WARNING: If the information in these instructions are not followed exactly, a fire
or explosion may result causing property damage, personal injury or death.
INSTALLATION AND OPERATING
INSTRUCTIONS
Atmospheric Model 130A Above-Ground Pool Spa Heater
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
Installation and service must be performed by a qualified installer, service agency,
or the gas supplier.
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 sup-
plier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Note: Retain this manual in order to reference the safety warnings and cautions, installation instructions, operation
and maintenance procedures, troubleshooting information, and service and support contact information. Keep this
manual and your installation invoice with the appliance or in another safe place.
Catalog No: 6100.59C Effective: 05-01-07 Replaces: 07-31-06 P/N 241255 Rev. 4
READ THIS MANUAL BEFORE INSTALLATION OR OPERATION.
WATER CHEMISTRY
NOTE: Corrosive water voids all warranties.
Chemical imbalance can cause severe damage to your
heater and associated equipment. Maintain your water chemistry according to Table 1. 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.
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.
CAUTION
FREE CHLORINE MUST NOT EXCEED 5 PPM WHICH CAN
DAMAGE THE HEATER AND VOID THE WARRANTY.
WATER CHEMISTRY TIPS
• Occasional chemical shock dosing of the pool or spa water
should not damage the heater providing the water is bal-
anced.
• 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.
• Further advice should be obtained from your pool or spa
builder, accredited pool shop, or chemical supplier for the
correct levels for your water.
AUTOMATIC CHLORINATORS / 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).
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. See Figure 1.
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.
Page ii
Water Chemistry
Recommended Level(s) 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
Salt (PPM)
6000 MAXIMUM 6000 MAXIMUM 6000 MAXIMUM
Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3
Total Dissolved Solids (PPM)
3000 MAXIMUM 3000 MAXIMUM 3000 MAXIMUM
Table 1. Water Chemistry.
Figure 1. Pool/Chlorinator Setup.
*Free Chlorine Must Not Exceed 5 PPM!
Heater
Filter
Auto-Chlorinator
Check Valve
Pump
Skimmer
Pool
Check Valve
Return to Pool
Table of Contents / Safety
Page 3
TABLE OF CONTENTS
WATER CHEMISTRY . . . . . . . . . . . . . . . . . . . . . . . . . .ii
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . .3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Water Temperature Safety . . . . . . . . . . . . . . . . . . .4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Ratings and Certifications . . . . . . . . . . . . . . . . . . . .4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . .4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . .5
Indoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6
Combustion and Ventilation Air (Indoor . . . . . . . . .7
Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . .8
Water Connections . . . . . . . . . . . . . . . . . . . . . . . . .9
Electrical Connections . . . . . . . . . . . . . . . . . . . . . .11
Control Adjustments - Millivolt . . . . . . . . . . . . . . . .11
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .12
Post Start-Up Inspection . . . . . . . . . . . . . . . . . . . .15
Cold Weather Operation . . . . . . . . . . . . . . . . . . . .15
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Water Pressure Switch . . . . . . . . . . . . . . . . . . . . .16
Flame Roll-Out Safety Switch . . . . . . . . . . . . . . . .16
High Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Pilot Safety - Millivolt Models . . . . . . . . . . . . . . . .17
Burner Tray Removal . . . . . . . . . . . . . . . . . . . . . .17
Gas Valve Removal . . . . . . . . . . . . . . . . . . . . . . .18
Main Burner and Orifice Removal . . . . . . . . . . . . .18
Igniter Removal and Cleaning (Electronic) . . . . . .18
Ignition Control Fault Codes . . . . . . . . . . . . . . . . .18
Pilot Removal and Cleaning (Millivolt) . . . . . . . . .18
Heat Exchanger Removal . . . . . . . . . . . . . . . . . . .18
Tube Cleaning Procedure . . . . . . . . . . . . . . . . . . .19
Desooting Procedure . . . . . . . . . . . . . . . . . . . . . .19
Immersion Well Replacement - Millivolt . . . . . . . .19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . .19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . .20
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Electronic Control Logic Flowchart . . . . . . . . . . . .22
General - Heater Will Not Fire . . . . . . . . . . . . . . .23
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . .24
SAFETY
This appliance is to be installed and operated by trained
personnel in accordance with this Installation and Operation
Manual. Be sure to read and understand the entire
Installation and Operation Manual before attempting to install
or operate this appliance. Pay specific attention to the following Safety section. Failure to follow these warnings could
result in a fire or explosion, causing property damage, bodily
injury, or death. Should you have any problems understanding the warnings and instructions in this manual, STOP, and
get help from a qualified installer, service technician, or the
gas supplier.
SAFETY WARNINGS
DANGER
FAILURE TO INSTALL THE DRAFTHOOD ON INDOOR
INSTALLATION AND PROPERLY VENT THE HEATER TO
THE OUTDOORS AS OUTLINED IN THE VENTING SECTION OF THIS MANUAL CAN RESULT IN UNSAFE OPERATION OF THE HEATER. TO AVOID THE RISK OF FIRE,
EXPLOSION, OR ASPHYXIATION FROM CARBON
MONOXIDE, NEVER OPERATE THIS HEATER UNLESS IT
IS PROPERLY VENTED AND HAS AN ADEQUATE AIR
SUPPLY FOR PROPER OPERATION. BE SURE TO
INSPECT THE VENT SYSTEM FOR PROPER INSTALLATION AT INITIAL START-UP; AND AT LEAST ANNUALLY
THEREAFTER. REFER TO THE VENTING SECTION OF
THIS MANUAL FOR MORE INFORMATION REGARDING
VENT SYSTEM INSPECTIONS.
