INSTALLATION & OPERATING INSTRUCTIONS Gas-Fired Pool & Spa Heater Atmospheric Models 206A, 266A, 336A & 406A Lo NOx Models 207A, 267A, 337A & 407A WARNING: If 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 vapors 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 neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference. Catalog No. 6000.59Y Effective: 01-16-12 Replaces: 08-25-11 P/N 241236 Rev. 26 WATER CHEMISTRY (Corrosive water voids all warranties) For your health and the protection of your pool equipment, it is essential that your water be chemically balanced. The following levels must be used as a guide for balanced water. Fiberglass Pools Fiberglass Spas Other Pool & Spa Types Water Temp. (Deg. F) 68 to 88 89 to 104 68 to 104 pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8 Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120 Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400 4500 MAXIMUM 4500 MAXIMUM 4500 MAXIMUM 2 to 3 2 to 3 2 to 3 Recommended Level(s) Salt (PPM) Free Chlorine (PPM)* Total Dissolved Solids (PPM) 3000 MAXIMUM** 3000 MAXIMUM** 3000 MAXIMUM** * Free Chlorine MUST NOT EXCEED 5 PPM! ** In salt water chlorinated pools, the total TDS can be as high as 6000 ppm. • • • Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced. Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater, and which is not covered under warranty. A check valve should be installed between the heater outlet and a chlorinator or other chemical dosing device. Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water. Rev. 26 reflects the following: Changes to: Note on page 22, Wiring Diagrams on pages 29-30, Illustrated Parts Lists on pages 48-55. Additions: None Deletions: None 2 CONTENTS 4 PART ONE OWNER'S OPERATING INSTRUCTIONS 30 31 4 SECTION 1 START-UP PROCEDURES Before Start-Up Lighting Instructions & Shut-Off Procedures Manually Lighted Pilots MV Operating Instruction & Shut-Off Procedures Automatically Lighted Pilots IID After Start-Up SECTION 2 CAUTION SECTION 3 MAINTENANCE & CARE PROCEDURES Pool & Spa Water Chemistry Automatic Chlorinators & Chemical Feeders 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 Code Requirements Clearances Outdoor Heater Installation Florida and Texas Building Codes Indoor Heater Installation Outdoor Stack/Indoor Stack Atmospheric Specifications and Dimensions Lo NOx Specifications and Dimensions Combustion and Ventilation Air Vent Piping Gas Supply Connections Gas Pressure Regulator Gas Pressure Adjustment Locations Pipe Sizing For Gas Connections Flow Rates Heat Exchanger Pressure Drop Tables Polymer Headers Cast Iron Headers Unitherm Governor Operation Internal Automatic Bypass Valve External Auxiliary Bypass Valve Auxiliary Bypass Valve Adjustment Pressure Relief Valve Installation Plumbing—Water Connections Heat Exchanger Reversal Procedure Electrical Wiring Millivolt Models Advanced Flame Technology (AFT) Models Transformer Wiring Wiring Diagram - Millivolt (Mechanical Therm.) Wiring Diagram - AFT Models, Atmospheric 31 32 32 32 33 35 36 36 36 37 37 37 38 38 38 38 39 39 39 39 39 40 40 40 40 40 41 41 41 41 41 41 41 42 42 42 42 42 43 4 5 6 7 7 8 8 8 9 9 10 10 11 11 11 12 12 14 15 15 16 17 18 18 19 20 20 20 21 21 22 22 22 23 23 23 23 24 25 26 26 26 27 28 29 43 44 45 46 47 48 51 3 Wiring Diagram - AFT Models, Lo NOx SECTION 4 SERVICING INSTRUCTIONS General Location of Controls Control Panel Removal Control Adjustments - AFT Models Control Adjustments - Millivolt Models Thermostat Operation - AFT Board Status and Diagnostics Remote Control Installation and Operation Remote Operation Activating the Remote Remote Control Wiring 2-Wire Remote Control 3-Wire Remote Control Time Clock / Fireman’s Switch Water Pressure Switch Flame Roll-Out Safety Switch High Limits Pilot Safety Burner Tray Removal (ATM) Gas Valve Removal (ATM) Main Burner and Orifice Removal (ATM) Pilot Removal and Cleaning Heat Exchanger Removal Tube Cleaning Procedure Desooting Procedure Combustion Chamber Removal Immersion Well Replacement Unitherm Governor (U.G.) Replacement Lo NOx Pool Heaters Operation Start-Up Procedures Visual Inspection Electrical Flame Roll-Out Safety Switch Burner Tray Removal Gas Valve Removal Main Burner and Orifice Removal Pilot Removal Combustion Blower Removal SECTION 5 TROUBLESHOOTING Mechanical Electrical - Standing Pilot Millivolt Electrical - Electronic Ignition (IID) Control Logic - Flow Chart SECTION 6 REPLACEMENT PARTS Illustrated Parts List Part Numbers 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 Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with millivolt or electronic ignition. ASME-certified units, typically used in commercial applications, are also available. This manual provides installation, operation, maintenance, and service information for these heaters. ON OFF If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater contains the control center that allows you to turn the heater On or Off and adjust the temperature settings for the pool or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). See figure above for location of toggle switch to turn the heater On and Off. Section 4 of this manual contains more details about the use of the controls in the Control Adjustments subsection (page 32). BEFORE START-UP BURNERS WATER Clean main burners, combustion fan (if equipped) and air louvers 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 ventilation air. Water must be flowing through the heater during operation. Ensure that the system is filled with water and that the pump is operating. 4 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. LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES MILLIVOLT SYSTEM (MANUALLY LIGHTED PILOT) *If you cannot reach your gas supplier, call the fire department. A. This appliance has a pilot that must be lit by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING, smell all around the appliance area for gas. Be sure to smell near the floor because some gas is heavier than air and will settle on the floor. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. 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 neighbor's phone. Follow the gas supplier's instructions. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. LIGHTING INSTRUCTIONS 1. STOP! Read the safety information above. 2. Set the thermostat on the lowest setting. 3. Turn On/Off switch to the "Off" position. 4. Remove heater door panel. 5. Push in gas control knob slightly and turn clockwise to "Off". NOTE: Knob cannot be turned from "Pilot" to Off" unless knob is pushed in slightly. Do not force. 6. Wait 5 minutes to clear out any gas. If you ROBERTSHAW PILOT HONEYWELL PILOT then smell gas, STOP! Follow "B" in the safety information above. If you don't smell 8. Turn gas control knob counter-clockwise gas, go to the next step. to "Pilot" 7. Locate pilot mounted on the right side panel of 9. Place flame to end of pilot tube. Push in the burner tray. control knob all the way and hold to light pilot. Continue to hold control knob in for about one HONEYWELL minute after the pilot is lighted, release knob MILLIVOLT and it will pop back up. Pilot should remain GAS VALVE lighted. If it goes out, repeat steps 5 through 9. If knob does not pop up when released, stop and immediately call your service technician or gas supplier. 10. Stand to the side of the heater and turn the gas control knob counter-clockwise to "On". INVENSYS/ 11. Replace heater door panel. ROBERTSHAW 12. Turn On/Off switch to the "On" position. MILLIVOLT 13. Set thermostat to the desired setting. GAS VALVE 1. 2. 3. SHUT-OFF PROCEDURE Set the thermostat to the lowest setting. 4. Push the gas control knob slightly and turn Turn On/Off switch to the "Off" position. clockwise to "Off". Do not force. Remove heater door panel. 5. Replace heater door panel. 5 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. OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES ELECTRONIC IGNITION SYSTEM (AUTOMATICALLY LIGHTED PILOT) 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 near the floor because some gas is heavier than air and will settle on the floor. *If you cannot reach your gas supplier, call the fire department. 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 neighbor's phone. Follow the gas supplier's instructions. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. O STOP! Read the safety information above. HONEYWELL Set the thermostat to the lowest setting. VR 8300 GAS Turn off all electrical power to the appliance. VALVE IID This appliance is equipped with an ignition device which automatically lights the pilot. Do GAS INLET not try to light the pilot by hand. Remove heater door panel. For Honeywell valve: Turn gas control knob clockwise to "Off". For Robertshaw valve: Models 266-406: Turn gas control knob clockwise to ROBERTSHAW 7000 "Off". Model 206: Push in and move gas con- GAS VALVE IID trol lever counter-clockwise to "Off" position. Wait 5 minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go ROBERTSHAW 7200 to the next step. GAS CONTROL Turn gas control knob counter-clockwise LEVER SHOWN to "On". (Honeywell VR 8300 and IN “OFF” Robertshaw 7000) POSITION Replace heater door panel. Turn on all electrical power to the appliance. Set thermostat to desired setting. GAS If the appliance will not operate, follow the INLET instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier. SHUT-OFF PROCEDURES Set the thermostat at the lowest setting. to "Off". Make sure knob rest against stop. Turn off all the electrical power to the appliFor Robertshaw 7200 gas valve. ance if service is to be performed. Push in and move gas control lever counterRemove heater door panel. clockwise to "Off" position. For Honeywell VR 8300 and Robertshaw 5. Replace heater door panel. 7000 gas valve. Turn gas control knob clockwise F O 9. 10. 11. 12. 1. 2. 3. 4. 6 AFTER START-UP 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 heater. VISUAL INSPECTION - ATMOSPHERIC HEATERS 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. WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater, and will void the warranty. 4" MAX SECTION 2 - CAUTION Elevated water temperature can be hazardous. The U.S. Consumer Product Safety Commission has these guidelines: MAIN BURNER FLAME 1. Spa water temperatures should never exceed 104°F (40°C). A temperature of 100°F (38°C) 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. MILLIVOLT PILOT BURNER FLAME 3. Pregnant Women Beware! Soaking in water over 102°F (39°C) 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 100°F (38°C) maximum rule. A yellow or "floating" flame indicates restricted air openings or incorrect orifice 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 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 will likely 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 and periodically checked thereafter. Refer to Pressure Switch Adjustment on pg. 38 of this manual). 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 4°F (2.2°C). 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 anticoagulants, should not use spas or hot tubs. 7 SECTION 3 - MAINTENANCE AND CARE PROCEDURES 2. Your pump strainer basket may be full. remove debris. WARNING: Check the heater for possible rodent nests after long periods of non-use. 3. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, look to see if the filter pressure will be higher than usual). To be followed one month after start-up and then semiannually. If so 4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure; then you are not moving water (or your gauge is broken). Try to get the pump to run at its normal flow rate. 1. Inspect top of heater and drafthood for soot, a sticky black substance around finned tubes and "V" baffles, and open flue gas passageways. Any visible soot should be cleaned for proper operation. POOL & SPA WATER CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to the chart on page 2. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and damaging the heater. If the pH drops below 7.2, this will cause corrosion of the heat exchanger and severely damage the heater. Heat exchanger damage resulting from chemical imbalance is not covered by the warranty. CAUTION: Soot may be combustible. Wet sooted surfaces completely prior to cleaning. Do not use steel wire brush. 2. Clean main burners and pilot burner of dust and lint. 3. Inspect and operate all controls, gas valve and pressure relief valve (if equipped). 4. Make visual check of the burner and pilot flames. Flame pattern on the main burner and pilot is illustrated on page 7. