

Front Screws

Rain Shield

Side Panel

Figure 3

Flue

Collector

Figure 4

Rain Shield Front Panel fig2.tif

Four (4) Rear Screws

(2 per side) fig3.tif

fig4.tif

A.G.S.

High

Limit

Wires

High

Limit Wires

Figure 1

Left Side

Access

Panels

Pressure

Switch

Tube

Inner Jacket

Panel

Re-Route

Sensor Bulb

Through Hole

Thermostat

Temperature

Sensor

01-10-98

16

7. a) Disconnect the three (3) pin sensor plug from the poolstat circuit board (see figure

5).

b) Push the connector plug and wires down through the control box holes (see figure 5) and then through the inner jacket panel hole into the heat exchange area (see figure 4).

14.

OPTIONAL, re-route the AGS wires to the left side and overheat thermostat capillary to the right side. Connect the wires to the sensors in the header castings.

15. Replace the flue collector. Use caution not to damage any wiring and make sure no wiring comes in direct contact with the flue collector.

Reverse Heat Exchanger:

8. Lift the complete heat exchanger straight up and out of the unit.Use care not to damage the combustion chamber blocks.

16. Replace the rain shield and screws (see figure

2).

17. Reverse and replace right and left access panels

9. Re-route the pressure switch tube back through the right side of the inner cabinet panel.

18. Replace top side panels and jacket top panel.

10. Rotate the heat exchanger (inlet/outlet casting will be on the left) and lower it back into place above the combustion chamber. Again, be careful not to damage the combustion chamber blocks.

Assembly:

11. Re-route the three (3) pin plug and sensor wires from the heat exchange area through the hole in on the right side of the inner cabinet panel then up into the control box. Plug the three (3) pin connector back into the poolstat circuit board

(see figure 5).

12. Connect the pressure switch tube to the same hole it was removed from in the return header.

13. Re-route the pressure switch wires to the right side and connect them to the pressure switch.

board.tif

Wire Hole In Rear

Panel Of Control Box

CIRCUIT

BOARD

Three (3) Pin

Sensor Plug

Control Panel Door

(Shown In Open Position)

17

01-10-98

CONNECTIONS

All Models

LOCATION

The heater requires water flow and pressure to operate properly. It must therefore be installed downstream of the discharge side of the filter pump.

A typical installation is plumbed as follows:

2" CPVC Adapters

1. The inlet side of the filter is plumbed to the discharge side of the filter pump.

2. The outlet side of the filter is then plumbed to the inlet of the heater.

mbsmall.tif

Inlet/Outlet Header

PVC Pipe

3. The outlet of the heater is plumbed to the return line to the pool or spa. The pump, filter and heater are plumbed in series.

Plumbing from the heater back to the pool must not have any valves or restriction that could prevent flow when the pump is operating.

Heater must be located so that any water leaks will not damage the structure of adjacent area. High temperature 2" plastic pipe (CPVC) may be threaded directly into the header flanges. This is not the same as the Schedule 80 PVC pipe which is also coloured grey. PVC may be used immediately after the CPVC adapters.

600

M

B

A

R

500

400

300

200

100

0

Use the pressure loss chart below to specify a suitable pump.

NOTE: If operating pressure above 2 bar (30psi) are encountered then connection pipes must either be screwed into the flange or suitably anchored.

PRESSURE LOSS CHART 055 / 105 / 155 MODEL ONLY

500

M

B

A

R

400

300

200

100

0

0 100 200

LITRES / MIN

300 400

PRESSURE LOSS CHART 185 / 265 / 405 MODELS ONLY

CAUTION: flanges.

NEVER install PVC directly into header

FLOW RATES

MODEL PIPE SIZE

055

105

155

185

265

405

1

1

-1/4

-1/4

"-1

"-1

-1/2

-1/2

"

"

MINIMUM/min. MAXIMUM/min.

Litres (Gals) Litres (Gals)

77 (17)

77 (17)

1 -1/4 "-1 -1/2 " -2" 77 (17)

1 -1/4 "-1 -1/2 " -2" 77 (17)

1 -1/4 "-1 -1/2 " -2" 95 (21)

1 -1/4 "-1 -1/2 " -2" 150 (33)

225 (50)

430 (95)

430 (95)

470 (104)

470 (104)

470 (104)

*When flow rates exceed maximum an external auxiliary bypass valve is required. See external bypass valve section for details.

100 200

LITRES / MIN

300 400

COMPANION FLANGE CONNECTIONS

DO NOT use petroleum base assembly fluids (such as Petroleum Jelly or lubricating oil). If assembly lube is required, use a silicone base such as Amoral etc.

055 Model Only

The inlet/outlet header flange accepts a 1 ½" copper tube or 1 ¼" galvanized pipe as a slip connection directly into the manifold. The flange is also threaded for 1 ½" pipe thread.

18-11-02

18

055 Models Only

IN

OUT

1 2 gasket.tif

S80

UNITHERM GOVERNOR OPERATION

Does not apply to 105 Model

055hdr.tif

105 Model Only

The 105 accepts direct connection to 1 ½" plastic pipe using the adapters provided.

Inlet/Outlet Header

The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 40.6 to

46.1°C despite continually changing flow rates from the filter and changing pool temperatures. This narrow range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time below 37.8°C. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.

INTERNAL AUTOMATIC BY-PASS VALVE

Does not apply to 055 Model

1 ½" NPT

Inlet/Outlet

Connections

105 headers.tif

155, 185, 265 & 405 Models Only

Inlet/Outlet Header

Flange Gasket

In addition to the Unitherm Governor, a built-in automatic by-pass valve is provided in the in/out header.

While the Unitherm Governor responds to the changes in water temperature in the heater, the internal by-pass valve automatically responds to changes in water pressure in the piping system.

Proper amount of water flow is maintained through the heater under varying pressures dictated by the conditions of the pump and filter.

DAN MAINES ugov.tif

OUT

Inout.tif

IN

Header Flange

155, 185, 265 & 405 Models Only

There are two sets of flange gaskets supplied with your heater. Use the appropriate gaskets for all your heater connections. Discard unused set.

GASKET DESIGN 1: Accepts 1 -1/2 " copper tube or

1-1/4" galvanized pipe as a slip connection.

GASKET DESIGN 2: Accepts 2" copper tube as a slip connection. The flange is threaded for 2" screw in pipe connections. Also used with the 2" CPVC adapters.