WARNING
TO MINIMIZE THE POSSIBILITY OF IMPROPER OPERATION, SERIOUS PERSONAL INJURY, FIRE, OR DAMAGE
TO THE HEATER:
• ALWAYS KEEP THE AREAAROUND THE HEATER
FREE OF COMBUSTIBLE MATERIALS, GASOLINE,
AND OTHER FLAMMABLE LIQUIDS AND VAPORS.
• THE HEATER SHOULD NEVER BE COVERED OR
HAVE ANY BLOCKAGE TO THE FLOW OF FRESH AIR
TO THE HEATER DURING OPERATION.
CALIFORNIA PROPOSITION 65 WARNING
THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS, OR OTHER REPRODUCTIVE HARM.
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION,
SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. REFER
TO THE USER'S INFORMATION MANUAL PROVIDED
WITH THIS HEATER. INSTALLATION AND SERVICE MUST
BE PERFORMED BY AQUALIFIED INSTALLER, SERVICE
AGENCY, OR THE GAS SUPPLIER.
Safety / Introduction
Page 4
WARNING
GASOLINE, AS WELL AS OTHER FLAMMABLE MATERIALS AND LIQUIDS (ADHESIVES, SOLVENTS, ETC.), AND
THE VAPORS THEY PRODUCE, ARE EXTREMELY DANGEROUS. DO NOT HANDLE, USE, OR STORE GASOLINE
OR OTHER FLAMMABLE OR COMBUSTIBLE MATERIALS
IN THE VICINITY OF AHEATER.
CAUTION
VERIFY PROPER OPERATION AFTER SERVICING.
WATER TEMPERATURE SAFETY
Elevated water temperature can be hazardous. The U.S.
Consumer Product Safety Commission has these guidelines:
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 may cause drowsiness which could lead to
unconsciousness and subsequently result in drowning.
3. Pregnant Women Beware! Soaking in water over 102°F
(39°C) may 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.
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 spas or hot tubs.
6. Persons taking medications which induce drowsiness,
such as tranquilizers, antihistamines, anticoagulants, or
recreational drugs should not use spas or hot tubs.
INTRODUCTION
RATINGS AND CERTIFICATIONS
This pool/spa heater is design-certified and tested under
the latest requirements of ANSI Z21.56 / CSA 4.7 Standard
for Gas-Fired Pool Heaters. The heater can be used either
indoors or outdoors. If necessary, the top of the heater can
be changed after installation to accommodate indoors or outdoors.
WARNING
USE OF ANY PARTS NOT MANUFACTURED AND/OR
APPROVED BY THE MANUFACTURER WILL VOID THE
WARRANTY.
AMBIENT TEMPERATURE RATING OF COMPONENTS
Millivolt heater +32°F to +175°F
Electronic heater only -40°F to +175°F
MODEL IDENTIFICATION
The model identification number and heater serial number
are found on the heater rating plate.
Figure 2. Location of Heater Rating Plate.
The model identification number will be similar to P-
R130A-EN-X, where:
• "EP" designates an Electronic heater using Propane gas
• "EN" designates an Electronic heater using Natural gas
• "MP" designates a Millivolt heater using Propane gas
• "MN" designates a Millivolt heater using Natural gas
• "P" prefix designates plastic (Polymer) headers
• "X" suffix designates Cupro-Nickel tubing
• "C" suffix designates Copper tubing
SPECIFICATIONS
Table 2. 130ASpecifications.
UNPACKING
On receipt of the heater it is suggested that visual checks
are made for external damage to the shipping carton. If the
carton is damaged, make a note to that effect on the Bill of
Lading when signing for the shipment. Remove the heater
from the shipping packaging. Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that the
correct number of packages are received, as indicated on the
Bill of Lading.
Claims for shortages and damages must be filed with the
carrier by consignee. Authorization to return goods must be
received from the factory prior to shipping. Goods returned to
the factory without an authorized Returned Goods Receipt
number will not be accepted. All returned goods are subject
to a restocking charge.
p
)
Shipping
Weight (lbs.)
Gas
Connection
Heater Model
130A 130,000 1/2" 1-1/2" or 2" NPT
ut (BTUH
In
(NPT)
Connection
Water
Standard Heater
w/Stackless Top
140
Introduction / Installation
Page 5
When ordering parts, specify the model and serial number
of the heater. When ordering under warranty conditions,
specify the date of installation. Records of the installation
must be provided, when requested, to substantiate a claim.
Debits for defective replacement parts will not be accepted and will only be replaced in kind per the manufacturer's
standard warranties.