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supplier or qualified service agency. AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place sanitizing chemicals in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight). 5. On indoor heaters, clean room intake openings to ensure adequate flow of combustion and ventilation air. 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. A check valve should be installed between the heater outlet and the chlorinator. CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. 6. Keep area around heater clear and free from combustible materials, gasoline and other flammable and corrosive vapors and liquids. See plumbing diagrams on page 24. NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the warranty. IF HEATER WILL NOT FIRE: If you have no electrical power, it may be that your "circuit breaker" has tripped. Try re-setting it. LO NOx BURNERS If you have electrical power but the heater will not fire check the following or see Troubleshooting section: The Lo NOx burners and orifice areas should be inspected annually. Dirt and debris can affect the operation of the heater and could damage the burners or prevent the heater from firing. DO NOT clean the burners with a wire brush. 1. The time clock must be in the "ON" position. 8 WINTERIZING THE POOL & SPA HEATER COLD WEATHER OPERATION Heaters installed outdoors in freezing climate areas may be shut down for the winter. Observe the following procedure for winterizing the heater: IMPORTANT FREEZE INFORMATION MODERATE CLIMATE: Heater operation can continue during short-term cold spells. When temperatures are between 0° and 32°F, flow (continuous pump operation) must be maintained. 1. Turn off gas valve, manual gas valve, and electrical supply to the heater. 2. Open drain plug located on the inlet/outlet header, (under water pipes). Remove the heat exchanger inspection panel on the side opposite water piping to gain access to the drain plug on the return header. Open drain plug on return header. 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. Return Header COLD CLIMATE: Prolonged operation with water temperatures below 50°F is not recommended. When starting the heater with water temperatures below 50°F, operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F can seriously damage the heater, and is not covered by the warranty. Drain Plug 3. For ASME Heaters only: Disconnect compression fittings from the pressure switch and return header that connects to the 1/4" copper tube and allow the tube to drain. For cold climate areas, please follow the winterizing procedures listed. 9 PART TWO INSTALLATION AND SERVICE INSTRUCTIONS SECTION 1 - RECEIVING EQUIPMENT The manufacturer recommends 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 factory or your local representative. 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 Bill of Lading when signing for the equipment. Remove the heater from the carton. If it is damaged, report the damage to the carrier immediately. Save the carton. These items are shipped inside a box in the carton with the heater: 1. 2. 3. 4. STANDARD UNIT (POLYMER HEADERS) "Pagoda" top 2" CPVC union with "O" rings (2) Plastic pipe finish flange for gas line Bonding lug with mounting screw (AFT models only) 1. 2. 3. 4. 5. 6. 7. 8. 9. ASME UNIT (CAST IRON HEADERS) "Pagoda" top In/Out flanges (2) 1-1/2" flange gaskets (2) 2" flange gaskets (2) Flange bolts (4) Pressure relief valve 2" CPVC adapters (2) Plastic pipe finish flange for gas line. Bonding lug with mounting screw. (AFT models only) Be sure that you receive the number of packages indicated on the Bill of Lading. When ordering parts, you must specify the model and serial numbers of the heater. See below for location of serial number. When ordering under warranty conditions, you must also specify date of installation. The Model & Serial No. can also be found inside the bezel above the display Model & Serial No. Located on Rating Plate (Alternate Location) LABEL ON CARTON Serial No. 10 SECTION 2 - GENERAL SPECIFICATIONS These heaters are design-certified and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. The appropriate top designated for each type of use is required. If necessary, the top can be changed at a later date to change from outdoor to indoor or vice versa. Millivolt heaters contain a self-generating electrical system operating between .25 and .75 VAC. Ambient Temperature Rating of Heater Components +32°F to +175°F Millivolt Heater with Honeywell Gas Valve Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F Electronic Ignition Heater* -32°F to + 175°F *Requires 120 or 240VAC Power Supply Atmospheric heaters: Rated inputs are suitable for up to 2,000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1,000 feet above sea level, as high elevation reduces combustion performance. Lo NOx heaters: Rated inputs are suitable for up to 5,000 feet elevation. For elevations above 5000 feet, consult the factory. SECTION 3 - INSTALLATION INSTRUCTIONS CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as carcinogenic to humans. When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne fibers. When cleaning spills, use wet sweeping or High Efficiency Particulate Air (HEPA) filtered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certified respiratory protection, to avoid inhalation of airborne dust and airborne fiber particles. IMPORTANT NOTICE These instructions are intended only for the use by qualified personnel, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. If your state is such, be sure your contractor bears the appropriate license. Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these instructions. 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. CODE REQUIREMENTS NOTE: The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict combustion air flow. Installation must be in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1 Part 1 and Part 2. 11 CLEARANCES ALL HEATERS For clearances from combustible surfaces, see the chart below. When installed according to the listed minimum clearances from combustible construction, the pool heater can still be serviced without removing permanent construction around the heater. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION However for ease of servicing, we recommend a clearance of at least 24” in the front, and at least 18" on the water connection side. This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater. INDOOR INSTALLATIONS: Top* - 30” (Drafthood) Back - 6” Front - Alcove (Open) Right Side - 12” (Water Side) Vent - 6” Left Side - 6” Floor** - 0” (Opposite Water Side) Clearances less than these (6” minimum), may require removal of the heater to service either the heat exchanger or the burner tray. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater. OUTDOOR INSTALLATION: Top* - Unobstructed (Outdoor Stack) Top*** - 36” (Stackless Top) Floor - 0” Right Side - 12” (Water Side) Back - 6” Left Side - 6” (Opposite Water Side) FLOORING: This heater can be installed on combustible flooring. *Clearance from top of vent terminal. **Do not install on carpeting. ***Clearance from top of heater. OUTDOOR HEATER INSTALLATION These heaters are design-certified for outdoor installation, when equipped with the approved tops designated for outdoor use. WARNING: The heater shall not be located in an area where water sprinklers, or other devices, may cause water to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage electrical components, and void the warranty. WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit. Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury. HEATER WITH OUTDOOR STACKLESS TOP Pagoda Top Installation 1. Insert tabs into keyhole (4 places). Pagoda Top Pagoda Top (Shipped inside box in heater carton) 2. Snap tabs into keyholes so as not to pull out. 12 Heaters must not be installed under an overhang of less than three 3 ft from the top of the heater. Three 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. For U.S. installations, the point from where the flue products exit the heater must be a minimum of 4 ft below, 4 ft horizontally from, or 1 ft above any door, window or gravity inlet into any building. The top surface of the heater shall be at least 3 ft above any forced air inlet, or intake ducts located within 10 ft horizontally. For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 ft below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA-B149. 4 ft Minimum 4 ft Minimum 4 ft Minimum 3 ft Minimum 1 ft 10 ft Minimum Minimum Forced Air Inlet For installations in Florida and Texas, that must comply with the Florida or Texas Building Code, follow the directions on page 14 for the installation of hurricane tie-down brackets for all models. 13 FLORIDA AND TEXAS BUILDING CODES WIND SPEED = 150 MPH, 3 SECOND GUST EXPOSURE = C 206/266/336/406 Atmospheric MODEL # B 206 20” 266 23” 336 26” 406 29” B 40” 28” 2” x 6” x 1/8” Pallet Anchor Bracket (4 Total) (Kit# 011636) 3” Min. Conc. Pad by others 1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) NOTE: Use hole closest to unit with washer overlapping edge of unit. Min. Edge Distance 6” Min. Edge Distance HOT 6” (1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) Ea. Pallet Anchor Bracket (1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) Use hole closest to unit (4 total) Ea. Pallet Anchor Bracket 3” Min. Conc. Use hole closest to unit (4 total) Pad by others 14 INDOOR HEATER INSTALLATION The heater is also design-certified for indoor installation when equipped with the approved drafthood. For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with an occupied area. Refer to the latest edition of CAN/CSA-B149 for specific requirements. Locate heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent Piping section (pg. 18-19) for details. Minimum allowable space is shown on the nameplate. WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. OUTDOOR STACK / INDOOR STACK NOTE: The outdoor and indoor stacks are optional equipment and do not come standard with the heater. INDOOR STACK KIT INCLUDES: (1) Drafthood, unpainted (1) Adapter plate (3) Mounting brackets (clips) (3) Screws (1) Instructions OUTDOOR STACK KIT INCLUDES: (1) Drafthood, painted (1) Adapter plate (3) Mounting brackets (clips) (1) Top panel cover (2) 1-foot sections of metal tape (3) Screws Clips (1) Instructions Clips Model 206A/207A 266A/267A 336A/337A 406A/407A OUTDOOR STACK Part No. 009834 009835 009836 009837 ** REFER TO INSTALLATION INSTRUCTIONS INSIDE BOX FOR INSTRUCTIONS ON HOW TO INSTALL OUTDOOR/INDOOR STACK. INDOOR STACK Part No. 009838 009839 009840 009841 15 SPECIFICATIONS AND DIMENSIONS ATMOSPHERIC UNITS Amp Draw 120 Volt 240 Volt B AFT 4 2 CL FLUE 10" D 8-7/8" 4-3/8" J* (6-5/8" ASME) (3-3/8" ASME) C INDOOR DRAFTHOOD 38" 32-11/16" 40" ELECTRICAL CONNECTION STACKLESS OUTDOOR TOP 26-5/8" (28-5/8" ASME) 13-1/4" GAS CONNECTION A 28" Shipping Weights (lbs) Standard ASME Indoor Heater Heater Gas Water w/Stackless w/Stackless DraftConn. Conn. hood Top Top (A) Cabinet Width (B) Flue Dia. (C) Indoor Drafthood (D) Heater Model BTUH Input (000) (J) Min. R206A 199.5 20” 6” 61-5/8” 10.0” 11-3/4” 3/4” 2” 187 206 14 R266A 266.0 23” 7” 62” 11.5” 11” 3/4” 2” 210 229 16 R336A 332.5 26” 8” 63” 13.0” 10-5/8” 3/4” 2” 230 249 19 R406A 399.0 29” 9” 64-9/16” 14.5” 12-1/8” 3/4” 2” 249 268 21 Designation for an AFT heater using propane gas is “EP”; an AFT heater using natural gas is “EN”. Designation for a Millivolt heater using propane gas is “MP”; a Millivolt heater using natural gas is “MN”. Prefix “C” is for cast iron (ASME) headers; “P” is for plastic (polymer) headers. Suffix “X” is for cupro-nickel tubing; “C” is for copper tubing. EXAMPLE: P-R406A-EN-X = Plastic headers, 406 model size, AFT, natural gas, cupro-nickel. Reduce input 4% for each 1000 ft above sea level when installed above 2000 ft elevation. For Canada, no de-rating is required for elevations up to 4500 ft Plastic (polymer) headers cannot be used for ASME installations. *Note: For outdoor stack, use J dimension in the table above for appropriate size PLUS six (6) inches. 