19

10-12-01

EXTERNAL AUXILIARY BYPASS VALVE

(Where Required)

An auxiliary bypass valve should be used when flow rates exceed those shown in the table in the 'Connections' section on p18. (usually a high performance pump size larger than two HP will exceed this flow rate). This valve is required to complement the function of the automatic bypass valve, particularly when starting the heater in winter or early spring when the spa or pool temperature is down below 10°C. It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets, etc.

The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for the heat. The heater is supplied with a transformer for 230V mains input.

NOTE:

Heater is equipped with an electronic ignition device with a 100% safety lockout feature. If the heater fails to start or lockout, reset the ignition device by interrupting the power to the heater for 60 seconds.

Caution: If service replacement of the electronic ignition device is required, replace only with the ignition component supplied as a required spare.

From Heater To Heater

Robertshaw Intermittent

Ignition Device.

To Pool pass.tif

From

Pool

AUXILLARY BYPASS VALVE

(DO NOT USE GATE VALVE)

AUXILIARY BYPASS VALVE ADJUSTMENT

To set bypass: With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater.

Outlet pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold, open bypass.

ELECTRICAL WIRING ignbrd.tif

Wiring external to the appliance must be in accordance with the IEE Wiring Regulations and any local regulations which apply.

NOTE : If it is necessary to replace any of the original wiring, it must be replaced with 105° C wire or its equivalent, except all black wire which must be replaced with 150° C wire or its equivalent.

INTERNAL WIRING

GREEN/YELLOW

A 3 pin unswitched shuttered socket outlet, fused at

3A must be provided near to the heater, this should serve only the heater together with its controls and pumps.

Wiring should be 3 core PVC insulated (minimum,) not less than 24 x 0.2mm. All fuses must be ASTA approved to BS1362.

BLUE

BROWN

N

L mainsin.tif

INSTALLER WIRING

NOTE: Heaters are factory wired for 230V power supply.

Connect the power supply as shown above. Ensure that the cable is clamped in the cable clamp. The wires must be such that the current carrying conductors become taut before the earth conductor in the event of the cable clamp not gripping the cable adequately.

NOTE: 22mm Dia. holes not utilized on jacket and control box can be used for fireman switch or auxiliary control interface wiring.

20

NOTE: Input power to the heater (220V) should be supplied from the load (Pump) side of time clock or switch. Connecting heater to continuous power source will allow "Fail" indications (service and pressure switch) when pump is not operating.

09-12-99

WIRING DIAGRAM 055-105-155 MODELS ONLY

IGNITION DEVICE-ROBERTSHAW

KEY

24V 150ºC

BK-

BR-

R-

Y-

G/Y-

BL-

BLACK

BROWN

RED

YELLOW

GREEN &

YELLOW

BLUE

21 versa_wiring_08.01.tif

08-08-01

08-08-01

WIRING DIAGRAM 185-265-405 MODELS ONLY

IGNITION DEVICE-ROBERTSHAW

22

Rpwiring.tif

08-08-01

SECTION 4 / SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

055 MODEL

Manual High Limit

Reset Button

105 MODEL

Drain Valve

Unitherm

Governor

(Bronze Units Only)

Bypass Valve

High Limits

& Overheat

Thermostats

155 MODEL

Solid State

Thermostat Control

Ignition Control

Pressure Switch

Gas Valve

Thermal Fuse

Pilot

105cont.tif

23

Pressure Switch

Burners & Pilot

Gas Valve

Solid State Thermostat &

Ignition Control

High Limits &

Overheat

Thermostats

Unitherm Governor

8110.tif

Drain Valve

01-10-98

GENERAL LOCATION OF CONTROLS - continued.

185-265-405 MODEL

Overheat Thermostat Capillary

(Located in Return Header)

Drain Plug

(Located in Return Header)

Ignition Control (IID)

Solid State Thermostat Module

Ranco LM7

Overheat Thermostat

Pressure Switch

Roll-Out Safety Switch

Pilot rpunit.tif

Bypass

AGS Hi-Limit

(Located in

Inlet/Outlet Header)

Unitherm Governor

Drain Valve

Transformer

Gas Valve

155 Model

CONTROL PANEL REMOVAL

1.

Remove lower door.

2.

Remove (2) screws from bottom flange of control panel.

3.

Slide down control panel to clear jacket top panel.

4.

Rotate control panel down until panel stops.

Do not force.

NOTE: Caution must be taken not to damage controls or wiring.

185,265 & 405 Models

CONTROL PANEL REMOVAL

1.

Remove (4) screws from sides of control panel.

2.

Rotate control panel down until panel stops.

Do not force.

NOTE: Caution must be taken not to damage controls or wiring.

CONTROL PANEL Jacket Top Panel

Control Panel

MOUNTING SCREWS (4)

Mounting Screws (2)

8267.tif

24 rpdoor.tif

01-10-98

185,265 & 405 Models 185,265 & 405 Models

O F F

Service

Pressure/High Limit

Call forHeat

Power

P O O L S P A

On/Off

Switch

Thermostat

Knob &

Knobstop

Ring

E L E C T R O N I C rpcont.tif

405view.tif

There are four operational indicator lamps located on the 185, 265 & 405 Spa/Pool control panel.

They are as follows:

All Models

TEMPERATURE CONTROLS

1.

The “Power” (green) lamp is on when power is applied to the RP 2100 Spa/Pool heater.

Green ON – Power to Heater Normal

The pool or spa water temperature is controlled by the pool heater thermostat on the upper front panel of the heater. The control centre contains an On/Off switch and one thermostat (055,105 &155 models) or two thermostats (185,265 & 405 models) . Heaters fitted with two thermostats may be set up for one temperature setting when heating a spa and a second temperature setting for heating a swimming pool. The switch functions as a means for turning the heater on or off, and for switching between thermostats when fitted with two thermostats.

Thermostats are fitted with a means of limiting the upper temperature limit below the maximum level.

The knob stop adjustment ring illustrated below is adjustable by loosening the set screw, rotating the knobstop ring to the desired location and retightening the set screw.

Spa Temperature

Range

Pool Temperature

Range

2.

The “Call For Heat ” (green) is on when thermostat is functionally calling for heat.

Green ON – Call for Heater Normal

3.

The “Pressure/High Limit” (red) indicates

Red

"safety" failure.

ON

Limit Failure

– Pressure/High

Service Required

4.

The “Service” (red) indicates failure of control/ limit circuit.

Red ON – Service Required

NOTE: If both the "Service" and "Pressure/High

Limit" indicators are On, check first and make sure that the Filter/Strainer are clean before calling for service.