INSTALLATION
INSTALLATION CODES
Installations must be in accordance with local, state,
provincial, and national codes, laws, regulations and ordinances. In the absence of local codes, installations must be
in accordance with the latest editions of the:
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
• National Electrical Code, ANSI/NFPA 70
• For Canada only: CAN/CGA B149.1 and .2 installation
Code (B149.1 and .2) and CSA C22.1 C.E.C. Part 1 and
Part 2
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 beavoided, it is recommended that a suitable drain pan, with adequate
drainage, be installed under the heater. The pan
must not restrict combustion air flow.
CLEARANCES
The required minimum clearances from combustible surfaces are shown in Table 3.
BASE INSTALLATION
Heater must be mounted on a level base, such as
cementable slab, cement blocks or another non-combustible
surface. An alternate method for providing a base for combustible floors is illustrated. Heaters may not be installed on
carpeting.
Table 3. Required Minimum Clearances from Combustible
Surfaces.
*Clearance from top of vent terminal.
When installed according to the listed minimum clearances from combustible construction, the pool heater can be
serviced without removing permanent construction around
the heater.
However for ease of servicing, we recommend a clearance of at least 24" in the front, and at least 18" on the rear.
This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater.
Clearances less than these 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
NOTE: This heater is design-certified for outdoor
installation when equipped with the approved top(s)
for outdoor use.
WARNING
THE HEATER SHOULD 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.
DIMENSIONS
CLEARANCE FROM
COMBUSTIBLE CONSTRUCTION
INDOOR INSTALLATIONS:
Top* - 42" Back - 6"
Front - Alcove Right Side - 6"
Vent - 6" Left Side - 12"
OUTDOOR INSTALLATION:
Top* - Unobstructed Right Side - 6"
Back - 6" Left Side - 12"
Figure 3. 130A Dimensions.
ALTERNATE METHOD FOR PROVIDING A NON-COMBUSTIBLE BASE
12"
12"
Minimum
HEATER
Minimum
4"
Minimum
Sheet Metal
24 Gauge
Hollow concrete cinder block,
align holes and leave ends open.
Installation
Page 6
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
Heaters must not be installed under an overhang of less
than 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 heaters installed under overhangs with the use of gutters.
• For U.S. installations, the point from where the flue prod-
ucts exit the heater must be a minimum of 4 ft below, 4 ft
horizontally from, or 1 ft above any door, window or gravi-
ty 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. See Figure 6.
• 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/CGA-B149.1 and
B149.2
OUTDOOR HIGH-WIND TOP
NOTE: The outdoor high-wind top is optional equipment and does not come standard with the heater.
Use the following part numbers.
P/N 004301 (Green) P/N 011558 (Gray)
HIGH WIND CONDITIONS (OUTDOOR UNITS ONLY)
In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' from high vertical
walls, or install a wind-break so the heater is not in direct
wind current.
In areas of daily high winds, it may be necessary to
replace the outdoor stackless top with a stack adapter in
combination with a wind-resistant/weather-proof outdoor
stack. See Figure 4.
The outdoor stack serves the same function as the lowprofile stackless top and should be installed in accordance
with the same clearance requirements. Follow the installation
instructions provided with the High Wind Kit for installation.
Figure 4. Outdoor High-Wind Top.
INDOOR INSTALLATION
The heater is design-certified for indoor installation when
equipped with the approved drafthood.
NOTE: 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/CGA-B149.1 and B149.2
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 for details. Minimum allowable space is shown
on the nameplate. Follow the installation instructions provided with the Indoor Drafthood Kit for installation.
Figure 5. Indoor Drafthood.
INDOOR DRAFTHOOD
NOTE: The indoor drafthood is optional equipment
and does not come standard with the heater. Use
the following part number.
P/N 003723
HIGH-WIND
TOP
Indoor
Drafthood
Installation
Page 7
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(Canada-CAN/CGA-B149.1 and
B149.2) and any local codes that may have jurisdiction.
ALL AIR FROM INSIDE THE BUILDING
Each opening shall have a minimum net free area of 130
sq. in.
ALL AIR FROM OUTDOORS
When air is supplied directly from outside of building,
each opening shall have a minimum net free area of 33 sq.
in.
CAUTION
COMBUSTION AIR MUST NOT BE CONTAMINATED BY
CORROSIVE CHEMICAL FUMES WHICH CAN DAMAGE
THE HEATER AND VOID THE WARRANTY. DO NOT
STORE CHLORINE, BROMINE, BAQUASIL OR ACID IN
THE SAME ROOM AS THE HEATER.
VENT PIPING
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 the National Fuel Gas
Code, ANSI Z223.1 (Canada - CAN/CGA-B149.1 and
B149.2). 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 roof and walls.
For protection against rain or blockage by snow, the vent
pipe must terminate with a vent cap which complies with local
codes or, in the absence of such codes, the latest edition of
the National Fuel Gas Code, ANSI Z223.1 (Canada CAN/CGA-B149.1 and B149.2).
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.
Figure 6. Outdoor Installation Clearances.
4 ft
Minimum
4 ft
Minimum
3 ft
Minimum
10 ft
Minimum
4 ft
Minimum
1 ft
Minimum
Forced Air Inlet
Installation
Page 8
Figure 7. Vent Piping Requirements.