16 SPECIFICATIONS AND DIMENSIONS LO NOx UNITS Amp Draw B 120 Volt 240 Volt 6 3 CL FLUE 10" 8-7/8” D C (6-5/8” ASME) 4-3/8” (3-3/8” ASME) J* INDOOR DRAFTHOOD 34” 26-1/2” STACKLESS OUTDOOR TOP ELECTRICAL CONNECTION 31-13/16" 20-1/2" (22-1/2" ASME) 7-3/4" GAS CONNECTION 28” A Shipping Weights (lbs) Standard ASME Heater Heater Indoor Water w/Stackless w/Stackless DraftConn. Top Top hood (A) Cabinet Width (B) Flue Dia. (C) Indoor Drafthood (D) Heater Model BTUH Input (000) R207A 199.5 20” 6” 55-5/8” 10.0” 11-3/4” 3/4” 2” 174 193 14 R267A 266.0 23” 7” 56” 11.5” 11” 3/4” 2” 197 216 16 R337A 332.5 26” 8” 57” 13.0” 10-5/8” 3/4” 2” 219 238 19 R407A 399.0 29” 9” 58-1/2” 14.5” 12-1/8” 3/4” 2” 237 256 21 (J) Min. Gas Conn. Designation for an AFT heater using natural gas is “EN”. Prefix “C” is for cast iron (ASME) headers; “P” is for plastic (polymer) headers. Suffix “X” is for cupro-nickel tubing; “C” is for copper tubing. EXAMPLE: P-R407A-EN-X = Plastic headers, 407 model size, AFT, natural gas, cupro-nickel. For altitudes above 5,000 ft., consult the factory. For Canada, no de-rating is required for elevations up to 4500 ft. Plastic (polymer) headers cannot be used for ASME installations. *Note: For outdoor stack, use J dimension in the table above for appropriate size PLUS six (6) inches. 17 COMBUSTION AND VENTILATION AIR (Indoor Units Only) The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings are one opening that is 12 inches from the ceiling for ventilation, and one opening that is 12 inches from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI Z223.1(CanadaCAN/CSA-B149) and any local codes that may have jurisdiction. A. All Air From Inside The Building: Each opening shall have a minimum net free area as noted: Model Square Inches Model Square Inches 206/207 200 336/337 333 266/267 266 406/407 399 B. All Air From Outdoors: When air is supplied directly from outside the building, each opening shall have a minimum net free area as noted: Model Unrestricted Opening (sq. in.) Typical Screened or Louvered Opening (sq. in.) Typical Screened and Louvered Opening (sq. in.) 206/207 50 75 100 266/267 67 101 134 336/337 84 126 168 406/407 100 150 200 CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. VENT PIPING WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter 10 of the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). As much as possible, avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal runs, the vent pipe must have a minimum of 1/4 in. per ft rise and should be supported at not more than five foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the roofs and walls. Another option for installation that requires horizontal runs is using the D-2 power vent kit option. Power Vent Kit Model 120 VAC Part No. 240 VAC Part No. 206/207 010744 009832 266/267 010744 009832 336/337 010745 009833 406/407 010745 009833 The D-2 Power Vent operates with a positve vent static pressure and with a vent gas temperature that prevents excessive condensate production in the vent, and as such, is a CATEGORY III appliance. Optional Raypak D-2 Power Vent For more information consult the D-2 Power Vent manual, (Catalog No. 6000.57.1). The power vent assembly is a fan-assisted combustion system designed for application to models 206-407. The unit, when installed as directed, is capable of operating in applications such as through-the-wall venting and reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factory-wired for 240 VAC, with capability of rewiring for 120 VAC. 18 For protection against rain or blockage by snow, the vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such codes, to the latest edition of the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). GAS SUPPLY CONNECTIONS The discharge opening must be a minimum of 2 ft vertically from the roof surface and at least 2 ft higher than any part of the building within 10 ft. Vent stack shall be at least 5 ft in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 ft horizontally from, and in no case below, unless a 4 ft horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment. The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction. Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. All gas piping should be tested after installation in accordance with local codes. Type "B" double-wall or equivalent vent pipe is recommended. However single-wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z223.1 (Canada - CAN/CSAB149). 10' OR LESS 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 1/2 psi (3.45 kPa). 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 PRESSURIZED GAS VALVES ARE NOT COVERED BY WARRANTY. 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. VENT CAP 2' MIN 2' MIN 5' MIN VENT PIPE NOTE: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare. SUPPLY PRESSURES DRAFT HOOD A minimum of 6 in. WC for atmospheric units (5 in. WC for Lo NOx units), and a maximum of 14 in. WC upstream pressure under load and no-load conditions must be provided for natural gas. A minimum of 12 in. WC and a maximum of 14 in. WC are required for propane gas under load and no-load conditions. HEATER NOTE: With venting application of two or more heaters, contact the factory. 19 GAS PRESSURE REGULATOR The gas pressure regulator is preset at 4.0 in. WC for natural gas (3.1 in. WC for Lo NOx), and 10.5 in. WC. for propane gas. The pressure at the gas valve, taken with a manometer, should be about 4.0 in. WC natural gas (3.1 in. WC for Lo NOx) and 10.5 in. WC propane gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise to increase presto decrease pressure. sure or counter-clockwise ELECTRONIC IGNITION GAS VALVES-CONTINUED Gas Pressure Adjustment NOTE: Lo NOx gas valves are non-adjustable; settings are fixed by the manufacturer (Invensys/Robertshaw). Robertshaw 7200 (Heater Model 206) Robertshaw 7000 BDER (Heater Models 266-336) MANUAL SHUT-OFF VALVE Gas Pressure Adjustment Robertshaw 7000 DERHC (Heater Model 406) UNION Non-Adjustable Gas Valve MANOMETER GAS PRESSURE TEST AT GAS VALVE Robertshaw 7000 BDERF (Heater Models 207-407) GAS PRESSURE ADJUSTMENT LOCATIONS PIPE SIZING FOR GAS CONNECTIONS MILLIVOLT GAS VALVES Maximum Equivalent Pipe Length (ft) Gas Pressure Adjustment Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in. WC Pressure Drop Propane Gas 2500 BTU/FT3 1.53 Specific Gravity @ 0.5 in. WC Pressure Drop Input Robertshaw 7000 (Heater Models 206-406) 3/4” Model (KBTU) N ELECTRONIC IGNITION GAS VALVES Gas Pressure Adjustment Honeywell VR8304 (Heater Models 206406 and 207-407) 1” P N P 1-1/4” 1-1/2” N N P 206/207 199.5 25 60 90 215 360 266/267 266.0 15 35 50 125 210 480 445 336/337 332.5 10 20 30 80 140 320 290 406/407 399.0 * 15 20 55 95 P 225 215 480 *A 3/4” gas line can be used for up to 5 ft maximum length from the gas valve in addition to the sediment trap. 20 FLOW RATES MODEL PIPE SIZE MIN. GPM MAX. GPM* 206/207 1-1/4”–1-1/2” - 2” 20 125 266/267 336/337 1-1/4”–1-1/2” - 2” 1-1/4”–1-1/2” - 2” 25 35 125 125 406/407 1-1/4”–1-1/2” - 2” 40 125 *When flow rates exceed maximum GPM an external auxiliary bypass valve is required. See external bypass valve section for details. POLYMER HEADERS CAST IRON HEADERS (ASME) HEAT EXCHANGER PRESSURE DROP TABLES CAST IRON HEADER (ASME MODELS) POLYMER HEADER (STANDARD MODELS) PLASTIC INTERNAL BAFFLE (Manufactured after 11/08) PRESSURE DROP (FT OF HEAD) FLOW GPM 206/207 20 4.0 25 4.0 4.6 30 4.0 5.2 35 4.0 5.8 5.2 40 4.6 5.8 5.2 5.2 50 4.6 6.3 6.9 6.9 60 4.6 6.9 6.9 6.9 70 4.6 8.1 9.2 9.2 80 4.6 9.2 9.8 9.8 90 6.9 10.4 10.4 10.4 100 8.1 11.0 12.1 12.1 110 10.4 11.5 13.3 13.3 120 11.0 12.7 17.9 17.9 125 11.5 13.8 20.2 20.2 266/267 336/337 406/407 21 PRESSURE DROP (FT OF HEAD) FLOW GPM 206/207 20 1.8 30 2.2 8.0 40 2.5 50 266/267 336/337 406/407 9.0 9.0 9.0 2.7 9.8 9.8 9.8 60 3.3 10.5 10.5 10.5 70 4.3 11.0 11.0 11.0 80 5.5 11.5 11.5 11.5 90 6.8 14.0 14.0 14.0 100 8.2 17.0 17.0 17.0 required, use a silicon base such as AquaLube etc. POLYMER HEADERS (STANDARD MODELS) Before attaching the 2-inch unions to the inlet/outlet header, make sure the O-rings are properly seated in the grooves. Use AquaLube or equivalent non-petroleum-based lubricant on the O-ring. Hand tighten the unions. Glue PVC piping directly to the unions. 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. #1 #2 INLET/OUTLET HEADER - POLYMER O-Ring Header Flange (CPVC) Header Flange Nut (CPVC) INLET/OUTLET HEADER - ASME High-temperature CPVC header flanges and header flange nuts are provided. If there is any possibility of back-siphoning when the pump stops, it is suggested that a check valve (or valves) also be installed in the system. Flange Gasket CAST IRON HEADERS (ASME MODELS) 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 gray. PVC may be used immediately after the supplied CPVC adapters. Header Flange UNITHERM GOVERNOR OPERATION CAUTION: The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105° and 115°F 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 100°F. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures. Header Header Flange (Supplied) CPVC Connector (Supplied) Plumbing WARNING: NEVER install PVC directly into header flanges. Use the 2" CPVC adapter supplied loose with the heater. U.G. Plug (Polymer) NOTE: Some jurisdictions require the addition of a flow switch and T&P gauge on ASME installations. Kit # 013969 can be ordered that will allow a standard ASME unit to comply with the code requirements. Unitherm Governor DO NOT use petroleum-based assembly fluids (such as petroleum jelly or lubricating oil). If assembly lube is Gasket 22 PRESSURE RELIEF VALVE INSTALLATION INTERNAL AUTOMATIC BYPASS VALVE To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure relief valve, having a capacity equal to the BTUH output of the model to be installed, is recommended for this heater. The maximum acceptable pressure relief valve setting is 125 psi. In addition to the Unitherm Governor, a built-in automatic bypass valve is provided in the in/out header. While the Unitherm Governor responds to the changes in water temperature in the heater, the internal bypass 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. A 3/4" NPT connection is provided in the Polymer header for installation of a pressure relief valve. The valve shall be installed in a vertical position. Do not overtighten. Install pressure relief valve hand tight plus 1/2 turn. Bypass Disc POLYMER HEADER (STANDARD MODELS) Spring Bypass Body Pressure Relief Valve PRV Discharge Connection EXTERNAL AUXILIARY BYPASS VALVE (Where Required) An auxiliary bypass valve should be used when flow rates exceed 125 GPM. Usually a high-performance pump size larger than two horsepower 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 below 50°F. It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets, etc. From Heater To Pool/ Spa In/Out Header Fig. #2004 A 3/4" NPT connection is provided in the header for installation of a pressure relief valve. The valve shall be installed in a vertical position. CAST IRON HEADER (ASME MODELS) To Heater PRV From Pool/ Spa AUXILIARY BYPASS VALVE (DO NOT USE GATE VALVE) NOTE: To avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outlet and run to a safe place of discharge. Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve. No shut-off valve shall be installed between the relief valve and the drain line. Valve lever should be tripped at least once a year to ensure that waterways are clear. 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. 23 PLUMBING—WATER CONNECTIONS Single Pool Heater Installation Multiple Pool Heater Installation The heater requires water flow and positive pressure to fire and operate properly. It must therefore be installed downstream of the discharge side of the filter pump. A typical installation is plumbed as follows: 1. The inlet side of the filter is plumbed directly to the discharge side of the filter pump; 2. The outlet side of the filter is then plumbed to the inlet of the heater; and 3. The outlet of the heater is plumbed to the return line to the pool or spa. The pump, filter and heater are thus plumbed in series (Salt generators and chemical feeders must be down stream of the pool heater). Plumbing from the heater back to the pool or spa must not have any valves or restriction that could prevent flow when the pump is operating. CAUTION: An additional source of heated water, e.g. a solar system, must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source. If the primary system provides adequate heat to maintain set-point, the heater will not fire. Be advised that the control panel will then display sensed water temperatures downstream of the primary heating system, rather than the temperature of the water exiting the pool. Heater must be located so that any water leaks will not damage the structure of adjacent area. PVC pipe may be glued directly into header unions (Standard models only). 24 HEAT EXCHANGER REVERSAL PROCEDURE - STANDARD MODELS 1. Remove right and left side access panels (Figure 1). 2. Disconnect wires at high limit, AGS (automatic gas shut-off), and pressure switch on the in/out header (Figure 2). 