All Models

PRESSURE SWITCH

The pressure switch, or heater actuator, ensures that the heater operates only when the filter pump is in operation. It is factory set at 0.12 bar (1.75 PSI) for deck level installations. When the heater is located below the level of the spa or pool, it may be necessary to reset the pressure switch to compensate for the noflow static head. If it is necessary to reset the pressure switch, we recommend the following procedure: kstop.tif

Knobstop Ring Set Screw

Standby

Temperature

25

01-10-98

All Models

PRESSURE SWITCH ADJUSTMENT

1.

With pump and heater on, turn adjustment knob (clockwise) until a click is heard from the gas valve.

2.

Turn adjustment knob (counter clockwise)

1/4 turn.

3.

Turn pump off and on several times.

Heater should shut off immediately. If it does not,repeat steps above until proper adjustments is made.

FLAME ROLL-OUT SAFETY SWITCH rollout.tif

The heater is equipped with a thermal cutoff device to prevent flame roll-out in the event that the heat exchanger becomes blocked. This is a "Single-use" type fusible link or thermal fuse, that must be replaced when disabled by an over temperature condition, caused by excessive restriction in the heat exchanger flue passage.

HIGH LIMITS

Automatic

Gas Shut-off High

Limit Thermostat

Automatic

Reset

Thermostat

Adjustment

Knob press.tif

PRESSURE SWITCH ADJUSTMENT RANGE

1.5 m Max

1.5 m Max range.tif

ags.tif

Manual Reset

High Limit

Thermostat autoreset.tif

lm7.tif

NOTE: If heater is installed outside of the limits shown, a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater.

The heater is equipped with one manual reset overheat thermostat located in the return header, set to open at approx. 100°C. the other is the Automatic

Gas Shut-off limit, set to open at 57°C and located in the Inlet/Outlet header.

TWO SPEED PUMPS

In some cases, the flow on the low speed is insufficient to operate the heater. This is apparent when the pressure switch cannot be further adjusted or if the heater makes banging noises. In these cases, the pump must be run at high speed when heating the water.

NOTE: An erratic high limit is often characteristic of internal heat exchanger problem, i.e. scale buildup, defective bypass. Refer to troubleshooting sections.

055, 105 & 155 Models

HIGH LIMIT & MANUAL RESET HIGH LIMIT THER-

MOSTAT REMOVAL

CAUTION: Do not operate the heater without the functionof a properly adjusted pressure switch or flow switch.

Disconnect top portion of unit. (See heat exchanger removal procedure steps 1 thru 7 and step 10).

1.

Remove Jacket Top,Flue Collector and Baffle.

2.

Remove defective high limit and replace with new high limit.

17-08-00

26

3.

To remove the manual reset high limit, follow the procedure for the high limit thermostat but in addition, disconnect the electrical connections and release its mounting bracket from the side panel by removing the M4 nut at the front of the bracket. The thermostat can then be removed from its bracket. Ensure thermostat phial is correctly located in its pocket.

4.

Reverse above procedure to reinstall.

055, 105 & 155 Models

GAS VALVE REMOVAL

1.

Remove burner tray. (See burner drawer removal procedure).

2.

Disconnect pilot tubing from gas valve.

3.

Remove gas valve with manifold from burner tray.

4.

Remove manifold from gas valve.

5.

Reverse above procedure to re-install.

185, 265 & 405 Models

MANUAL RESET HIGH LIMIT REMOVAL 185, 265 & 405 Models

GAS VALVE REMOVAL

1.

Shut off main electrical power switch to heater.

2.

Remove inspection panels.

3.

Disconnect electrical connections from thermostat.

4.

Remove defective high limit and replace with a new high limit. Secure bulb in pocket with chip provided.

5.


1.

Shut off gas supply to the heater. Remove gas piping to gas valve inlet.

2.

Disconnect wires, pilot tubing and bleed line, if required.

3.

Turn vertical gas pipe from manifold slightly and unscrew gas valve.

4.


HIGH LIMIT REMOVAL (A.G.S.)

All Models

MAIN BURNER AND INJECTOR REMOVAL

1.


2.

Remove inspection panels.

3.

Drain heater.

4.

Remove defective high limit and replace with a new high limit.

5.


1.

Remove burner drawer. See burner drawer removal procedure.

2.

Remove screws and burner hold down bracket.

All Models

PILOT SAFETY IGNITION

NOTE: If the heat exchanger is sooted badly, the burner hold down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts.

The heater employs a pilot safety which closes the main gas valve within 8/10ths of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit.

3.

Lift burners from slotted spacers and slide from orifices. Clean with a wire brush.

4.

Orifices usually do not need to be replaced. To clean, run either copper wire or a drill shank through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from manifold.

DO NOT overtighten when reinstalling.

BURNER DRAWER REMOVAL

1.


2.

Shut off gas upstream of heater.

3.

Remove front door.

4.

Disconnect gas line from gas valve.

5.

Remove (2) screws that mount burner tray to unit.

6.

Disconnect wires that terminate at gas valve.

7.

Slide out burner tray.

8.


NOTE :IMPORTANT Reconnect Earth Connection

055, 105 & 155 Models

PILOT REMOVAL AND CLEANING

1.

Remove burner drawer. (See burner drawer removal procedure).

2.

Disconnect pilot tubing, disconnect wires from gas valve.

3.

Disconnect pilot bracket from burner shield.

4.

Remove pilot from bracket.

5.

Remove pilot orifice, and clean with wire or small brush.

CAUTION! DO NOT enlarge hole in pilot orifice.

6.


01-10-98

27

185, 265 & 405 Models

PILOT REMOVAL AND CLEANING

1.

Disconnect pilot tubing, and wires from gas valve.

2.

Remove pilot assembly from burner tray.

3.

Remove pilot from bracket.

4.

Remove pilot injector and clean with wire or small brush. CAUTION!

Do not enlarge hole in pilot orifice.

5.


HEAT EXCHANGER REMOVAL

All Models

CONTROL IMMERSION WELL REPLACEMENT

1.

Shut water off to heater and drain heat exchanger.

2.

Remove jacket top panel.

3.

Remove old control well with bushing and sleeve, with 7/8" wrench or socket.

4.

Slip "o" ring gasket over control well and install in header.

1.

Shut water, gas and electricity off, close valves and relieve pressure, remove relief valve. Remove side inspection panels.

2.

Remove top holding screws.

3.

Remove draft diverter, lift and remove top and flue collector. Remove inspection panels.

4.

Loosen bolts and disconnect flange nuts on inlet-outlet header, loosen union(s) at gas pipe and slide boiler away from piping until studs clear the header.

5.

Lift heat exchanger straight up using caution not to damage refractory.