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.
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/CGA-B149.1 and
B149.2).
GAS CONNECTIONS
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.
Figure 8. Gas Line Sediment Trap.
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 PSIG (3.5 KPA). 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.
NOTE: Do not use Teflon tape on gas line pipe
thread. A flexible pipe sealant suitable for LP gases
is recommended.
GAS PRESSURE REGULATOR
If adjustment is needed, remove seal and turn adjustment
screw clockwise to increase pressure or counterclockwise to
decrease pressure.
Table 4. Gas Pressure.
*Static means without heater operating. Dynamic refers to heater operating.
GAS PRESSURE ADJUSTMENT LOCATIONS
Figure 9A. Honeywell DSI VR 8205 Gas Valve.
Figure 9B.
Robertshaw MV Gas Valve.
Gas Pressure* Natural Gas Propane Gas
Max Inlet (static) 10.5" W.C. 13" W.C.
Min Inlet (dynamic) 7" W.C. 11" W.C.
Manifold Gas (dynamic) 3.5" W.C. 10" W.C.
Gas Pressure Adjustment
(field supplied)
(field supplied)
(field supplied)
A.
Gas Pressure Adjustment
B.
Installation
Page 9
Figure 9C. Honeywell MV Gas Valve.
ELECTRONIC IGNITION GAS VALVES
Figure 10. Location of Gas Pressure Adjustment.
PIPE SIZING FOR GAS CONNECTIONS
Table 5. Maximum Equivalent Pipe Length.
WATER CONNECTIONS
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:
Maximum Equivalent Pipe Length
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 1/2” 3/4” 1”
Model (KBTU) N P N P N P
130A 130 15 35 60 145 200 500
Installation
Page 10
High-temperature CPVC header flanges and header
flange nuts are available as an option. If there is any possibility of back-siphoning when the pump stops, it is recommended that a check valve (or valves) also be installed in the
system.
INTERNAL AUTOMATIC BYPASS VALVE
A built-in automatic bypass valve is provided in the In/Out
header. The internal bypass valve automatically responds to
changes in water pressure in the piping system. The proper
amount of water flow is maintained through the heater under
varying pressures dictated by the conditions of the pump and
filter.
Figure 13. Internal Automatic Bypass Valve
EXTERNAL AUXILIARY BYPASS VALVE
An auxiliary bypass valve must be used when flow rates
exceed 100 GPM. Usually a high-performance pump size
larger than one 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.
Figure 14. Auxiliary Bypass Valve.
NOTE: Do not use a gate valve as an auxiliary
bypass valve.
AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is made by
feeling the inlet and outlet pipes at the heater. Outlet pipes
should be slightly warmer than inlet and comfortable to the
touch. If pipe is hot, close bypass; if cold, open bypass.
PRESSURE RELIEF VALVE INSTALLATION
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 heater to
be installed, is recommended for this heater. The maximum
pressure relief valve setting is 125 psi. This relief valve
needs to be installed on the outlet pipe from the header as
noted in Figure 15 below.
Figure 15. Pressure Relief Valve Installed.
If required, this needs to be installed in a field-supplied fitting external to the heater. The valve shall be installed in a
vertical position. Do not overtighten. Install pressure relief
valve hand tight plus 1/2 turn.
WARNING
TO AVOID WATER DAMAGE OR SCALDING DUE TO
RELIEF VALVE OPERATION, DRAIN PIPE MUST BE CONNECTED TO VALVE OUTLET AND RUN TO ASAFE 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. if relief valve does not function properly, replace it immediately.
HEAT EXCHANGER PRESSURE DROP TABLE
Table 7. 130APressure Drop Table.
FLOW (GPM) PRESSURE DROP (FT. OF HEAD)
20 5.5
30 8.3
40 8.4
50 8.5
60 8.6
70 8.7
80 10.0
90 12.5
100 14.5
Bypass Disc
Spring
Bypass Body
From Heater
To Heater
Full Port
Ball Valve
or Globe
Val ve
To Pool/Spa
Pool/Spa
Bypass Valve
From
Installation
Page 11
ELECTRICAL CONNECTIONS
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.
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.
See Figures 18 and 19 for wire ratings.
MILLIVOLT HEATERS
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.
When installing a remote switch, do not exceed 10 ft of
wiring from the heater. Use 18-gauge stranded wire.
ELECTRONIC HEATERS
NOTE: Electronic heaters come standard with a
120 VAC 3-prong power cord. For 240 VAC applications, see instructions below. Power source must be
a wired ground, with ground fault circuit interruption
circuitry.
Figure 16. Electronic Heater Power.
The Direct Spark Ignition Device automatically lights the
main burners upon a call for heat. The heater is supplied with
a dual voltage transformer for 120/240 VAC input power
hookup.
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: Input power to the heater (120 VAC) can be
supplied from the load (pump) side of time clock or
directly from the GFCI power source. It is preferred
to make connection to the load/pump side of the
time clock.
WARNING
RISK OF ELECTRICAL SHOCK. MORE THAN ONE DISCONNECT SWITCH MAY BE REQUIRED TO DE-ENERGIZE
THE EQUIPMENT BEFORE SERVICING.