3. AFT Models: Remove the thermostat temperature sensor by loosening the compression fitting nut (Figure 3). Re-route the sensor to the left side of the heater. 4. Millivolt Models: Remove the temperature sensor bulb and retainer clip from the sensor well (Figure 4). Re-route the sensor bulb to the left side of the heater. 5. Remove (12) bolts holding the inlet/outlet and return headers to the tube sheets. Clean off tube sheet area where the gasket seats. Also clean off the header and the gasket. Apply a non-petroleum-based lubricant to the gasket such as AquaLube. Re-attach the headers to the opposite sides, making sure they are installed in an upright position (Figure 5). Do not over tighten. Torque should not exceed 7 ft/lb. 6. Reconnect high limit, AGS, and pressure switch wires. 7. AFT Models: Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting. Tighten 1/2 turn past hand-tight. 8. Millivolt Models: Insert sensor bulb and retainer clip into sensor well. 9. Allow for water flow through the heater and check for leaks. 10. Re-attach access panels to the opposite sides. Fig. #1 Fig. #2 For ASME Models call your factory representative. Fig. #3 Fig. #5 Fig. #4 25 ELECTRICAL WIRING CAUTION: Heater must be electrically grounded and bonded. Bonding lug is provided loose with the heater. Install bonding lug on lower right or left side of jacket as necessary for bonding the heater. Mounting hole is provided on the jacket. NOTE: If it is necessary to replace any of the original wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring. MILLIVOLT MODELS The Millivolt models are equipped with a self-generating electrical system in which the electrical current is provided by a pilot generator. No external electrical connections are required. NOTE: Failure to ground the heater electrically could affect the heater’s electronics. The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for heat. The heater is supplied with a dual-voltage transformer for 120 VAC or 240 VAC input power hookup. When installing a remote switch, do not exceed 10 ft of wiring from the heater. Use 18-gauge stranded wire. NOTE: See page 38 for further instructions if using a time clock/fireman’s switch. ADVANCED FLAME TECHNOLOGY (AFT) MODELS OPTION LOCATION LEFT SIDE FIELD WIRING WARNING: CONTROL BOX (FACTORY MOUNTED LOCATION) Heaters are factory-wired for 240 VAC power supply. DO NOT attempt to operate at 208 VAC. The standard field-wiring connection is on the right side of the heater. To wire the heater from the left side, follow these steps : 1. Remove the two (2) screws that hold the front door to the heater. Remove and set aside door for better access to wiring. 2. Remove the four (4) screws that hold down the junction box to the sway brace. 3. Remove the transformer cover located on the far right by removing one (1) screw. 4. Remove the two (2) screws that hold down the transformer. 5. Remove the one (1) screw that holds down the ground wires. 6. Disconnect P6 connector from PC board. 7. Remove transformer from its current location and relocate it on the far left side of the heater. 8. Re-route all high-voltage wires and ground wires through the left jacket side of heater. 9. Re-install P6 connector, ground wires (SPG), transformer, junction box, front door, and plug right side with the left side’s grommet plug. SWAY BRACE BONDING LUG (STANDARD LOCATION) BONDING LUG (OPTIONAL LOCATION) ATMOSPHERIC Wiring locations OPTION LOCATION LEFT SIDE FIELD WIRING NOTE: 7/8" dia. holes not utilized on jacket and control box can be used for fireman switch, auxiliary control interface or power vent (D-2) wiring. CONTROL BOX (FACTORY MOUNTED LOCATION) SWAY BRACE BONDING LUG (OPTIONAL LOCATION) BONDING LUG (STANDARD LOCATION) LO NOx Wiring locations 26 TRANSFORMER WIRING 120 VAC WIRING For 120 VAC input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the white wire to the “Ret” or neutral leg of the power supply. Attach the wire nut to the red wire. There should be no connection to the red wire for 120 VAC operation. For Lo NOx pool heaters attach a wire nut to each red wire independently. 120V ATMOSPHERIC HEATER 120V LOW NOx HEATER HOT HOT L1 SUPPLY SIDE RETURN or NEUTRAL BLACK L1 BLACK WHITE WHITE GREEN GREEN SUPPLY SIDE HEATER 4 WIRES RETURN or NEUTRAL BLACK BLACK BLACK WHITE WHITE WHITE GREEN GREEN HEATER 7 WIRES GROUND RED RED RED 240 VAC WIRING For 240 VAC input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the red wire to the “L2” or second hot leg of the power supply. Attach the wire nut to the white wire. There should be no connection to the white wire for 240 VAC operation. For Lo NOx pool heaters attach a wire nut to each white wire independently. WARNING: DO NOT attempt to operate the heater at 208 VAC. 240V LOW NOx HEATER 240V ATMOSPHERIC HEATER HOT HOT L1 SUPPLY SIDE BLACK L1 BLACK HOT SUPPLY SIDE L2 RED GREEN RED HEATER 4 WIRES BLACK HOT RED RED RED L2 HEATER 7 WIRES GROUND GREEN BLACK BLACK GREEN GREEN WHITE WHITE WHITE Heater must be electrically grounded and bonded in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70. (Canada - Canadian Electrical Code, CSA C22.1, Part 1 and Part 2.) NOTE: If the transformer’s primary side is wired for 120 VAC and 240 VAC is applied, damage to the transformer and PC board may result. Such damages are not covered under manufacturer’s limited warranty. NOTE: Input power to the heater (120 or 240 VAC) can be supplied from the load (pump) side of time clock or directly from the GFCI power source. It is preferred that full-time power be supplied to the heater from the GFCI power source, and that the heater be controlled by the fireman’s switch connection or using a two or three-wire remote. See pages 36-38. If using a switched GFCI power source, the heater could display false service indicators on the display panel if the pump is turned off. 27 WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT) 28 WIRING DIAGRAM - ATMOSPHERIC 29 WIRING DIAGRAM - LO NOx 30 SECTION 4 - SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS ATMOSPHERIC Drain Plug (Located in rear header) Mounted On Top Of Header HL1 - High Limit HL2 - High Limit Pressure Switch Temp Sensor/Well AFT Thermostat Circuit Board Unitherm Governor Drain Plug Roll-Out Switch Transformer Gas Valve Pilot LO NOx Drain Plug (Located in rear header) Draw Plug AFT Thermostat Circuit Board Blower Hose Mounted On Top Of Header HL1 - High Limit HL2 - High Limit Pressure Switch Temp Sensor/Well Unitherm Governor Roll-Out Switch (Manual) Blower Gas Valve Air Switch Pilot Transformer 31 CONTROL PANEL REMOVAL CONTROL ADJUSTMENTS - MILLIVOLT MODELS The water temperature is controlled by the heater thermostat on the upper front panel of the heater. The control center contains an On/Off switch and one thermostat. 1. Remove screw from front door. Set aside door for serviceability. KNURLED SCREW The thermostat is 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 knob stop ring to the desired location and re-tightening the set screw. SPA TEMPERATURE RANGE POOL TEMPERATURE RANGE 2. Remove (4) screws from sides of control panel. 3. Rotate control panel down until panel stops. Do not force. NOTE: Caution must be used to not damage controls or wiring. CONTROL ADJUSTMENTS ADVANCED FLAME TECHNOLOGY (AFT) MODELS KNOB STOP RING SET SCREW STAND-BY TEMPERATURE KNOB STOP SHOWN ABOVE IS IN THE SPA TEMPERATURE RANGE Temp Adjust Buttons Mode Button ON OFF LCD Display 32 THERMOSTAT OPERATION - ADVANCED FLAME TECHNOLOGY (AFT) BOARD Program button LCD Display Temp Buttons Mode Button The pool heater touchpad, located on the upper front panel of the heater, allows the user to select either POOL or SPA operation, and to adjust the setpoint temperature. The LCD display window indicates the mode (OFF, SPA, POOL) and the actual water temperature. A manual power switch provided below the touchpad turns the control power ON or OFF. the pilot flame current using a bar graph and numerical display. A signal of less than 4 indicates a weak flame signal and may require service. Refer to Section 5 – Troubleshooting for possible causes and corrections. Mode Button The MODE button is used to select either POOL or SPA operation. It also allows the user to turn the heater off electronically, allowing the LCD display to remain energized and to continue showing the actual water temperature. Press the DOWN button. The Supply Voltage screen indicates the voltage supplied to the control board. Normal readings range from 24 to 29 volts. Temp Buttons If the heater is in POOL or SPA mode, the desired water temperature (SETPOINT) will also be displayed and may be adjusted using the UP or DOWN buttons. SUPPLY VOLTAGE INDICATOR FLAME STRENGTH INDICATOR Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured by the amount of time that the main gas valve has been powered. The Cycle count indicates the number of on/off cycles of the heater, as measured by the number of times the pilot valve has been powered. Operation In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SETPOINT). When the water temperature is above the setpoint, “Water Temp” will alternate with “No Demand.” When the water temperature is below the setpoint and the heater is firing, “Water Temp” will alternate with “Heating.” To adjust the setpoint temperature, make sure the control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons. RUN TIME INDICATOR ALTERNATING DISPLAYS DURING HEATING Press the DOWN button. The Fault History can display up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, and proceeds through ten most recent messages in chronological order. The second line of the display shows the fault message. If there are no faults in the history buffer, the second line reads “All Faults Clear.” Service Menu and Fault History To access the Service Menu and fault history, press the MODE and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate normally while in the Service Menu. The first screen displayed is the Flame Strength indicator, which indicates FAULT HISTORY 33 Program Button 1) Remove the four screws holding the control cover, and swing the panel down so the back side of the board is visible (see page 31). Locate the Program Mode button (marked as SW1) as shown on page 33. Press and hold the button (5-7 seconds) until Set Factory Defaults appears on the display. Release the program button. Fahrenheit or Celsius Refer to step one above to access the program screen. Press the Mode button until Fahrenheit or Celsius appears on the digital display. The digital display is capable of displaying Celsius as well as Fahrenheit temperatures. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale. 2) Press the Mode button sequentially until the desired program event is reached. There are 5 different events that can be programmed. They appear in the sequence listed below: Spa Max Temp – Spa Set Point Maximum Adjustment Refer to step one above to access the program screen. Press the Mode button until Spa Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F. Resets board to factory default settings. Pool Max Temp – Pool Set Point Maximum Adjustment Refer to step one above access into the program screen. Press the Mode button until Pool Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F. Resets faults in the History File. Change from Fahrenheit to Celsius. Control Lockout The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings. To lock out the controls, press the DOWN button and Mode button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the Mode button to lock in selections. Confirm your selection and record your PIN. SPA setpoint maximum adjustment. POOL setpoint maximum adjustment. Set Factory Defaults Refer to step one above to access the program screen. Set Factory Defaults should appear on the screen. If it does not, press the Mode button until Set Factory Defaults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Defaults Set appears. This operation resets the operating program to its factory default values. Both the POOL and SPA setpoints will revert to 65°F (18.5°C) and both POOL and SPA maximum temperature settings will be 104°F (40.0°C). The Control Lockout PIN will be cleared and the control will resume normal operation. To unlock the controls, press any button to bring up the Enter PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Successfully unlocking the control will display “Lockout Cleared.” Failure to enter the correct PIN will display “Invalid PIN.” In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to Set Factory Defaults. This will clear the PIN and allow normal operation and selection of a new PIN if desired. See the Program Button directions on this page for details. Clear Faults Refer to step one above to access the program screen. Press the Mode button until Clear Faults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Faults Cleared appears. This operation resets the Fault History file to “0” and clears all the stored faults. NOTE: Both the POOL and SPA setpoints will revert back to 65°F (18.5°C) and the POOL and SPA maximum temperature settings will be 104°F (40.0°C). These setpoints will need to be readjusted to desired settings. 