6.


well.tif

Olive

Well Assembly

TUBE CLEANING PROCEDURE (Typical)

055, 105 & 155 Models

HEAT EXCHANGER REMOVAL

1.

Shut water, gas, and electricity off, close valves and relieve pressure.

2.

Drain heat exchanger.

3.

Loosen and remove flange bolts.

4.

Remove flange and inlet/outlet pipes from the header.

5.

Remove outdoor stackless top or indoor stack top from unit.

6.

Remove jacket top, flue collector, and baffles.

7.

Remove upper front jacket panel, and disconnect wires at toggle switch.

8.

Remove capillary bulb from inlet/outlet header.

9.

Disconnect press switch tube from return header.

10. Disconnect hi-limit wire from thermostat, and pressure switch. Remove overheat thermostat capilliary & phial.

11. Lift heat exchanger straight up from combustion chamber, using caution not to damage refractory.

12. Reverse above procedure to re-install.

Establish a regular inspection schedule, frequency depending on local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1.5 mm in thickness.

The heater must be cleaned from the rear as shown.

It is preferable, however, to remove the heat exchanger and the in/out header for better visibility through the tubes and to be sure the ground-up lime dust does not get into the system,

Note that you do not remove the top panel or the heat exchanger, generally.

After reaming, mount the wire brush in place of the auger and clean out debris remaining in the tubes.

Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in noninhibited de-scale solvent.

drill.tif

01-10-98

28

All Models

DESOOTING PROCEDURE

To test the operation of the Unitherm Governor, place in hot water (over 43°C) and watch for movement against spring. If there is no movement, replace unit.

CAUTION: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE. NEVER USE A WIRE BRUSH.

Soot can clog areas between fins and cause eventual tube failure. Any sign of soot at the base of the burners or around the outer jacket indicates a need for cleaning.

055, 105 & 155 Models

COMBUSTION CHAMBER REMOVAL

1.

Remove heat exchanger (See heat exchanger removal procedure).

2.

Lift up and remove front and rear refractory shield.

3.

Remove refractory panels.

4.


1.

Disconnect top portion of unit. (See heat exchanger removal procedure steps 1 through 6).

2.

Remove burner tray (See burner drawer removal procedure.)

3.

Take a garden hose and wash heat exchanger,making sure soot is removed completely from between fins. Avoid excessive water against refractory.

Ensure no gaps in corners

NOTE: DO NOT WIRE BRUSH.

155, 185, 265 & 405 Models

UNITHERM GOVERNOR (U.G.) REPLACEMENT

1.

Shut water, gas and electricity off, close valves and relieve pressure.

2.

Drain heat exchanger.

3.

Remove retainer plug located under outlet pipe connection.

4.

Remove spring and replace old U.G. with a new U.G.

5.


Refractory Panels Top View

185, 265 & 405 Models

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber, you must first have removed the heat exchanger. Unbolt metal combustion chamber retainer from top and remove combustion chamber panels individually.

U.G.

Gasket

Retainer Plug

Spring

Ensure no gaps in corners ugrep.tif

Extension Pieces (2) ref265.dwg

Refractory Panels Top View

Auger with Carbide Tip Wire Brush soot.tif

08-08-01

29

SECTION 5 / TROUBLE SHOOTING GUIDE

IMPORTANT NOTICE: These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components.

Installation and service personnel must be Corgi Registered. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.

All Models

MECHANICAL ( FOR QUALIFIED SERVICE PERSONNEL ONLY )

PROBLEM CAUSE SOLUTION

Harmonics, or whining noise.

U.G. inoperative........................ Check movement by putting into hot water (43°C or higher). If no movement, replace.

*Debris or restriction in system...Locate the restriction and remove.

Flush system and clean.

*Debris in gas line.................... Remove debris or blow out gas line.

Low flow................................... Scale forming in heat exchanger - clean heat exchanger and check pool pH and total alkalinity.

Heater going on and off continuously.

Dirty filter..................................Backwash filter.

Low water level in pool...............Raise water level.

External bypass setting out of adjustment................................Adjust bypass

*Pressure switch out of adjustment................................Adjust pressure switch

Liming or scale forming on heat exchanger.

PPM

PPM

Sooting

Pool water.................................Recommended pH should be between

7.4 and 7.8 total alkalinity 100-150 maximum. Hardness 150-400 maximum.

High flow rates.......................... Reduce by adding manual bypass valve and adjust by putting thermometer in header (1/4" NPT) drain opening. Set bypass so thermometer reads between

40°C and 43°C.

U.G. Inoperative.........................Check movement by putting in hot water

(43°C or higher). If no movement, replace.

*Air starvation..........................

Refer to installation instructions.

*Improper venting..................... Follow recommended installation instructions.

*Insects or debris clogging burner intake ports.....................Clean burners.

(* Usually occurs on initial start-up.)

08-08-01

30

PROBLEM

Pilot outage.

CAUSE SOLUTION

Low gas pressure..................... Adjust gas pressure.

Restricted pilot......................... Clean pilot.

Weak pilot generator.................. Replace pilot.

Faulty Detection Electrode or PCB

Yellow lazy flame Low gas pressure...................... Adjust gas pressure.

*Insects or debris clogging burner intake ports.....................Clean burners.

Inner & Outer panels very hot *Gaps in corner of refractory

(paint blistered - thermal fuse Broken refractory caused by in transformer failed) shipping damage or improper combustion............................... Replace or re-align refractory to seal gaps. Replace transformer.

Excessive sooting of heat exchanger................................ Determine cause of sooting & correct.

Takes long time to heat pool or spa.

Calculate temperature in °/hr......

Heat rise (°/hr.)= Heater Output

Pool gallonage x 8.33

or refer to heater sizing chart.

This does not take into account heat loss due to weather.

Liming

Leaking at well.

Leaking at heat exchanger.

Gasket brittle and leaking -

(overheated).

Filter not running long enough.....Reset time clock.

Dirty filter.................................

Clean filter.

Gas line or meter undersized......Refer to installation instructions.

Bypassing too much water..........Inspect bypass for movement, if no movement, replace.

U.G. not functioning................. Replace if no movement when heated.

Overacid..................................

Replace well and maintain water chemistry properly.

Overacid..................................

Replace heat exchanger and maintain chemistry properly.

Heater running after pump shuts off...................................

See pressure switch adjustment.

Refractory damage.................... Replace refractory.

Sooted heater........................... Determine cause of sooting and correct.

(* Usually occurs on initial start-up.)