Installation
Page 12
Figure 18. Wiring Diagram - Millivolt Models.
HI Limit HI Limit
BK
(In/Out) (In/Out)
O
AGS
Water
Press
O
Switch Switch
Thermostat Manual
BK
Y/BK
Switch
Gas Valve
Roll Out
R
TH/PP
W
-
TH
PP
Val ve
Pilot
+
Generator
V/BK
To Firemans Switch
(field installed)
Optional
V/BK
R
Operation
Page 13
FOR YOUR SAFETY READ BEFORE OPERATING
A. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners 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.
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.
*If you cannot reach your gas supplier, call the
fire department.
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.
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners by hand.
5. Remove heater door panel.
6. Turn gas control knob clockwise to
"Off".
7. 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 to
the next step.
8. Turn gas control knob counter-clockwise
to "On".
9. Replace heater door panel.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
1. Set the thermostat at the lowest setting.
2. Turn off all the electrical power to the appliance if service is to be performed.
3. Remove heater door panel.
4. Turn gas control knob clockwise
to "Off."
5. Replace heater door panel.
SHUT-OFF PROCEDURES
HONEYWELL
VR 8205 GAS
VALVE
GAS
INLET
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Operation
Page 14
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.
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.
*If you cannot reach your gas supplier, call the
fire department.
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.
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
then smell gas, STOP! Follow "B" in the
safety information above. If you don't smell
gas, go to the next step.
7. Locate pilot mounted on the right side panel of
the burner tray.
LIGHTING INSTRUCTIONS
8. Turn gas control knob counter-clockwise
to "Pilot"
9. Place flame to end of pilot tube. Push in
control knob all the way and hold to light pilot.
Continue to hold control knob in for about one
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
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".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
SHUT-OFF PROCEDURE
Fig.# 9265
Fig.# 9263
HONEYWELL
MILLIVOLT
GAS VALVE
INVENSYS/
ROBERTSHAW
MILLIVOLT
GAS VALVE
HONEYWELL PILOT
ROBERTSHAW PILOT
Fig.# 8083.0
Fig.# 8084.1
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.
Operation
Page 15
POST STAR T-UP INSPECTION
Feel the inlet and outlet pipes. Outlet pipe should
be only slightly warmer than the inlet. It should not be
hot.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY
FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL TO THE APPLIANCE.
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.
Figure 20. Correct Main Burner Flame Pattern.
A yellow or "floating" flame indicates restricted air openings or incorrect orifice size. Should this occur, shut the
heater off and contact the installer or gas supplier.
Figure 21. Millivolt Pilot Burner Flame.
Figure 22. DSI Igniter Location.
Head of Pilot
must be above
Burner Deck.
Igniter
Minimum Spark Gap is 0.15” - 0.18”
3/8” Nominally from burner surface
Maintenance / Service
Page 16
MAINTENANCE
The following preventative maintenance is to be per-
formed one month after start-up and semi-annually thereafter.
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. See the Desooting Procedure in the
Service Section.
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 in the
Post Start-Up Inspection section. Yellow flame means
restriction of the air openings. Lifting or blowing flame
indicates high gas pressure. Low flame means low gas
pressure. Should these occur, shut the heater off and contact your gas supplier or qualified service agency.
5. On indoor heaters, clean room intake openings to ensure
adequate flow of combustion and ventilation air.
6. Keep area around heater clear and free from combustible
materials, gasoline and other flammable and corrosive
vapors and liquids.
SERVICE
WATER PRESSURE SWITCH
The water pressure switch, ensures that the heater oper-
ates only when the filter pump is in operation. It is located on
the In/Out 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 ADJUST THE PRESSURE SWITCH UNTIL ALL
AIR HAS BEEN EVACUATED FROM THE SYSTEM AND
THE WATER FLOW RATE MEETS THE REQUIREMENTS
LISTED IN TABLE 6.
WATER PRESSURE SWITCH ADJUSTMENT
Figure 24. Water Pressure Switch Adjustment.
1. With pump and heater on, turn adjustment knob clockwise until a click is heard from the gas valve.
2. Turn adjustment knob counter-clockwise 1/4 turn.
3. Turn pump off and on several times. Heater should shut
off immediately. If it does not, repeat the above steps.
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 factorymounted pressure switch. See Illustrated Parts List
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.
CAUTION
DO NOT OPERATE THE HEATER WITHOUT THE FUNCTION OF A PROPERLY ADJUSTED WATER PRESSURE
SWITCH OR FLOW SWITCH.
FLAME ROLL-OUT SAFETY SWITCH
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, roll-out, high winds, etc.
Figure 25. Flame Roll-Out Safety Switch.
HIGH LIMITS
The heater is equipped with two automatic high limits.
Both are located in the In/Out header. Both are set to open at
135°F.
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.
HIGH LIMIT REMOVAL
Figure 26. High Limit Switch.
1. Shut off main electrical power switch to heater.
2. Remove In/Out inspection panel.
Adjustment Knob
Service
Page 17
3. Remove defective high limit and replace with a new high
limit.