34 NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa. STATUS AND DIAGNOSTICS The digital thermostat models are programmed to display a variety of status and diagnostic messages, depending on the operating conditions. The following heat status messages are displayed in Pool, Spa, and Remote modes when there are no active fault conditions. Display The following conditions are displayed only while there is a demand for heat present. Condition Display Condition Heating Call for heat established, flame present Water Sw Open Water pressure switch open. Spark Spark operating No Demand Heat demand is satisfied Vent/Field Sw #1 Vent spill switch/field switch #1 open. Hi Limit 1 Fault High limit 1 open. Hi Limit 2 Fault High limit 2 open. Rollout Sw Open Rollout switch open. The following conditions are displayed in Pool, Spa and Remote modes. Display Condition Sensor Failure Thermistor temperatures disagree by more than 2°F Flow/Field SW #2 Field-supplied flow switch/field switch #2 open. Sensor Open Thermistor sensor failed open. (Below -20°F) Fan Lockout Sensor Short Thermistor sensor failed short. (Above 217°F) 3 fan switch faults within same heat demand cycle, power must be cycled to clear the fault. Flame w/o CFH Board is sensing flame when both main and pilot valves are commanded shut. Fan 5 Min Delay Heater shut down for 5 minutes because LoNox fan switch didn't close. PV Output Fault Pilot gas valve output is not in commanded state. MV Output Fault Main gas valve output is not in commanded state. LoNox Tab Fault Voltage is sensed at the Lo NOx terminal on a non-Lo NOx heater (Lo NOx tab is intact). Alternating with “No pilot sensed” - Pilot flame not estabIgnition lished within the required time (15 Lockout sec or 90 sec). (Propane Tab Alternating with “Main Ign Broken) Failure” - Pilot flame lost during the 8 second trial to ignite the main burner. Ignition Alternating with “No pilot Failure sensed” - Pilot flame not estab(Propane Tab lished within 90 seconds. Not Broken) Internal Fault Board fault, replace board. EEPROM Fault Memory fault, reset set points, replace board if fault does not clear. Clock/ Fireman Sw Time clock/fireman switch circuit is open. Low Temp Lockout Water temperature below 36°F. Alternating with “Main Ign Ign 6min Failure” - Pilot flame lost 4 times Delay within the 8 second trial to ignite the (Propane Tab main burner. Heater will lockout for Not Broken) 6 minutes before retrying. 35 REMOTE CONTROL INSTALLATION AND OPERATION CAUTION: Before installing remote controls to the AFT thermostat model heaters, read the following: The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad on the control panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is controlling the heater by displaying Remote in the display. When connecting the heater to a remote system, identify whether it is a two- or three-wire remote system. Select the appropriate instruction listed below to properly install the remote to the heater. OFF Mode Heating in the POOL Mode Heating in the SPA Mode ACTIVATING THE REMOTE To activate or deactivate the remote function, follow these steps: Pool Common (BLK/ORN) Spa Common (ORN/BLK) 7-PIN Remote Interface Harness Remote Mode Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds. 24VAC HOT (BLU) REMOTE OPERATION The AFT model heaters are equipped with the ability to work with external remote controls. The supplied 7pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote. The remote works by either making or breaking the circuit created by the remote wiring. Typically, a remote does not supply power to the heater, it only provides a switching function to turn the heater On or Off. If your remote is supplying its own voltage to the heater, it will not work with this heater and may damage the digital circuit board. The second line of the display will alternate even when the unit is off (“No Demand”). For operation of the heater using the onboard thermostatic controls with a time clock, see the “Time Clock / Fireman’s Switch” section. NOTE: When in remote operation, the keypad mode and temp buttons are disabled. Note: Electrostatic Discharge (ESD) damage can be caused by direct or indirect contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact of a finger allows the body to discharge, possibly causing device damage. This damage can be limited if the service person discharges himself, following ESD preventive/removal practices, and holds on to the heater enclosure for 5 seconds before proceeding. 36 REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration • Remote wiring must be run in a separate conduit. • Remote wiring must not be run parallel to high voltage lines. • For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5 to 2.5 in. lay and jacketed. • For runs over 30 feet, the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to 2.5 inch lay that is shielded and jacketed. • Maximum cable length is 200 feet. • For both two- and three-wire remote systems, the provided 7-pin wiring connector must be utilized. Please refer to the wiring instructions. NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board. 2-Wire Remote Control (On-Off) This application assumes that only one heating function (pool or spa) is required. 1. Turn on power to the heater. 2. For a 2-Wire Remote Control from a remote without its own sensor, push the mode button to the “POOL” or “SPA” mode and set the desired setpoint (eg. 102 °F for Spa). 3. For a 2-Wire Remote Control from a remote with its own sensor, push the mode button “POOL” or “SPA” mode and set the temperature to the highest setting available on the control. The actual setpoint will be controlled by the remote control. 4. Turn the mode button to "OFF" and remove power from the heater. 5. On the "Remote Interface Harness", connect the BLUE wire to one side of the "REMOTE" switch and connect the other side to either the ORANGE/BLACK wire for "SPA" operation or the BLACK/ORANGE wire for "POOL" operation. 6. Attach wire nut on unused wire to the "Remote Interface Harness." 7. Install the "7-Pin Remote Interface Harness" to the P8 connector and turn power “On” to the heater. To activate the remote control, see page 36. 3-Wire Remote Control Using Three-Position Switch (Pool-Off-Spa, or Low-Off-High) This application assumes that both heating functions (pool and spa) are required. 1. Turn on power to the heater. 2. Push the mode button to the "POOL" or "SPA" mode and set the desired temperature for each (eg. 80°F for Pool and 102°F for Spa). 3. Turn the mode button to "OFF" and remove power from the heater. 4. On the "Remote Interface Harness" connect the BLUE wire to one side of the "REMOTE" switch and connect the ORANGE/BLACK wire for "SPA" operation and the BLACK/ORANGE wire for the "POOL" operation. 5. Install the "Remote Interface Harness" to the P8 connector and turn power "ON" to the heater. To activate the remote control, see page 36. P8 Connector P8 Connector Wire Nut - BLK/ORN To Pool (COMM) BLK/ORN - To Pool (COMM) ORN/BLK - To Spa (COMM) ORN/BLK - To Spa (COMM) AFT Board BLU - 24VAC BLU - 24VAC 2-Wire Remote Control 3-Wire Remote Control 37 AFT Board 4. Turn the heater ON. 5. Manually turn the pressure adjustment knob clockwise until the heater shuts off. (A flat screwdriver may be necessary if knob is too tight.) 6. Slowly turn the adjustment knob counter-clockwise until the heater calls for heat again. 7. Turn an additional 1/2 turn counter-clockwise. 8. While the heater is running, check the adjustment by turning the pump off and on several times. The burners should shut off immediately when the pump is turned off. If it does not, repeat the above steps until proper operation is observed. TIME CLOCK/FIREMAN’S SWITCH To operate the heater with a time clock, connect the timer to the fireman’s switch connection in the heater’s wiring. The time clock should be of the dual switch type and set to shut off the call for heat to the pool heater 15 to 20 minutes prior to shutting down the pool pump. On millivolt heaters the fireman’s switch connection is a wire nut located in the Violet/Black wiring between the manual toggle switch and the gas valve. For AFT heaters the fireman’s switch connection is located on the 14-pin header connected to the digital control board. Splice into the red wire jumper tagged “Where necessary add “Fireman’s” switch circuit here” to connect the time clock. The fireman’s switch connection on both millivolt and AFT heaters must be a dry contact and must not supply power to the heater. Powering the fireman’s switch connection externally may damage the heater, and is not covered by warranty. MAY REQUIRE ADJUSTMENT FOR LOWER PRESSURE PRESSURE SWITCH ADJUSTMENT RANGE 5 FT. MAX MAY REQUIRE ADJUSTMENT FOR HIGHER PRESSURE 5 FT. MAX Millivolt heaters: Do not exceed 15ft of total wiring using 14 AWG stranded copper wire rated for 105ºC (221ºF) minimum. POOL OR SPA NOTE: If heater is installed outside of the limits shown, a higher pressure rated (11 psi) switch may be used. A flow switch, mounted and wired adjacent to the heater, may be used in place of the factory-mounted pressure switch. See Parts List (page 52) for 11 psi water pressure switch. TWO-SPEED PUMPS In some cases, the flow on the low-speed is insufficient to operate the heater. This is apparent when the water pressure switch cannot be further adjusted or if the heater makes banging noises or shuts off on high limit. In these cases, the pump must be run at high speed when heating the water. AFT heaters: Do not exceed 50ft of total wiring using 18 AWG stranded copper wire rated for 105ºC (221ºF) minimum. NOTE: When using a time clock, the heater will display “Clock/ Fireman Sw” when the fireman’s switch is open, indicating that the time clock has shut off the call for heat. WATER PRESSURE SWITCH The water pressure switch ensures that the heater operates only when the filter pump is in operation. It is located on the inlet/outlet header. It is factory set at 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 adjust the pressure switch to compensate for the no-flow static head. If it is necessary to adjust the water pressure switch, utilize the following procedure: CAUTION: Do not operate the heater without the function of a properly adjusted water pressure switch or flow switch. FLAME ROLL-OUT SAFETY SWITCH Atmospheric heaters are equipped with a thermal cutoff device to prevent flame roll-out in the event 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. WATER PRESSURE SWITCH ADJUSTMENT 1. Make sure the pool filter is clean before adjusting the switch. 2. Set the heater control to the OFF mode. 3. Turn the filter pump on and Adjustment Knob confirm that the pressure switch is closed (use a multimeter to check). If the pressure switch fails to close, either the switch setting is too high or not enough pressure is being supplied by the filter pump. HIGH LIMITS The heater is equipped with two automatic high limits. Both are located in the inlet/outlet header. Both are set to open at 135°F. 38 NOTE: An erratic high limit is often characteristic of an internal heat exchanger problem, e.g. scale build-up, defective bypass. Refer to Troubleshooting section (starting on page 43). MAIN BURNER AND ORIFICE REMOVAL ATMOSPHERIC MODELS 1. Remove burner tray. 2. Remove screws and burner hold-down bracket. HIGH LIMIT REMOVAL 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. 1. Shut off main electrical power switch to heater. 2. Remove inlet/outlet inspection panel. 3. Remove defective high limit and replace with a new high limit. 4. Replace inspection panel. 