31

08-08-01

055, 105 & 155 Models

ELECTRICAL (ELECTRONIC IGNITION IID)

START

SET THERMOSTAT

TO CALL FOR HEAT

DOES THE GREEN

DIAGNOSTIC

LED STAY ON?

*

YES

AFTER PREPURGE

IS THERE SPARK

AT THE PILOT

ASSEMBLY?

YES

PILOT BURNER

LIGHTS

YES

SPARK STOPS WHEN

PILOT IS LIT

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

CALL FOR HEAT OVER

SYSTEM SHUTS OFF

YES

NO

CHECK FOR 25VAC

NOMINAL AT TH & TR

TERMINALS

YES

REPLACE CONTROL

NO

IS THERE ANY

AUDIBLE SPARK

NOISE @ 5 SPARKS/

SEC?

NO

NO

CHECK LINE VOLTAGE POWER.

CONFIRM TRANSFORMER OUTPUT,

LIMIT CONTROLLERS, THERMOSTAT

AND WIRING. ALSO, INDUCED

DRAFT FAN AND AIR PROVING

SWITCH ON INDUCED DRAFT

SYSTEMS.

YES

CHECK IGNITION CABLE, GROUND

WIRING, PILOT ASSEMBLY

INSULATOR AND GAP. CHECK

CABLE FOR SIGNS OF MELTING.

REPLACE CONTROL

NO CHECK VALVE, VALVE WIRING, GAS

SHUT OFF VALVES.

NO

NO

NO

NO

WARNING

HIGH VOLTAGE

For qualified Technicians ONLY

*

NOTE: This heater is equipped with an ignition module that shuts off pilot gas if pilot fails to light after the third attempt. This is identified by the green LED flashing on the ignition module. To reset, interrupt power to heater.

CHECK FLAME SENSE WIRE AND GROUND

WIRE. CHECK PILOT FLAME COVERS SENSE

ROD. CLEAN SENSE ROD.

CHECK VALVE, VALVE WIRING.

CHECK LIMITS AND CIRCULATION FAN. CHECK

CONTINUITY OF SENSOR CABLE AND GROUND

WIRE. POOR GROUNDING MAY CAUSE

OCCASIONAL SHUTDOWNS. CHECK FOR EXCESSIVE

HEAT AT FLAME SENSOR INSULATOR.

CHECK THERMOSTAT

CHECK VALVE

END TROUBLESHOOTING

30-09-99

32

ELECTRICAL (SOLID STATE THERMOSTAT IID)

055, 105 & 155 Models If the pool/spa water is too cold, troubleshoot the system as follows:

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V.

Set control to max. temperature. After 2-3 cycles, check water temperature.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.

Check transformer, 23•20 V supply, correct as necessary.If 230 V side of transformer is open circuit, check combustion chamber for heat leaks

Check 3 Amp fuse.

TEMPERATURE BELOW 40°C

Disconnect sensor leads from circuit board.

Measure sensor resistance with ohmmeter.

TEMPERATURE 40°C-40.5° C.

Control ok.

RESISTANCE 1-14k OHMS.

Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE

MATCH WITHIN 20 PERCENT.

Disconnect potentiometer leads from circuit board.

Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting;

9k to 11k at maximum setting, replace circuit board.

Above 11k ohms but less than

15 k ohms, replace potentiometer.

Above 15k ohms, fix loose or broken wires; replace potentiometer if necessary.

Reconnect all leads and check out system.

RESISTANCE 0 OHMS (SHORT CIRCUIT)

Check system for shorted wires or open circuits.

Replace sensor if necessary.


DON'T MATCH.

Replace sensor. Reconnect all leads and check out system.

If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V.

Set control to max. temperature. After 2-3 cycles, check water temperature.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.

Check transformer, 230 V supply, correct as necessary.

If 230 V side of transformer is open circuit, check combustion chamber for heat leaks

Check 3 Amp fuse.

TEMPERATURE ABOVE 42°C

Disconnect sensor leads from circuit board.

Measure sensor resistance with ohmmeter.

TEMPERATURE 40°C-40.5° C

Control ok.

RESISTANCE 1-14k OHMS.

Check water temperature; estimate expected sensor resistance from chart below.

RESISTANCE ABOVE 15k OHMS (OPEN

CIRCUIT) OR SHORT CIRCUIT.

Fix loose or broken wires. Replace sensor if necessary.


MATCH WITHIN 20 PERCENT.

Disconnect potentiometer leads from circuit board.

Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting:

9k to 11k at maximum setting, replace circuit board.


DON'T MATCH.

Replace sensor. Reconnect all leads and check out system.

Above 11k ohms, replace potentiometer.

0 ohms (short circuit), replace potentiometer.

Reconnect all leads and check out system.

Temperature (deg C)

(deg. F)

Resistance (k ohms)

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

16°C 20°C 21°C 25°C 30°C 31°C 35°C 40°C 41°C

61 68 70 77 86 88 95 104 106

14.9

12.5 11.9 10.0 8.1 7.7 6.5 5.3 5.1

33

08-08-01

185, 265 & 405 Models

- IID DIAGNOSTIC FLOW CHART

HEATER WILL NOT FIRE

START

"Green" Power Light "ON" NO

YES

"Green" Call-For-Heat

Light "ON"

YES

YES

"Red" Service Light "ON"

YES

NO

• Check for 230 V Power to Transformer

(Circuit Breaker,Time Clock, Wire Connections)

• Check for Fireman Switch/Remote Thermostat

Operation (Red Jumper Wire from TP4 to TP5)

Bypass If Necessary.

• Check for 24 VAC from TP6 to TP7

(Transformer Output) If No Power, Replace

Transformer.

• Check Combustion chamber for heat leaks

• Check Fuse F1 on Back of heater Control Board.

If Fuse is Open, Replace with Auto Reset Poly Fuse,

Proceed.

• Check Toggle Switch for "Pool" or "Spa" Selection. Set Temperature Control Knob to

Maximum (Counter-Clockwise)

• Check Water Temperature - Must be Less than

40°C ( Maximum Call-For Heat)

• Check Pool/Spa Selector switch and wiring to terminal TP2 and TP3.

Is Green "Call For Heat" And/Or Red "Service"

Light On?

NO ( Or Flashes On-Off)

Temporary Condition may have caused problem.

Does Heater Now Operate

Normally?

NO ( Pg 35)

YES

Interrupt Power to

Heater. Wait 10

Seconds, Re-apply

Power (to Reset

Poly Fuse) Green

"Call For Heat "On?

NO (Or

Flashes

On-Off) NO

Heater Sparks ?