4. Replace inspection panel.
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.
BURNER TRAY REMOVAL
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 igniter.
8. Remove (1) screw that mounts ground wire to burner tray.
9. Slide out burner tray.
10. Reverse above procedure to reinstall.
Igniter
Orifice
Rear Hold Down Bracket
Burner
DSI Gas Valve
(Honeywell shown)
Manifold
Orifice Placement Bracket
Burner Tray Panel
Service
Page 18
GAS VALVE REMOVAL
1. Remove burner tray from heater as described in the
Burner Tray Removal section..
2. Disconnect pilot tubing (if removing a Millivolt valve).
3. Disconnect wires to gas valve.
4. Unscrew gas valve from manifold.
5. Reverse above procedure to reinstall.
MAIN BURNER AND ORIFICE REMOVAL
1. Remove burner tray.
2. Remove screws from rear burner hold-down bracket.
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.
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.
5. Reverse above procedure to reinstall.
Figure 29. Igniter position to burners.
IGNITER REMOVAL AND CLEANING (ELECTRONIC)
1. Disconnect high tension wire from igniter.
2. Remove (2) screws that mount the igniter to the burner
tray.
3. Remove igniter from burner tray.
4. Reverse above procedure to reinstall.
Figure 30. Direct Spark Igniter.
IGNITION CONTROL FAULT CODES
The following ignition control fault codes can be used to
troubleshoot ignition problems:
Steady On - Power applied, control OK.
Steady Off - No power or control hardware fault.
1 Flash - Ignition lockout from too many trials.
2 Flashes - Ignition lockout from too many flame losses
in single call for heat.
3 Flashes - Control hardware/software fault detected.
PILOT REMOVAL AND CLEANING (MILLIVOLT)
Figure 31. Honeywell Millivolt Pilot.
A
Thermopile
Pilot
ir Opening
Orifice
Service
Page 19
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.
CAUTION
DO NOT ENLARGE HOLE IN PILOT ORIFICE.
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. Remove the jacket
top.
3. Remove the four (4) screws holding down the flue collector. Remove the flue collector.
4. Remove upper in/out access panel.
5. Disconnect all electrical wiring from in/out header.
6. Remove temperature sensor from in/out header.
7. Disconnect flange nuts on In/Out header.
8. Set aside heat exchanger side baffles.
9. Lift heat exchanger straight up using caution not to damage refractory.
10. Reverse above procedure to reinstall.
TUBE CLEANING PROCEDURE
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.
NOTE: Please remove heat exchanger from heater
prior to reaming or removing debris.
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.
DESOOTING PROCEDURE
CAUTION
SOOT MAY BE COMBUSTIBLE. WET SOOTED SURFACES
COMPLETELY PRIOR TO CLEANING. DO NOT USE STEEL
WIRE BRUSH.
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, including side
baffles.
3. Remove burner tray.
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.
NOTE: In extreme cases it may be necessary to do
high-pressure cleaning at a local car wash. DO NOT
WIRE BRUSH.
IMMERSION WELL REPLACEMENT - MILLIVOLT
Figure 33. Immersion Well Assembly.
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.
NOTE: Installation in polymer header should be
hand tight plus 1/2 turn.
REPLACEMENT PARTS
NOTE: When ordering parts, it is important that the
heater model number, serial number, and type of
gas are specified.
Any part returned for replacement under standard compa-
ny 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.
If determined defective by the Company and within war-
ranty, a like part or equal substitution will be returned, freight
collect. Credit will not be issued.
MANUFACTURER:
2151 EASTMAN AVENUE
OXNARD, CA 93030
Figure 32. Tube Cleaning Tool.
Extension Pieces (2)
Auger with Carbide Tip
Wire Brush
Troubleshooting
Page 20
TROUBLESHOOTING
MECHANICAL
These instructions are intended for use by 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 *Debris or restriction in system............ Locate the restriction and remove. Flush system and clean.
Low flow............................................... Scale forming in heat exchanger - clean heat exchanger and
check pool pH and total alkalinity.
Outlet pipes hot to touch Low flow.............................................. Scale forming in heat exchanger - clean heat exchanger and
check pool pH and total alkalinity.
Heater going on and off Dirty filter.............................................. Clean or replace filter.
continuously Low water level in pool........................ Raise water level.
External bypass setting out of
adjustment............................................ Adjust bypass.
*Pressure switch out of adjustment..... Adjust pressure switch.
Liming or scale forming in Pool water............................................ See Water Chemistry section.
exchanger Bypassing too much water................... Inspect bypass for movement, if no movement, replace.
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. (Refer to Figure 14.)
*Air starvation....................................... Refer to installation instructions.
*Improper venting................................ Follow recommended installation instructions.
*Insects or debris clogging
burner intake ports............................. Clean burners.
Pilot outage Low gas pressure................................ Adjust gas pressure.
Restricted pilot..................................... Clean pilot.
Weak pilot generator............................ Replace pilot.
Yellow lazy flame Low gas pressure................................ Adjust gas pressure.
*Insects or debris clogging
burner intake ports............................... Clean burners.
Outer jacket very hot *Broken refractory caused by
(paint blistered) shipping damage or improper
combustion......................................... Replace refractory panels.