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 wood toothpick through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from manifold. DO NOT overtighten when reinstalling. PILOT SAFETY - Millivolt Models Heaters equipped with the standing pilot (millivolt system) have pilot generators which act as a safety device to shut off the flow of gas to the main burners and the pilot burner in case the pilot flame is extinguished. The pilot burner must be manually re-lighted to place the heater in operation again. Refer to the lighting instructions provided on the heater label. GAS VALVE PILOT BURNER GAS ORIFICE BURNER HOLD-DOWN BRACKET PILOT SAFETY - AFT Models The heater employs a pilot safety which closes the main gas valve within 8/10ths of a second whenever the pilot flame is interrupted. The pilot flame is automatically lit when the device is powered. The heater performs its own safety check and opens the main valve only after the pilot is proven to be lit. 206-406 Atmospheric 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 orifice and air opening (Honeywell MV unit only), and clean with wire or small brush. BURNER TRAY REMOVAL ATMOSPHERIC MODELS 1. Shut off main electrical power switch to heater. 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, and (2) screws that secure gas valve to jacket. 6. Disconnect wires that terminate at gas valve. 7. Disconnect hi-tension wire from PC board. 8. Slide out burner tray. 9. Reverse above procedure to reinstall. CAUTION! Do not enlarge hole in pilot orifice. 5. Reverse above procedure to reinstall. HONEYWELL MILLIVOLT PILOT GAS VALVE REMOVAL ATMOSPHERIC MODELS 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. Remove burner tray from heater. 4. Turn vertical gas pipe from manifold slightly and unscrew gas valve. 5. Reverse above procedure to reinstall. Pilot ROBERTSHAW MILLIVOLT PILOT Pilot Air Opening Orifice Orifice 39 Extension Pieces (2) Auger with Carbide Tip Wire Brush 4. Remove heat exchanger from the heater and wash with a garden hose, making sure soot is removed from spaces between fins. 5. Reverse above procedure to reinstall. HEAT EXCHANGER REMOVAL 1. Shut water, gas and electricity off, close valves and relieve pressure, then remove relief valve. Remove side inspection panels. 2. Remove top jacket holding screws. 3. Remove rear top panel. 4. Remove screws mounting the rain shield to the rear panel. Also remove the screws that mount the rain shield to the sway brace. Remove rain shield. 5. Remove the four (4) screws holding down the flue collector. Remove the flue collector. 6. Disconnect flange nuts on Inlet/Outlet header, loosen union(s) at gas pipe and slide heater away from piping. 7. Lift heat exchanger straight up using caution not to damage refractory. 8. Reverse above procedure to reinstall. Make sure the insulation strips are properly replaced on top of the refractory retainer. NOTE: In extreme cases it may be necessary to do steam cleaning at the local car wash. DO NOT WIRE BRUSH. COMBUSTION CHAMBER REMOVAL To remove combustion chamber, you must first have removed the heat exchanger. Atmospheric Heaters TUBE CLEANING PROCEDURE Lo NOx Heaters REFRACTORY PANELS - TOP VIEW Establish a regular inspection schedule, the frequency depending on the local water conditions and the severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness. IMMERSION WELL REPLACEMENT (Millivolt and ASME) 1. Shut off water to heater and drain heat exchanger. 2. Remove access panel on water connection side. 3. Remove old immersion well with bushing and sleeve. 4. Install replacement well in header. The heater may be cleaned from the return header side, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the ground-up lime dust does not get into the system. NOTE: Installation in polymer header should be hand tight plus 1/2 turn. Note that you do not remove the top panel or the heater 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 non-inhibited de-scale solvent for severe scale build-up. Well Assembly DESOOTING PROCEDURE WARNING: SOOT IS COMBUSTIBLE. EXERCISE EXTREME CARE. Soot will 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. 1. Remove top and flue collector from cabinet. 2. Remove "V" baffles from heat exchanger. 3. Remove burner tray. (See page 39). 40 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 next to the outlet pipe connection. 4. Unsnap old U.G. to remove from retainer plug. Snap in new U.G. 5. Reinstall retainer plug, taking care to lubricate gasket with a non-petroleum based grease such as AquaLube. Retainer Plug U.G. Spring Gasket To test the operation of the Unitherm Governor, place in hot water (over 110°F) and watch for movement against spring. If there is no movement, replace unit. LO NOx POOL HEATERS The Lo NOx pool heaters are certified and tested under the ANSI Z21.56/CSA 4.7 Standard for GasFired Pool Heaters. deck under cold-start conditions. After about five minutes of operation, the flames should settle down and blue tips should become visible. Lifting of flames beyond five minutes would indicate too much combustion air. The heater should be installed to meet all local codes, and the latest editions of the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA 70. VISUAL INSPECTION Flames can be observed through the opening below the plenum. Flame color is blue and evenly spread on the top surface of the burner. At least every three months a visual inspection should be made of the burners. OPERATION On call for heat, the ignition system, consisting of an electronic spark module, gas valve and pilot system, is energized. Providing the pilot is proven, the blower will start running, the main gas valve will open and the heater will operate. When the operating control is satisfied the heater will shut down. ELECTRICAL Be sure that electrical service to the heater has proper overload fuse or circuit breaker protection, wire size and connections which comply with all applicable codes. START-UP PROCEDURES 1. Turn on power to the heater with gas supply off. 2. Turn on gas supply. 3. Set controller to call for heat. 4. System should start as follows: a. Spark will turn on, pilot gas valve will open, and the blower will begin running. b. Once the blower provides pressure, the main gas valve will open. c. Heater will operate until call for heat is satisfied. FLAME ROLL-OUT SAFETY SWITCH Lo NOx heaters are equipped with a thermal cut-off device to prevent flame roll-out in the event the heat exchanger becomes blocked. It is a "manual reset" type roll-out switch that must be reset by a service technician after any over-temperature conditions have been fixed. Excessive restriction in the heat exchanger flue passage may cause the switch to disable the heater. NOTE: Door must be in place for proper operation. BLOWER ADJUSTMENT This Lo NOx pool heater is equipped with a combustion air plate (baffle) mounted on the air intake to the combustion air blower. The baffle has a hole that is utilized to control the air inlet to the blower. When the combustion air setting is proper, there will be some lifting of the flames on some areas of the burner Manual Reset Switch 41 LO NOx HEATERS (CONTINUED) MAIN BURNER AND ORIFICE REMOVAL BAFFLE MOUNTED INLET SIDE 1. Remove burner tray, following above procedure. 2. Remove pilot. See pilot removal procedure. 3. Remove (8) total screws from the burner holddown brackets, front and rear of tray. 4. Remove (8) total screws from the left and right sides of the manifold assembly. Detach the air/gas manifold assembly from the burner tray assembly. 5. Remove burners by raising them straight up off the rear end slots. 6. Use a long 9/16” socket wrench to remove orifice from the gas manifold. 7. Reverse above procedure to reinstall. COMBUSTION AIR BLOWER PILOT LOW NOx BURNER GAS ORIFICE GAS VALVE BURNER HOLD-DOWN BRACKET Electrode Alignment Detail 207-407 Lo NOx Burner Tray BURNER TRAY REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Shut off main electrical power switch to heater. Shut off gas upstream of heater. Remove front door. Disconnect gas line from gas valve. Remove (2) screws that mount burner tray to the base of the unit, and (2) screws that mount the blower box to the burner tray, and (1) screw that secures the anti-rotation bracket to the heater. Disconnect wires that terminate at gas valve. Unscrew (4) screws that secure the control box. Disconnect pilot wire from the pilot assembly. Disconnect wire connector from the combustion blower. Carefully slide out the burner tray assembly. Reverse above procedure to reinstall. Lo NOx Horizontal Pilot PILOT REMOVAL 1. Disconnect pilot tubing from gas valve. 2. Remove the pilot wire from the pilot assembly. 3. Remove (2) screws that mount the pilot assembly to the burner tray. 4. Pull the pilot assembly downwards and outwards. 5. Reverse above procedure to reinstall. COMBUSTION BLOWER REMOVAL GAS VALVE REMOVAL 1. Remove the (2) screws that secure the blower box to the burner tray. 2. Remove (2) screws that mount the blower box to the base of the heater. 3. Disconnect wire connector from the combustion blower. 4. Carefully remove blower box with combustion blower. 5. Remove (2) screws that secure combustion blower to blower box. 6. Reverse above procedure to reinstall. 1. Remove burner tray, following above procedure. 2. Disconnect, pilot tubing from gas valve. 3. Remove (2) screws that mount anti-rotation bracket to the burner tray. 4. Turn vertical gas pipe from manifold slightly and unscrew gas valve. 5. Reverse above procedure to reinstall. 42 SECTION 5 - TROUBLESHOOTING MECHANICAL IMPORTANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions. PROBLEM CAUSE SOLUTION Harmonics, or whining noise U.G. inoperative................................... *Debris or restriction in system............ *Debris in gas line................................ Low flow............................................... Heater going on and off continuously Check movement by putting in hot water (110°F or higher). If no movement, replace. Locate the restriction and remove. Flush system and clean. Remove debris or blow out gas line. Scale forming in heat exchanger - clean heat exchanger and check pool pH and total alkalinity. Dirty filter.............................................. Low water level in pool........................ External bypass setting out of adjustment............................................ *Pressure switch out of adjustment..... Clean or replace filter. Raise water level. Liming or scale forming in exchanger Pool water............................................ Bypassing too much water................... U.G. not functioning............................. See Water Chemistry on page 2. Inspect bypass for movement, if no movement, replace. Replace if no movement when heated. Sooting High flow rates..................................... Reduce by adding manual bypass valve. Adjust manual bypass valve until heater outlet water temperature is between 105°F and 110°F. Check movement by putting in hot water (110°F or higher). If no movement, replace. Refer to installation instructions. Follow recommended installation instructions. U.G. Inoperative................................... *Air starvation....................................... *Improper venting................................ *Insects or debris clogging burner intake ports............................. Adjust bypass. Adjust pressure switch. Clean burners. Pilot outage or “Weak Flame” signal Low gas pressure................................ Restricted/dirty pilot............................. Weak pilot generator............................ Adjust gas pressure. Clean pilot and/or electrode. Replace pilot. Yellow lazy flame Low gas pressure................................ *Insects or debris clogging burner intake ports............................... Adjust gas pressure. Outer jacket very hot (paint blistered) Takes too long to heat pool or spa *Broken refractory caused by shipping damage or improper combustion......................................... Excessive sooting of heat exchanger.. Under-sized heater............................... Clean burners. Replace refractory panels. Determine cause of sooting & correct. Filter not running long enough............. Dirty filter.............................................. Gas line or meter undersized............... Calculate heating capacity of heater: Htr. output(BTUH) Pool gallonage x 8.33 or refer to heater sizing chart. This does not take into account heat loss due to weather. Reset time clock. Clean filter. Refer to installation instructions. Leaking at well Overacid............................................... Replace well and maintain proper water chemistry. Leaking at heat exchanger Overacid............................................... Replace heat exchanger and maintain proper water chemistry. Gasket brittle and leaking (overheated) Heater running after pump shuts off.... Refractory damage.............................. Sooted heater....................................... See Pressure Switch Adjustment. Replace refractory. Determine cause of sooting and correct. Combustion fan not running “Fan 5 min Delay” signal or “Fan Lockout” signal Fan relay.............................................. Fan........................................................ Burned motor ...................................... Air pressure switch............................... Replace fan relay. Loose connection or failed motor. Incorrect wiring, replace blower. Replace air switch. * Indicates symptom which usually occurs on initial start-up. 43 ELECTRICAL - STANDING PILOT MILLIVOLT POOL OR SPA HEATER ELECTRICAL CHECK WITH MILLIVOLT GAS VALVE CAUTION: For qualified service personnel only. 1. Filter must be on with adequate water flow through heater. 2. Gas valve must be in "ON" position. Thermostat set higher than pool water temperature. 3. Jumpers are for temporary check only. If left in place, they could cause the heater to burn up. Light pilot If pilot burner goes out when main burner lights or when gas valve knob is released If pilot burner remains lit Jump across both "TH" wires on gas valves If main burner fires, remove jumper If main burner does not fire, remove jumper Jump across pressure switch terminals If pilot burner stays on If main burner fires, remove jumper If main burner does not fire, remove jumper Clean filter Jump across thermostat Check for adequate water flow from filter If main burner fires, remove jumper Replace pressure switch Replace thermostat Remove both "TH" wires from gas valve. Relight pilot Replace gas valve Problem is a wire or component short to cabinet or low gas pressure If main burner does NOT fire... Jump across each high limit and remove jumper Replace high limit that caused heater to fire 44 If pilot burner does not light Check gas supply, gas line size, gas pressure. Also check for insects or debris in pilot output If burner does not remain lit, attach millivolt meter and read pilot output If above 500mV, replace gas valve If below 500mV, check gas pressure. Also check for insects or debris in the pilot burner If output is still low, replace pilot generator 1 Raw Output (700mV± 100) Pilot generator disconnected from valve (knob must be held down to keep pilot on). White – Negative Red + Positive 2 Pilot Load (500mV± 100) Pilot generator connected to valve-Power applied to pilot solenoid. TP(Thermopile-Robertshaw) PP(Power Pile-Honeywell) TH TP – Common TH PP – Common 3 Main Valve Load (200mV± 100) Control/Limit circuit closed (All switches "ON") TP(Thermopile-Robertshaw) PP(Power Pile-Honeywell) TH TP – Common TH PP – Common ELECTRICAL - ELECTRONIC IGNITION IID WARNING HIGH VOLTAGE For qualified technicians ONLY NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO PC BOARD? (24 V NOMINAL) YES SPARK ACROSS IGNITER/SENSOR GAP? YES NOTE: Before troubleshooting, familiarize yourself with the start-up and check-out procedure. NO NO Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Make sure that the line voltage is NOT 208 VAC. Pull ignition lead and check spark at PC board. Spark Okay? YES NO Replace the PC board. • Check ignition cable, ground wiring, ceramic insulator and gap, and correct. • Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from excessive temperatures. TURN GAS SUPPLY ON PILOT BURNER LIGHTS? YES MAIN BURNER LIGHTS? YES SYSTEM RUNS UNTIL CALL FOR HEAT ENDS? YES NO • Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked. • Check electrical connections between PC board and pilot operator on gas control. • Check for 24 VAC across PV-MV/PV terminals on PC board. If voltage is okay, replace gas control; if not, replace PC board. NOTE: If PC board goes into lockout, reset system. Lockout is used on L.P.G. models. NO • Check for 24 VAC across MV-MV/PV terminals. If no voltage, replace module. • Check electrical connections between PC board and gas control. If okay, replace gas valve or gas control operator, i.e. pilot gas valve, flow switch etc. NO NOTE: IF PC board goes into lockout, reset system. • Check continuity of ignition cable and ground wire. NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the time of checkout. • Check that pilot flame covers flame rod and is steady and blue. • If checks are okay, replace PC board. CALL FOR HEAT ENDS SYSTEM SHUTS OFF? YES NO • Check for proper thermostat (controller) operation. • Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve. TROUBLESHOOTING ENDS 45 CONTROL LOGIC - FLOW CHART Power On Is the water temperature displayed? NO • Check On/Off switch (under lid on control panel) • Check for 120/240 volts to the transformer (time clock, circuit breaker, wire connections) • Check for 24 volts to Circuit Board (P6 connector) YES “Remote” and Water Temperature displayed (a remote control is controlling the heater) Push MODE switch to select "Pool" or "Spa" Note: Disconnect the remote by turning the remote function off. See page 36 for instructions. Push Temp arrow to scroll to desired temperature Water temperature and set temperature displayed? NO NO Is a fault code displayed and flashing? YES Diagnostic Readouts “Sensor Failure,” “Sensor Open” or “Sensor Short” Temperature sensor out of range (replace sensor) YES Sensor Failure Inspect thermister, wires, and connector at Terminal P1 Check resistance value of the thermister. Reference to chart below. Replace thermister if not within 10% of values shown below. If okay, replace Circuit Board. Sensor resistance at various temperatures “Heating” will display briefly Temp Degrees F 40 50 60 70 80 90 Resistance (k) 261.1 199.0 153.1 118.8 93.0 73.3 100 58.3 106 51.0 If okay, replace Circuit Board “Spark” Flame icon displayed and flashing? OR Water temp displayed? (pilot lit and rectified) “Water Sw Open” Pressure switch. Verify water flow and pressure CLEAN FILTER / STRAINER - backwash if neccessary. “Hi Limit 1 Fault” “Hi Limit 2 Fault” High limit switch. Verify water flow. Inspect internal Thermostat (Unitherm Governor) and bypass valve. “Rollout Sw Open” Rollout Sensor - Check for blocked heat exchanger and soot. Atmospheric Units - Replace fusible link. Lo NOx Units - Press manual reset button. “Clock/Fireman Sw” Fireman or Remote switch connected to safety loop is in the OFF mode. “Vent/Field Sw #1” Vent switch open. Check connections to the board. If extractor installed, troubleshoot extractor. NO “Ignition Lockout” Ignition lockout. Check power at pilot valve. Check spark (bad ignition circuit or hi-tension wire). Verify clean pilot orifice and clearance from igniter to ground hood. “Ignition Failure” YES Heater Fired? NO Ignition failure. Verify gas to the heater. Verify valve operation (gas present at tube fitting). Verify power at MV on P-4 Terminal on digital circuit board. Verify power to valve MV voltage. (Replace valve.) YES END 46 SECTION 6 - REPLACEMENT PARTS NOTE: To supply you with the correct part, it is important that you supply the heater model number, serial number and type of gas when applicable. If determined defective by the Company and within warranty, a like part or equal substitution will be returned, freight collect. Credit will not be issued. Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. MANUFACTURER: 2151 EASTMAN AVENUE OXNARD, CA 93030 47 3-V ATMOSPHERIC HEATERS I-S 14-M I3-S 4-V 1-V 2-S 6-HP 2-V 5-HP 7-HP I5-HP 3-HP 6-HP 4-HP 7-HP I2-S 3-R 8-C 6-S 14-M 4-S 7-S 17-HM 8-S 11-S 5-C 10-M 3-M 9-M 7-C 4-C 2-R 4-S 2-M 4-M 11-M 2-B 2-J 13-M 5-M 12-M 3-S 1-G 1-R 16-M 5-S 16-M 1-J 3-B 5-B 10-S 1-B 48 4-B 3-V LO NOx HEATERS I-S 9-M I3-S 4-V 1-V 2-S 2-V 6-HP 5-HP 7-HP I5-HP 3-HP 6-HP 8-C 3-R 9-M 4-HP I2-S 6-S 4-S 17-HM 11-S 7-S 8-S 5-C 2-J 4-C 6-M 3-J 2-R 4-S 7-M 2-M 8-M 3-B 1-G 3-S 2-B 4-B 1-R 12-M 7-C 13-M 10-M 5-B 1-B 10-S 6-B 49 12-M 5-S 1-J 13-HM 1-M 6-HM 5-HM 3-M (OPTIONAL) 6-C 14-HM 2-S 16-HM 9-S 15-HM 2-HM 3-C 7-HM 2-C 12-HM 4-HM 10-HM 4-S 3-HM 18-HM 17-HM 9-HM 8-HM 11-HM 2-P 7-P 9-P HONEYWELL IID ATMOSPHERIC PILOT POLYMER IN/OUT HEADER AND ACCESSORIES 1-P 1-P 5-P 8-P 2-P 6-P 6-P 3-P 4-P 9-P HONEYWELL MILLIVOLT PILOT IID LO NOx PILOT 50 ATMOSPHERIC HEATERS 1-B CALL OUT B 2-B 3-B 4-B 5-B C 1-C 2-C 3-C 4-C 7-C 8-C 5-C 6-C 1-G 1-HP G HP 2-HP 3-HP 4-HP 5-HP 6-HP 7-HP 8-HP 9-HP 10-HP 11-HP 12-HP 13-HP 14-HP 15-HP 16-HP 17-HP 18-HP 19-HP DESCRIPTION BURNER TRAY Burner Tray w/Burners (sea level)* Burner Tray w/o Burners (sea level)* Burner Tray w/Gas Valve Nat Millivolt Burner Tray w/Gas Valve Pro Millivolt Burner Tray w/Gas Valve Nat IID Burner Tray w/Gas Valve Pro IID Burner Spacer/Hold Down Kit Burner Burner Orifice Nat. #50 (Sea Level)* Burner Orifice Pro. #57 (Sea Level)* Burner Tray w/o Manifold w/o burners CONTROLS Thermostat Auto Reset 135 Deg Surface Mount AGS 135° (Auto Gas Shut-Off) - Red Epoxy High Limit 140° - Black Epoxy P. C. Board/Control LCD Display Units manufactured prior to 5/2011 Units manufactured From 5/2011 Fuse 5 AMP Thermostat Control MV Units Mechanical Temperature Sensor IID Units GAS VALVE Combination Valve - Nat. MV Combination Valve - Pro. MV Combination Valve - Nat. IID Combination Valve - Pro. IID HEAT EXCHANGER - POLYMER Heat Exchange Assy Copper Heat Exchange Assy Cupro Nickel Inlet/Outlet Header Complete Inlet/Outlet Header (Includes 6-HP) Return Header (Includes 6-HP) Tube Bundle Copper ** Tube Bundle Cupro Nickel ** Baffle Flange Nut Kit O Ring Gasket (2) Sensor Adapter Digital Electronic Sensor Well Millivolt Bypass Kit Bypass Valve Bypass Dam / Shaft Bypass Spring (All Sizes Included) Unitherm Governor Unitherm Governor Plug Drain Plug Inlet/Outlet Header Dam 2" PVC Connector & Nut (2) O Ring (2) Inlet/Outlet Header Baffle w/Header Dam 206A 266A 336A 406A 010391F 010395F 010399F 010403F 010407F 010411F 010415F 301210/13 350079F/13 350083F/13 010421F 010392F 010396F 010400F 010404F 010408F 010412F 010416F 301210/18 350079F/18 350083F/18 010422F 010393F 010397F 010401F 010405F 010409F 010413F 010417F 301210/22 350079F/22 350083F/22 010423F 010394F 010398F 010402F 010406F 010410F 010414F 010418F 301210/27 350079F/27 350083F/27 010424F 006725F 600892B 600893B 013464F 006725F 600892B 600893B 013464F 006725F 600892B 600893B 013464F 006725F 600892B 600893B 013464F N/A 013640F 013733F 003346F 009577F N/A 013640F 013733F 003346F 009577F N/A 013640F 013733F 003346F 009577F N/A 013640F 013733F 003346F 009577F 003898F 003899F 003900F 004306F 003898F 003899F 003900F 004306F 003898F 003899F 003900F 004306F 003898F 003899F 003900F 004306F 010043F 010356F 006827F 006706F 006707F 010059F 010364F 010038F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F 010044F 010357F 006827F 006706F 006707F 010060F 010365F 005261F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F 010045F 010358F 006827F 006706F 006707F 010061F 010366F 010040F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F 010046F 010359F 006827F 006706F 006707F 010062F 010367F 010041F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP 006723F 006724F 006826F 006723F 006724F 006826F *FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL. **WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part. 51 006723F 006724F 006826F 006723F 006724F 006826F ATMOSPHERIC HEATERS CALL OUT HM 1-HM 2-HM 15-HM 16-HM 3-HM 4-HM 5-HM 6-HM 7-HM 8-HM 9-HM 18-HM 10-HM 11-HM 12-HM 13-HM 14-HM 17-HM J 1-J 2-J M 1-M 2-M 3-M 4-M 5-M 6-M 7-M 8-M 9-M 10-M 11-M 12-M 13-M 14-M 15-M 16-M 17-M 1-P P 2-P 3-P Pilot Nat & Pro IID 4-P 5-P 6-P 7-P 8-P 9-P 10-P 11-P 1-R 2-R 3-R DESCRIPTION HEAT EXCHANGER - METAL Heat Exchange Assy.Copper ASME CI Heat Exchange Assy.Cupro Nickel ASME CI Inlet/Outlet Header ASME CI Complete Inlet/Outlet Header ASME CI Inlet & Outlet Flange Flange Gasket 1 1/2" Connections Flange Gasket 2" Connections Return Header ASME CI Tube Bundle Copper ASME * Tube Bundle Cupro Nickel ASME * Baffle Stud Bolt Kit Header Gasket (9) Unitherm Governor U.G. Retainer Spring U.G. Plug Bypass Valve Bypass Spring Drain Valve Sensor Well Well Retaining Clip Rear Drain Plug & Cover CONTROL BOX Transformer 120/240/24V Rocker Switch MISCELLANEOUS COMPONENTS Pressure Switch 1.75 PSI Pressure Switch 11 PSI Special-See Water Pressure Switch Adj. Thermostat Knob Thermostat Shaft MV Knobstop Thermal Fuse PRV 125 PSI (Optional) Deliming Kit Wire/Harness Millivolt Wire/Harness IID Control Bezel MV (Includes Dial Decal) Dial Decal MV Control Bezel (Includes Switch Decal) Units manufactured prior to 5/2011 Units manufactured From 5/2011 Switch/Decal-Membrane Units manufactured prior to 5/2011 Units manufactured From 5/2011 Control Bezel Cover Gasket Insulation (Swaybrace & Jacket Top) Touch-up Paint Green Dark Gray Cool Dark Gray Warm Dark Gray Tie Down Bracket (Optional) Texas Code Add/On (ASME Only) PILOT Pilot Nat. MV Pilot Pro. MV R Pilot Orifice Nat. MV Pilot Orifice Pro. MV