NO ( Pg 35)

YES

"Red" Pressure/Hi-Limit

Light"ON"

YES

If All Okay, Replace heater

Control Board

NO

• Check for "Fail" Pressure or High

Limit. Lights on Back of heater

Control Board.

Verify Proper Water Flow/

Pressure.Identify and Replace

Faulty Limit/Switch as Necessary.

• Check for "Fail" of Limit/Switch LED

Lights on back of heater Control Board.

Identify and Verify Fault. Replace Switch/

Control as Necessary.

• Check for "Fail" of "Overtemp" or

"Sensor" LED Lights on Back of heater Control Board.

"Sensor" Fail "ON" / "Overtemp" Fail "ON"

YES YES

• Check that All Manual Gas Valves

Are Open, Supply Tubing & Gas

Pressure Good.

• Check "PV" Power Monitor On

Back of Control Board (24 VAC

From IID to Pilot Gas Valve). If

No Power, Replace IID.

• Check for Gas to Pilot (Crack

Fitting on Gas Valve Pilot Tube

Connection-Clear Tube/Pilot

Orifice as Necessary)

• Verify Pilot Rectification (Pilot On

- Spark Off)

• Check "MV" Power Monitor on

Back of heater Control Board

(24 VAC from IID to Main Gas

Valve) If No Power, Replace IID.

Sensor "Fail"

• Inspect Thermister, wires, and connector at Terminal P1.

• Using andOhmmeter, measure resistance from Red (ST) to

Back (Com) and Red (SR) to Black (Com), if not within 5% of each other replace Thermister.

• Check resistance value of Thermister. Reference to chart below.

Replace Thermister in not within 10% of values shown.

• If all okay, replace heater Control Board.

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

TEMP

°C DEGREES 22 27 33 39 44 50 55 59

Resistance (K ) 26.11 19.90 15.31 11.88 9.30 7.33 5.83 5.10

If All Okay, Replace heater Control Board

34

• If All Okay, Replace Gas Valve.

OVERTEMP "FAIL"

Fail May indicate temporary residual

heat in heat exchanger. Reset &

repeat. If problem continues, call

service agent

- OR -

Fail May indicate failure of heater

Control Board. If power to heater

must be interrupted to reset,

replace heater Control Board.

08-08-01

From Pg 34

• Check for 24 VAC Power to IID - (24 V to

24V GND Terminals on IID). If No Power,

Replace heater Control Board, or wire harness to IID.

• Check for Spark at IID Spark Terminal

(Remove Hi-Tension Lead from IID Module-

Position end near spark terminal. Turn control on. If spark jumps to wire, check Hi-Tension wire, insulators, ceramic ignitor and gap. If no spark jumps to wire, replace IID Module.

Replace heater

Control Board

NO

Probable Component or Wire Short to Ground.

• Interrupt power to heater.

• Remove Molex Connectors P1, P2, P3 and

P4 on heater Control Board

• Re-Apply Power to Heater, Does "Power" and "Service" Light Stay On?

YES

• Reconnect temp.sensor plug at connector P1

Does "Power" and "Service" light stay on? (Front Panel)

Replace

Temp Sensor

NO

NO

YES

Verify "Call For Heat" light

(Front Panel)

• Reconnect safety circuit plug at connector P2.

Does "Power" and"Service" light stay on? (Front Panel)

• Remove Molex Connector Plug

P2 on heater Control Board.

• With OHM Meter, check for continuity from each pin in plug to ground (cabinet)

• If continuity exits trace to wire/ component; repair or replace as necessary.

• Re-check door clearance to terminals on gas valve.

• Trace wires to gas valve. Inspect for proper connection on valve.

• If connections okay, replace gas valve.

Check for proper wire connections on IID module. If okay, replace

IID module.

NO

NO

YES

• Reconnect IID Module plug at connector P3

Does "Power" and "Call for

Heat" Light stay on? (Front

Panel)

YES

• Place cabinet door on heater. Check for adequate clearance from door to terminals on gas valve.

Remove door, correct if necessary.

• Reconnect gas valve plug

P4 on heater Control

Board

Does "Power" and "Call for

Heat" Light stay on?

YES

Heater should operate normally. If not, refer to start.

01-10-98

35

SECTION 6

REPLACEMENT PARTS LIST

055 Model

NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable.

spares2.pcx

Pilot ( Silver )

1-P

Pilot ( Black ) europilot.tif

5-P

4-P

2-P

3-P inject.tif

6-P

7-P

8-P

2-G softlite.tif

36

17-08-00

Key

B

1-B

2-B

3-B

P

1-P

2-P

3-P

4-P

M

1-M

2-M

3-M

4-M

5-M

6-M

7-M

8-M

9-M

R

1-R

C

2-C

3-C

4-C

6-C

7-C

8-C

SPMB502

G

1-G

2-G

H

1-H

2-H

3-H

4-H

5-H

6-H

7-H

8-H

9-H

10-H

11-H

12-H

13-H

S

1-S

2-S

3-S

4-S

5-S

V

1-V

2-V

Description - 055 Model

BURNER TRAY

Burner Tray w/Gas Valve Natural

Burner Tray w/Gas Valve Propane

Burner

Burner Injector Natural No.50

Burner Injector Propane No.57

CONTROLS

High Limit 57ºC (135ºF)

High Limit Manual Reset 102ºC

Thermostat Control (Solid State)

Potentiometer

Temperature Sensor

Ignition Control Robertshaw 100-00834 NL-3-L

Ignition Control, Abbey

Part Code

301210

350079

-

-

350083

600889B

M3029

600960

600961

600962

SPMB502/1

GAS VALVE

Honeywell Gas Valve

L.P.G. Softlight Adapter

HEAT EXCHANGER

Heat Exchanger Assembly (Complete)

Header / Tubed Kit

Baffle Kit

Unitherm Governer

U.G. Cap

U.G. Spring

Drain Valve

Sensor Well, High Limit

Bulb Retainer Clip

U.G Gasket

Inlet/Outlet Flange

Flange Gasket

Bypass Baffle

M3265

M3694

063780

004695F

306790

600885

400734

850247

500719

M3028

300203

800276

350746

800013B

306079

MISCELLANEOUS COMPONENTS

Pressure Switch

Pressure Switch Tube Assembly

Thermostat Knob

Knob Stop

Dial Plate

Transformer

Toggle Switch

Wire Harness IID

Thermal Fuse

PILOT (Silver) Part Code

Pilot Natural/Propane 600799

Pilot Injector Natural M3274

Pilot Injector Propane 601218

Pilot Tube

Hi-Tension Wire

400013

651012

650634

062212

800201

305138

M3060

M650531

650595

M3552

651360

PILOT (Black)