Excessive sooting of heat exchanger.. Determine cause of sooting & correct.
Takes too long to heat Under-sized heater............................... Calculate heating capacity of heater:
pool or spa Htr
. output(BTUH)
Pool gallonage x 8.33
This does not take into account heat loss due to weather.
Filter not running long enough............. Reset time clock.
Dirty filter.............................................. Clean filter.
Gas line or meter undersized............... Refer to installation instructions.
*Debris in gas line................................ Remove debris or blow out gas line.
Leaking at well Overacid............................................... Replace well and maintain proper water chemistry.
Over chlorination.................................... Check location of chlorinator and backflow preventer.
Leaking at heat exchanger Overacid............................................... Replace heat exchanger and maintain proper water chemistry.
Over chlorination.................................... Check location of chlorinator and backflow preventer.
Gasket brittle and leaking - Heater running after pump shuts off.... See Pressure Switch Adjustment.
(overheated) Refractory damage.............................. Replace refractory.
Sooted heater....................................... Determine cause of sooting and correct.
* Indicates symptom which usually occurs on initial start-up.
Troubleshooting
Page 21
ELECTRICAL
STANDING PILOT MILLIVOLT
The following information is presented for use by 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.
Figure 34. Millivolt Troubleshooting Flowchart.
Light pilot
If pilot burner remains lit
Jump across both "TH"
wires on gas valves
If main burner fires,
remove jumper
Jump across pressure
If main burner fires,
remove jumper
Clean filter
Check for adequate water
flow from filter
Replace pressure switch
If main burner does not
switch terminals
fire, remove jumper
If main burner does not
fire, remove jumper
Jump across thermostat
If main burner fires,
remove jumper
Replace thermostat
If pilot burner goes out
when main burner lights
or when gas valve knob
Replace
gas
valve
If pilot burner stays on
Problem is a wire or
If main burner does
NOT fire...
Jump across each
high limit and remove
jumper
Replace high limit that
prevented from firing
Remove both "TH"
wires from gas valve.
component short to
cabinet or low gas
pressure
is released
Relight pilot
If pilot burner
does not light
Check gas supply, gas
line size, gas pressure.
Also check for insects
or debris in pilot assy.
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 assembly
If output is still low,
replace pilot generator
Troubleshooting
Page 22
TERMINAL BLOCK WIRING
Figure 35. Terminal Block Wiring.
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 (Invensys)
TH PP – Common (Honeywell)
3. Main Valve Load (200mV± 100)
Control/Limit circuit closed (All switches "ON")
TP(Thermopile-Robertshaw)
PP(Power Pile-Honeywell)
TH TP – Common (Invensys)
TH PP – Common (Honeywell)
Troubleshooting
Page 23
ELECTRONIC CONTROL LOGIC FLOWCHART
Figure 36. Control Logic Flowchart.
GENERAL - HEATER WILL NOT FIRE
If there is no electrical power, it may be that the home "circuit breaker" has tripped. Try re-setting it.
If there is electrical power but the heater will not fire check the following:
1. The time clock must be in the "ON" position.
2. The pump strainer basket may be full. If so remove debris.
3. The filter may be dirty. If so, backwash or clean filter. (To tell if the filter is dirty, look to see if the filter pressure will be higher than usual).
4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure; then there is
not enough moving water (or the gauge is broken). Try to get the pump to run at its normal flow rate.
START
Turn knob to a
desired temperature
zone.
Turn switch ON.
After (6)
seconds, does
the igniter
spark?
Yes
Does the
burner tray
light?
Yes
No
No
•Check water flow. Pressure switch is set for 1.75 PSI.
•Turn knob counterclockwise (setpoint may be lower
than actual temperature)
•Check High Limit. Both are normally closed.
•Check Roll-Out switch. Must be normally closed.
•Check wiring in control box against wiring diagram.
Ensure the heater is OFF. Attempt each step individually and
manually restart the heater after each attempt.
•Check gas line. There may be some air in the system.
•Make sure high tension wire is not grounding out to metal
or other voltage wire.
•Make sure high tension wire is properly connected to the
igniter.
•Check the gas valve. There must be 24VAC while the ignition
module is sparking.
Does the
burner tray
stay lit?
Yes
END
No
•Check the igniter. Igniter may not be sensing correctly.
Check that the spark plug gap is ~.18”.