Pilot Orifice Nat. IID .020 Pilot Orifice Pro. IID .012 Pilot Generator MV Pilot MTG Bracket MV Pilot Mounting Bracket IID Lighter Tube (MV Units Only) Pilot Tube Hi Tension Wire IID with Pilot Electrode Pilot Shield REFRACTORY Refractory Common Lt & Rt Refractory Uncommon (Front & Rear) Refractory Retainer Kit 206A 266A 336A 406A 010051F 010360F 006730F 012319F 003766F 062236B 800080B 006731F 010055F 010368F 010038F 007870F 800014B 062234B 013792F 013738F 062235B 850252 013793F 003765F 300203 005264F 006727F 010361F 006730F 012319F 003766F 062236B 800080B 006731F 006733F 010369F 005261F 007870F 800014B 062234B 013792F 013738F 062235B 013794F 013793F 003765F 300203 005264F 010053F 010362F 006730F 012319F 003766F 062236B 800080B 006731F 010057F 010370F 010040F 007870F 800014B 062234B 013792F 013738F 062235B 013794F 013793F 003765F 300203 005264F 010054F 010363F 006730F 012319F 003766F 062236B 800080B 006731F 010058F 010371F 010041F 007870F 800014B 062234B 013792F 013738F 062235B 013794F 013793F 003765F 300203 005264F 006736F 009493F 006736F 009493F 006736F 009493F 006736F 009493F 006737F 009133F 009499F 800307 006886F 005899F 008091F 052871F 010386F 009490F 009489F 009858F 006737F 009133F 009499F 800307 006886F 005899F 007224F 052871F 010386F 009490F 009489F 009858F 006737F 009133F 009499F 800307 006886F 005899F 007224F 052871F 010386F 009490F 009489F 009858F 006737F 009133F 009499F 800307 006886F 005899F 007224F 052871F 010386F 009490F 009489F 009858F 009491F 013491F 009491F 013491F 009491F 013491F 009491F 013491F 009492F 013492F 009487F 010350F 009492F 013492F 009487F 010350F 009492F 013492F 009487F 010350F 009492F 013492F 009487F 010350F 750125 750126 750256 750258 011636 012011 750125 750126 750256 750258 011636 012011 750125 750126 750256 750258 011636 012011 750125 750126 750256 750258 011636 012011 600525B 600575B 002003F 003901F 003902F 003903F 004308F 600019B 010352F 306692 062996 004078F 007864F 010351F 600525B 600575B 002003F 003901F 003902F 003903F 004308F 600019B 010352F 306692 062996 004078F 007864F 010351F 600525B 600575B 002003F 003901F 003902F 003903F 004308F 600019B 010352F 306692 062996 004078F 007864F 010351F 600525B 600575B 002003F 003901F 003902F 003903F 004308F 600019B 010352F 306692 062996 004078F 007864F 010351F 010088F 010089F 010387F 010088F 010090F 010388F 010088F 010091F 010389F 010088F 010092F 010390F *WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part. 52 ATMOSPHERIC HEATERS 1-S 2-S CALL OUT S 3-S 4-S 5-S 6-S 7-S 8-S 9-S 10-S 11-S 12-S 13-S 1-V 2-V 4-V 3-V V DESCRIPTION SHEETMETAL Jacket Top (Louvered) Flue Collector (Units with Polymer Header) Flue Collector (Units with Metal Header) Door Assy Raypak Green Cool Dark & Warm Dark Gray Rheem Green Cool Dark & Warm Dark Gray Ruud Green Warm Dark Gray Access Panel Set (3 Pcs Units with Polymer Header) Access Panel Set (3 Pcs. Units with Metal Header) Jacket Side Panel Right Jacket Side Panel Left Jacket Rear Panel (2 Pcs.) Poolstat Cover/Lock High Limit Cover Base Heat Shield Up Front Control Panel Green Cool Dark Gray Warm Dark Gray High Limit Shield Weather Shield VENTING Indoor Stack Kit (Includes inner adapter panel) Outdoor Stack Kit (Includes inner adapter panel) Stack Adapter Outer Stack Adapter "Pagoda" Top Green Cool Dark Gray 206A 266A 336A 406A 010047F 010071F 010075F 010048F 010072F 010076F 010049F 010073F 010077F 010050F 010074F 010078F 010378F 013859F 010379F 013860F 010380F 013861F 010381F 013862F 010382F 013863F 010383F 013864F 010384F 013865F 010385F 013866F 010382F 013867F 010311F 010312F 010376F 010377F 010372F 009505 010319F 010320F 010383F 013868F 010311F 010312F 010376F 010377F 010373F 009505 010319F 010320F 010384F 013869F 010311F 010312F 010376F 010377F 010374F 009505 010319F 010320F 010385F 013870F 010311F 010312F 010376F 010377F 010375F 009505 010319F 010320F 010321F 013887F 013891F 010342F 010325F 010322F 013888F 013892F 010342F 010326F 010323F 013889F 013893F 010342F 010327F 010324F 013890F 013894F 010342F 010328F 009838 009834 010330F 011461F 009839 009835 010331F 011462F 009840 009836 010332F 011463F 009841 009837 010333F 011464F 010334 013883F 010335 013884F 010336 013885F 010337 013886F 266A 336A 406A 004690B 010419F ** ** 004692B 010420F ** ** 004692B 010420F ** ** Atmospheric CONVERSION KITS* 206A Gas Conversions Nat. to Pro. MV Pilot 004690B Pro. to Nat. MV Pilot 010419F Nat. to Pro. IID Pilot ** Pro. to Nat. IID Pilot ** * Gas conversions are to be done only by a qualified agency. ** Conversion must be made with complete burner tray and gas valve (see item 1-B). 53 LO NOx HEATERS CALL OUT BB DESCRIPTION 207A 267A BURNER TRAY*** Burner Tray w/Burners (0-5000) 010343F 010344F 1-B Burner Tray w/o Burner (0-5000) 010084F 010085F 2-B Burner Hold Down Kit 010254F 010255F 3-B Burner 310732/3 310732/4 4-B Burner Orifice Nat. #26 (0-5000)* 351632/3 351632/4 351523/3 351523/4 Burner Orifice Nat. #31 (above 5000 ft.)* 5-B Blower 010042F 010042F 7-B Cooling Fan 010871F 010871F 6-B Combustion Air Orifice Plate 010338F 010339F C CONTROLS Thermostat Auto Reset 135 Deg Surface Mount 006725F 006725F 1-C 2-C AGS 135° (Auto Gas Shut-Off) - Red Epoxy 600892B 600892B 3-C High Limit 140° - Black Epoxy 600893B 600893B 4-C P. C. Board/Control 013464F 013464F 5-C LCD Display Units manufactured prior to 1/2011 N/A N/A Units manufactured From 1/2011 013640F 013640F 8-C Fuse 5 AMP 013733F 013733F Temperature Sensor 009577F 009577F 6-C 7-C Blower Pressure Switch 008062F 008135F G GAS VALVE 1-G Combination Valve - Gas On/Off -Nat 010329F 010329F HEAT EXCHANGER - POLYMER HP 1-HP Heat Exchange Assy Copper 010043F 010044F 010356F 010357F Heat Exchange Assy Cupro Nickel 2-HP Inlet/Outlet Header Complete 006827F 006827F Inlet/Outlet Header (Includes 6-HP) 006706F 006706F 3-HP Return Header (Includes 6-HP) 006707F 006707F 4-HP Tube Bundle Copper ** 010059F 010060F Tube Bundle Cupro Nickel ** 010364F 010365F 5-HP Baffle 010038F 005261F 6-HP Flange Nut Kit 008259F 008259F 7-HP O Ring Gasket (2) 006713F 006713F 8-HP Sensor Adapter Digital Electronic 006714F 006714F Sensor Well Millivolt 006805F 006805F 9-HP Bypass Kit 006715F 006715F 10-HP Bypass Valve 006716F 006716F 11-HP Bypass Dam / Shaft 006717F 006717F 12-HP Bypass Spring (All Sizes Included) 006718F 006718F 13-HP Unitherm Governor 006719F 006719F 14-HP Unitherm Governor Plug 006720F 006720F 15-HP Drain Plug 006721F 006721F N/A Use 19-HP N/A Use 19-HP 16-HP Inlet/Outlet Header Dam 17-HP 2" PVC Connector & Nut (2) 006723F 006723F 18-HP O Ring (2) 006724F 006724F 19-HP Inlet/Outlet Header Baffle w/Header Dam 006826F 006826F HM HEAT EXCHANGER - METAL 1-HM Heat Exchange Assy.Copper ASME CI 010051F 006727F Heat Exchange Assy.Cupro Nickel ASME CI 010360F 010361F 2-HM Inlet/Outlet Header ASME CI (Complete) 006730F 006730F Inlet/Outlet Header ASME CI 012319F 012319F 15-HM Inlet & Outlet Flange 003766F 003766F 16-HM Flange Gasket 1 1/2" Connections 062236B 062236B Flange Gasket 2" Connections 800080B 800080B 3-HM Return Header ASME CI 006731F 006731F 4-HM Tube Bundle Copper ASME ** 010055F 006733F Tube Bundle Cupro Nickel ASME ** 010368F 010369F 5-HM Baffle 010038F 005261F 6-HM Stud Bolt Kit 007870F 007870F 7-HM Header Gasket (9) 800014B 800014B 8-HM Unitherm Governor 062234B 062234B 9-HM U.G. Retainer Spring 013792F 013792F 18-HM U.G. Plug 013738F 013738F 10-HM Bypass Valve 062235B 062235B 11-HM Bypass Spring 850252 013794F 12-HM Drain Valve 013793F 013793F 13-HM Sensor Well 003765F 003765F 14-HM Well Retaining Clip 300203 300203 17-HM Rear Drain Plug & Cover 005264F 005264F *FOR INSTALLATIONS AT OVER 5,000 FEET ABOVE SEA LEVEL, CONSULT THE FACTORY **WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part. ***Replacement burner trays are built for sea level, natural gas applications unless otherwise specified at the time the order is placed. 54 337A 407A 010345F 010086F 010256F 310732/5 351632/5 351523/5 010042F 010871F 010340F 010346F 010087F 010257F 310732/6 351632/6 351523/6 010042F 010871F 010341F 006725F 600892B 600893B 013464F 006725F 600892B 600893B 013464F N/A 013640F 013733F 009577F 010354F N/A 013640F 013733F 009577F 010355F 010329F 010329F 010045F 010358F 006827F 006706F 006707F 010061F 010366F 010040F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F 010046F 010359F 006827F 006706F 006707F 010062F 010367F 010041F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F N/A Use 19-HP N/A Use 19-HP 010053F 010362F 006730F 012319F 003766F 062236B 800080B 006731F 010057F 010370F 010040F 007870F 800014B 062234B 013792F 013738F 062235B 013794F 013793F 003765F 300203 005264F 010054F 010363F 006730F 012319F 003766F 062236B 800080B 006731F 010058F 010371F 010041F 007870F 800014B 062234B 013792F 013738F 062235B 013794F 013793F 003765F 300203 005264F 006723F 006724F 006826F 006723F 006724F 006826F LO NOx HEATERS CALL OUT J 1-J 2-J 3-J 1-M M 2-M 3-M 4-M 5-M 6-M 7-M 8-M 9-M 10-M 11-M 12-M 13-M 14-M P 1-P 2-P 3-P 4-P 5-P 6-P R 1-R 2-R 3-R S 1-S 2-S 3-S 4-S 5-S 6-S 7-S 8-S 9-S 10-S 11-S 12-S 13-S 1-V 2-V 4-V 3-V V DESCRIPTION CONTROL BOX Transformer 120/240/24V Rocker Switch Relay Low Nox MISCELLANEOUS COMPONENTS Pressure Switch 1.75 PSI Pressure Switch 11 PSI Special-See Water Pressure Switch Adj. Roll-Out Switch 300ºF PRV 125 PSI (Optional) Deliming Kit Wire/Harness Control Bezel (Includes Switch Decal) Units manufactured prior to 1/2011 Units manufactured From 1/2011 Switch/Decal-Membrane Units manufactured prior to 1/2011 Units manufactured From 1/2011 Control Bezel Cover Gasket Insulation (Swaybrace & Jacket Top) Blower / Air Pressure Switch Sample Tube Touch-up Paint Green Dark Gray Cool Dark Gray Warm Dark Gray Tie Down Bracket (Optional) Roll-Out Switch 250ºF (Optional) Roll-Out Switch 250ºF (Upgrade) Texas Code Add/On (ASME Only) PILOT Pilot Nat. IID Low Nox Pilot Electrode Pilot Mounting Bracket Pilot Tube Hi Tension Wire IID Adapter Nut (Metric) REFRACTORY Refractory Common (Left & Right) Refractory Uncommon (Front and Rear) Refractory Retainer Kit SHEETMETAL Jacket Top (Louvered) Flue Collector (Units with Polymer Header) Flue Collector (Units with Metal Header) Door Assy. Raypak Green Cool Dark & Warm Dark Gray Rheem Green Cool Dark & Warm Dark Gray Ruud Green Warm Dark Gray Access Panel Set (3 Pcs. Units with Polymer Header) Access Panel Set (3 Pcs. Units with Metal Header) Jacket Side Panel Right Jacket Side Panel Left Jacket Rear Panel (2 Pcs.) Poolstat Cover/Lock High Limit Cover Base Heat Shield Up Front Control Panel Green Cool Dark Gray Warm Dark Gray High Limit Shield Weather Shield VENTING Indoor Stack Kit (Includes inner adapter panel) Outdoor Stack Kit (Includes inner adapter panel) Stack Adapter Outer Stack Adapter "Pagoda" Top Green Cool Dark Gray 55 207A 267A 337A 407A 006736F 009493F 008784F 006736F 009493F 008784F 006736F 009493F 008784F 006736F 009493F 008784F 006737F 009133F 006035F 008091F 052871F 010347F 006737F 009133F 006035F 007224F 052871F 010347F 006737F 009133F 006035F 007224F 052871F 010347F 006737F 009133F 006035F 007224F 052871F 010347F 009491F 013491F 009491F 013491F 009491F 013491F 009491F 013491F 009492F 013492F 009487F 010350F 010348F 009492F 013492F 009487F 010350F 010348F 009492F 013492F 009487F 010350F 010348F 009492F 013492F 009487F 010350F 010348F 750125 750126 750256 750258 011636 011745F 011733F 012011 750125 750126 750256 750258 011636 011745F 011733F 012011 750125 750126 750256 750258 011636 011745F 011733F 012011 750125 750126 750256 750258 011636 011745F 011733F 012011 010232F N/A 010233F 011926F 010349F 011927F 010232F N/A 010234F 011926F 010349F 011927F 010232F N/A 010235F 011926F 010349F 011927F 010232F N/A 010236F 011926F 010349F 011927F 010079F 010080F 010262F 010079F 010081F 010263F 010079F 010082F 010264F 010079F 010083F 010265F 010047F 010063F 010067F 010048F 010064F 010068F 010049F 010065F 010069F 010050F 010066F 010070F 010267F 013871F 010268F 013872F 010269F 013873F 010270F 013874F 010271F 013875F 010272F 013876F 010273F 013877F 010274F 013878F 010271F 013879F 010311F 010312F 010313F 010314F 010315F 009505 010319F 010320F 010272F 013880F 010311F 010312F 010313F 010314F 010316F 009505 010319F 010320F 010273F 013881F 010311F 010312F 010313F 010314F 010317F 009505 010319F 010320F 010274F 013882F 010311F 010312F 010313F 010314F 010318F 009505 010319F 010320F 010321F 013887F 013891F 010342F 010325F 010322F 013888F 013892F 010342F 010326F 010323F 013889F 013893F 010342F 010327F 010324F 013890F 013894F 010342F 010328F 009838 009834 010330F 011461F 009839 009835 010331F 011462F 009840 009836 010332F 011463F 009841 009837 010333F 011464F 010334 013883F 010335 013884F 010336 013885F 010337 013886F www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.