5-P Pilot Natural/Propane M3685

6-P Pilot Injector Natural M3687

Pilot Injector Propane M3688

7-P Pilot Tube

8-P Hi-Tension Wire

M3705

M3695

REFRACTORY

Refractory Kit FT/RR

LT/RR

SHEETMETAL

Jacket Top

Flue Collector

Door Assembly

Upper Jacket Control Panel

Cable Clamp Bracket

VENTING

Stackless Top (Outdoor)

Drafthood (Indoor)

M700348

M700349

305658

-

063783

M306120

M3299

003709

003722

19-08-03

37


105 Model

1-V

2-V

1-S softlite.tif

5-M

3-M

4-M

3-C

2-G

16-H

6-C

2-C

11-H

12-H

14-H

8-H

4-H

2-H

1-H

6-S

5-C

4-S

4-J

9-M

1-R

3-S

5-S

4-C

1-G

2-J

1-B

2-G

3-J

6-H

7-H

6-P

3-H

2-S

2-M

10-M

1-M

6-S inject.tif

Pilot (Silver)

1-P

2-B

3-B spares105_2.tif

2-P

4-P

3-P

Pilot (Black)

5-P

8-P

10-12-01

38 europilot.tif

7-P

Key

B

1-B

2-B

3-B

J

2-J

3-J

4-J

M

1-M

2-M

3-M

4-M

5-M

8-M

9-M

10-M

P

1-P

2-P

3-P

4-P

R

1-R

S

1-S

2-S

3-S

4-S

5-S

V

1-V

2-V

C

2-C

3-C

4-C

5-C

6-C

G

1-G

2-G

H

1-H

2-H

3-H

4-H

6-H

7-H

8-H

11-H

12-H

14-H

15-H

16-H


BURNER TRAY



Burner

Burner Orifice Natural

Burner Orifice Propane

No.50

No.59

CONTROLS

Automatic Reset Thermostat



Potentiometer

Temperature Sensor

GAS VALVE

Honeywell Gas Valve




Inlet/Outlet Header

Return Header

Tube Bundle

Baffle Kit

Bolt Kit

Header Gasket

Bypass Valve

Bypass Spring

Drain Valve (not shown)

Sensor Well, Pool Temperature

Well Retaining Clip

Sensor Well, High Limit

Part Code

-

-

301210

350079

350350

601549

M3029

600960

600961

600962

M3265

M3694

064187

006887F

351047

006889F

306255

006890F

800014B

006716F

850252

500719

M3028

300203

M3028

J BOX/CONTROL BOX

Ignition Control Robertshaw 100-00834 NL-3-L

Transformer 230V/24V

Toggle Switch


Pressure Switch


Thermostat Knob

Knob Stop

DialPlate

Wire Harness

Thermal Fuse

Elbow Adapter

PILOT (Silver)

Pilot Natural/Propane

Pilot Injector Natural

Pilot Injector Propane

Pilot Tube

Hi-Tension Wire

Part Code

600799

M3274

601218

400013

651012

M3031

M650531

650595

650634

064685

800201

305138

M3060

M3551

651360

M4031

PILOT (Black)




7-P Pilot Tube

8-P Hi-Tension Wire

M3700

M3695

REFRACTORY


LT/RT

SHEETMETAL

Jacket Top

Flue Collector

Door Assembly

Upper Jacket Control Panel

Control Panel IID Pilot

VENTING


Drafthood (Indoor)

700443

700444

306894

064624

M306893

M306892

M306895

004898

004897

39 10-12-01


155 Model

12-H

2-C bits.tif

Pilot (Silver) inject.tif

4-P

1-P

Pilot (Black)

5-P europilot.tif

6-P

2-P

3-P

7-P

40

8-P

2-G softlite.tif

17-08-00

Key

B

1-B

3-B

4-B

C

1-C

2-C

3-C

5-C

6-C

7-C

G

1-G

2-G

9-H

10-H

11-H

12-H

13-H

14-H

15-H

16-H

17-H

H

1-H

2-H

3-H

4-H

6-H

7-H

8-H

J

2-J

3-J

4-J

M

1-M

2-M

3-M

4-M

5-M

8-M

9-M

P

1-P

2-P

3-P

4-P

R-1

1-R

S

1-S

2-S

3-S

4-S

5-S

V

1-V

2-V


BURNER TRAY



Burner

Burner Orifice Natural

Burner Orifice Propane

No.49

No.57

CONTROLS

Thermostat Pocket, High Limit




Potentiometer

Temperature Sensor

GAS VALVE

Honeywell Gas Valve




Inlet/Outlet Header

Return Header

Tube Bundle

Baffle Kit

Bolt Kit

Header Gasket

Unitherm Governor

U.G. Retainer Spring

Bypass Valve

Bypass Spring

Drain Valve


Well Retaining Clip

Inlet & Outlet Flange

Flange Gasket 1-1/2" Connections

Flange Gasket 2" Connections

Part Code

-

-

301210

350078

350083

M3028

600893B

M3029

600960

600961

600962

M3265

M3694

066126

004963F

004964F

004896F

303232

004889F

800086B

062234B

850254

062235B

850252

500719

003765F

300203

003766F

800217

800080B


Ignition Control IID Robertshaw 100-00834 NL-3-L


Toggle Switch


Pressure Switch


Thermostat Knob

Knob Stop

DialPlate

Wire Harness IID

Thermal Fuse



Pilot Injector Natural

Pilot Injector Propane

Pilot Tube

Hi-Tension Wire

REFRACTORY


LT/RT

Part Code

600799

M3274

601218

400381

651013

M3031

M650531

650761

650634

054374

800201

305138

M3060

M3553

651360

PILOT (Black)




7-P Pilot Tube

8-P Hi-Tension Wire

M3703

M3696

M700341

M700114

SHEETMETAL

Jacket Top

Flue Collector

Door Assembly

Access Panel Group

Control Panel IID Pilot

VENTING


Drafthood (Indoor)