Illustrated Parts List
Page 24
Illustrated Parts List
Page 25
1-P
5-P
4-P
2-P
6-P
HONEYWELL MILLIVOLT PILOT
3-P
7-P
8-P
Illustrated Parts List
Page 26
CALL Plastic Plastic
OUT DESCRIPTION Green Gray
B BURNER TRAY
1-B Burner Tray w/Burners (Sea Level)* 011578F 011578F
2-B Burner Hold Down Kit 011584F 011584F
3-B Burner 301210/10 301210/10
4-B Burner Orifice Nat. #51 (Sea Level)* 350080F/10 350080F/10
C CONTROLS
1-C Thermostat Auto Reset 135º Surface Mount 006725F 006725F
2-C Thermostat Control MV (Mechanical) 003346F 003346F
3-C Thermostat Control DSI (Solid State) 011585F 011585F
4-C PC Board 005086B 005086B
5-C Potentiometer 011586F 011586F
6-C Temperature Sensor 011587F 011587F
G GAS VALVE
1-G Combination Valve Nat. MV 011588F 011588F
H HEAT EXCHANGER
1-H Heat Exchange Assy Copper 011592F 011592F
2-H Inlet/Outlet Header Complete 011594F 011594F
3-H Return Header (Includes 6-H) 011596F 011596F
4-H
5-H Baffle 011599F 011599F
6-H Flange Nut Kit 008259F 008259F
7-H O Ring Gasket (2) 011600F 011600F
8-H Sensor Adapter DSI 006714F 006714F
9-H Bypass Kit 011601F 011601F
10-H Bypass Valve 006716F 006716F
11- H Bypass Dam / Shaft 006717F 006717F
12-H Bypass Spring 011602F 011602F
13-H Drain Plug 006721F 006721F
14-H Inlet/Outlet Header Dam 011603F 011603F
15-H Hose Adapter 1-1/2" MPT x 1-1/2" Hose 011635 011635
16-H 2" PVC Connector & Nut (2) Optional 006723F 006723F
17-H O Ring (2) Optional 006724F 006724F
J CONTROL BOX
1-J Control Box DSI (Includes 3-C) 011604F 011604F
2-J Transformer 120/240/24V 011605F 011605F
3-J Ignition Control Direct Spark 011606F 011606F
4-J Rocker Switch 009493F 009493F
*FOR ALTITUDES ABOVE 2,000 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. We recommend you inspect
the bypass assembly. Failure to do so could cause premature failure of this replacement part.
Burner Tray w/o Burners (Sea Level)* 011579F 011579F
Burner Tray w/Gas Valve Natural MV 011580F 011580F
Burner Tray w/Gas Valve Propane MV 011581F 011581F
Burner Tray w/Gas Valve Natural DSI 011582F 011582F
Burner Tray w/Gas Valve Propane DSI 011583F 011583F
Burner Orifice Pro. #59 (Sea Level)* 350350F/10 350350F/10
Combination Valve Pro. MV 011589F 011589F
Combination Valve Nat. DSI 011590F 011590F
Combination Valve Pro. DSI 011591F 011591F
Heat Exchange Assy Cupro Nickel 011593F 011593F
Inlet/Outlet Header (Includes 6-H) 011595F 011595F
Tube Bundle Copper **
Tube Bundle Cupro Nickel **
011597F 011597F
011598F 011598F
Sensor Well Millivolt 006805F 006805F
Illustrated Parts List
Page 27
CALL Plastic Plastic
OUT DESCRIPTION Green Gray
M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 1.75 PSI 006737F 006737F
Pressure Switch 11 PSI Special-See Adj in Service Manual 009133F 009133F
2-M Thermostat Knob 009499F 009499F
3-M Knob Stop 006886F 006886F
4-M Dial Plate 901768 901769
5-M PRV 125 PSI (Optional) 008091F 008091F
6-M Deliming Kit 052871F 052871F
7-M Wire Harness MV 011607F 011607F
Wire Harness DSI 011608F 011608F
(not shown)
(not shown)
(not shown)
8-M Line Cord 011609F 011609F
9-M Thermal Fuse 005899F 005899F
10-M Touch-up Paint (Green) 750125
Touch-up Paint (Dark Gray) 750126
P PILOT
1-P Pilot Nat. MV 600525B 600525B
Pilot Pro. MV 600575B 600575B
2-P Pilot Orifice Nat. MV 003901F 003901F
Pilot Orifice Pro. MV 003902F 003902F
3-P Pilot Generator MV 600019B 600019B
4-P Pilot Mounting Bracket MV 011610F 011610F
5-P Lighter Tube MV 052797 052797
6-P Pilot Tube MV 004078F 004078F
7-P Ignitor DSI 011611F 011611F
8-P Hi Tension Wire DSI 011612F 011612F
R REFRACTORY
1-R Refractory Kit 011613F 011613F
2-R Refractory Retainer Kit 011614F 011614F
S SHEETMETAL
1-S Jacket Top 011615F 011616F
2-S Jacket Left 011617F 011618F
3-S Jacket Right 011619F 011620F
4-S Jacket Rear 011621F 011622F
5-S Flue Collector 011623F 011623F
6-S Door Assy. 011624F 011625F
7-S Access Panels 011626F 011627F
8-S Control Panel 011628F 011629F
9-S Poolstat Control Cover 006492 006492
V VENTING
1-V Stackless Top (Outdoor) 011630F 011631F
2-V "Pagoda" Top 010334 011632
3-V Drafthood (Indoor) 003723 003723
4-V Outdoor Stack w/Adapter (Outdoor) 004301 011558
5-V Outdoor Stack N/A N/A
CONVERSION KITS**
GAS CONVERSIONS
Natural to Propane MV 011633F
Propane to Natural MV 011634F
Natural to Propane DSI N/A
Propane to Natural DSI N/A
** Gas Conversions are to be done only by a qualified agency.
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