305703

053243

060146

-

063243

003710

003723

41 10-12-01


185, 265 & 405 Model

1-V

18-H

1-J

Pilot (Silver) inject.tif

4-P

8-H

2-C

3-H

6-H

18-H

2-M

1-M

4-S

8-S

7-H

2-S

4-H

3-V

17-H

16-H

5-C

15-H

14-H

14-M

2-H

13-H

10-H

9-H

11-H

1-C

12-H

7-S

5-S

12-S

4-S

10-S

3-C

4-M

3-M

13-M

11-M

4-J

1-B

6-S

5-M

2-J

6-C

3-B

4-B

1-G 3-S

Pilot (Black) europilot.tif

1-P

5-P

6-P

2-P

3-P

2-G softlite.tif

7-P

8-P

08-08-01

42

Key

B

1-B

3-B

4-B

C

1-C

2-C

3-C

5-C

6-C

J

1-J

2-J

4-J

M

1-M

2-M

3-M

4-M

5-M

8-M

11-M

13-M

14-M

G

1-G

2-G

9-H

10-H

11-H

12-H

13-H

14-H

15-H

16-H

17-H

H

1-H

2-H

3-H

4-H

6-H

7-H

8-H

18-H

Description -

185, 265 & 405 Models

185

BURNER TRAY

Burner Tray w/Burners

Burner Tray w/o Burners



Burner

Burner Orifice Natural No.50

Burner Orifice Propane No.59

301210

350079

350350

CONTROLS

Thermostat Pocket, High Limit


P.C Board Control Units

Temperature Sensor Units


M3028

600893B

601213

601226

M3029

GAS VALVE

Honeywell Gas Valve



Heat Exchanger Assembly CI(Complete)

Inlet/Outlet Header CI

Return Header CI

Tube Bundle

Baffle Kit (8)

Bolt Kit

Header Gasket

Unitherm Governor

U.G. Retainer Spring

Bypass Valve

Bypass Spring

Drain Valve


Well Retaining Clip

Inlet & Outlet Flange

Flange Gasket 1-1/2" Connections

Flange Gasket 2" Connections

Rear Drain Plug & Cover


Ignition Control

Robertshaw 100-00834 NL-3-L


Rocker Switch Units


Pressure Switch


Thermostat Knob (1)

Knob Stop (1)

Thermal Fuse

Wire Harness IID

Control Panel IID

Thermostat Shaft IID

CPVC Adapter

M3031

M650531

650903

650634

065391

800303

305138

651360

M3554

800312

800304

501750

M3265

M3694

065254

003759F

002450F

005252F

307237

001303F

800014B

062234B

850254

062235B

850252

500719

003765F

300203

003766F

800217

800080B

005264F

265

301210

350079

350350

M3028

600893B

601213

601226

M3029

M3031

M650531

650903

650634

065391

800303

305138

651360

M3555

800312

800304

501750

M3265

M3694

065258

003759F

002450F

005253F

307238

001303F

800014B

062234B

850254

062235B

850253

500719

003765F

300203

003766F

800217

800080B

005264F

405

SPMB405

SPMB403

301210

350079

350350

M3028

600893B

601213

601226

M3029

M3031

M650531

650903

650634

065391

800303

305138

651360

M3555

800312

800304

501750

M3265

M3694

065266

003759F

002450F

005255F

307240

001303F

800014B

062234B

850254

062235B

850253

500719

003765F

300203

003766F

800217

800080B

005264F

Parts list is continued on next page

»»»»»»»»»»

43

10-12-01

7-P

8-P

R-1

1-R

2-R

S

1-S

2-S

3-S

4-S

5-S

6-S

7-S

8-S

10-S

12-S

185, 265 & 405 Replacement Parts List (continued)

Key Description 185

P

1-P

2-P

3-P

4-P



Pilot Orifice Natural

Pilot Orifice Propane

Pilot Tube

Hi-Tension Wire

600799

M3274

601218

400607

650998

P

5-P

6-P

PILOT (Black)


Pilot Orifice Natural

Pilot Orifice Propane

Pilot Tube

Hi-Tension Wire

REFRACTORY

Refractory Common (Left & Right)

Refractory Uncommon

SHEETMETAL

Jacket Top (Louvred)

Flue Collecter

Door Assembly

Access Panel Set (3 Pcs.)

Side Panel Right

Side Panel Left

Side Panel Cap

Rear Panel Kit (2 Pcs.)

High Limit Cover

Up-Front Control Panel

M3685

M3687

M3688

M3690

M3696

700461

M700462

065218

065148

065162

-

307099

307100

307098

-

307280

065170

V

1-V

3-V

VENTING

Indoor Stack Kit

(Includes inner adapter panel)

"Pagoda" Top

006696

065310

006697

065312

265

600799

M3274

601218

400607

650998

M3685

M3687

M3688

M3690

M3696

700461

M700463

065219

065149

065163

-

307099

307100

307098

-

307280

065171

405

600799

M3274

601218

400607

650998

M3685

M3687

M3688

M3690

M3696

700461

700465

065221

065151

065364

-

307099

307100

307098

-

307280

065173

006699

065311

44

19-03-03

Booklet issue 12 27-08-03

Station Lane

Industrial Estate

Witney

Oxon.

Tel. 01993 778855

Fax. 01993 703407

Certikin MB055 Operating instructions

MODEL:

Operating, Installation and

Servicing Instructions for

Pool & Spa Heaters

MB055PEH

MB055

MB105

MB155

MB185

MB265

MB405

Contents

PART ONE - OWNER'S OPERATING INSTRUCTIONS

PART TWO - INSTALLATION/SERVICE INSTRUCTIONS

PART ONE - OWNER'S OPERATING INSTRUCTIONS

FOR YOUR SAFETY - READ BEFORE OPERATING

SECTION 1 / START-UP PROCEDURES

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

CARE OF YOUR HEATER

SECTION 2/CAUTION

SECTION 3/MAINTENANCE AND

CARE PROCEDURES

PART TWO - INSTALLATION/SERVICE INSTRUCTION

SECTION 1 / RECEIVING EQUIPMENT

WARNING:

SECTION 2 / GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SECTION 3 / INSTALLATION

INSTRUCTIONS

Model Input Plant Room (cm

)

055

105

155

185

265

405

(kW)

High

Inside

Low

High

Outside

Low

IN

OUT

OUT

IN

WIRING DIAGRAM 055-105-155 MODELS ONLY

WIRING DIAGRAM 185-265-405 MODELS ONLY

SECTION 4 / SERVICING INSTRUCTIONS

SECTION 5 / TROUBLE SHOOTING GUIDE

- IID DIAGNOSTIC FLOW CHART

HEATER WILL NOT FIRE

055 Model

Key

Description - 055 Model

Part Code

105 Model

Key

Description - 105 Model

Part Code

155 Model

Key

Description - 155 Model

Part Code

185, 265 & 405 Model

Key

Description -

185

265

405

Parts list is continued on next page

185, 265 & 405 Replacement Parts List (continued)

Key Description 185

265

405