Certikin MB055PEH, MB055, MB105, MB155, MB185 Operating, Installation And Servicing Instructions

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

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

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

Operating, Installation and
Servicing Instructions for

Pool & Spa Heaters

M3556

MB055PEH

MB055
MB105
MB155
MB185
MB265
MB405

0087

MB055 MB105 MB155 MB185 - MB265 - MB405

Natural Gas L.P.G.

MODEL: MB055PEH MB055 MB105 MB155 MB185 MB265 MB405

1

01-10-98

2 PART ONE - OWNER'S OPERATING INSTRUCTIONS

2 SECTION 1 / START-UP PROCEDURES

2 Before Start-Up

3 Operating Instruction & Shut-Off Procedures

4 After Start-Up

4 SECTION 2 / CAUTION

4 SECTION 3 / MAINTENANCE & CARE PROCEDURE

5 Pool & Spa Water Chemistry
5 Cold Weather Operation
5 Winterizing the Pool & Spa Heater

6 PART TWO - INSTALLATION/SERVICE INSTRUCTIONS

6 SECTION 1 / RECEIVING EQUIPMENT

6 SECTION 2 / GENERAL SPECIFICATIONS

8 SECTION 3 / INSTALLATION INSTRUCTIONS

11 Outdoor Heaters
11 Indoor Heaters
14 Combustion Air
15 Gas Supply Connections
16 Plumbing For Water Connections
16 Left Side Water Connection Conversion
20 Electrical Wiring

23 SECTION 4 / SERVICING INSTRUCTIONS

23 General Location of Controls
25 Temperature Controls
25 Pressure Switch
26 High Limit
27 Pilot Safety
27 Burner Drawer Removal
27 Gas Valve Removal
27 Main Burner & Orifice Removal
27 Pilot Removal & Cleaning
28 Heat Exchanger Removal
28 Control Immersion Well Replacement
28 Tube Cleaning
29 Desooting Procedure
29 Combustion Chamber Removal
29 Unitherm Governor Replacement

30 SECTION 5 / TROUBLE SHOOTING GUIDE

30 Mechanical
32 Electrical IID Units 055, 105 & 155.
34 Electrical IID Units 185, 265 & 405.

36 SECTION 6 / REPLACEMENT PARTS

36 Replacement Parts List - 055
38 Replacement Parts List - 105
40 Replacement Parts List - 155
42 Replacement Parts List - 185, 265 & 405

Contents

PART ONE - OWNER'S OPERATING INSTRUCTIONS

2

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.

01-10-98

SECTION 1 / START-UP PROCEDURES

BEFORE START-UP

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

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

055 105

155 185 - 265 - 405

8111.tif

405view.tif

105view.tif

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.

3

08-08-01

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING:

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

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

A. This appliance is equipped with an ignition

device which automatically lights the pilot.
Do not try to light the pilot by hand.

B. BEFORE OPERATING Smell all around the

appliance area for gas. Be sure to smell
next to the floor because some gas is
heavier than air and will settle on the floor.

* WHAT TO DO IF YOU SMELL GAS
* Do not try to light any appliance.

Do not touch any electric switch;
Do not use any phone in your building.

* Immediately call your gas supplier from a

neighbour's phone. Follow the gas suppli
er's instructions.

* If you cannot reach your gas supplier, call

the fire service.

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

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.

5. Remove heater door panel.

6. Turn " OFF " gas supply to appliance.

1. Set the thermostat to the lowest setting.

2. Turn off all the electric power to the appli

ance if service is to be performed.

3. Remove heater door panel.

C. Use only your hand to push in or move the gas

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

D. Do not use this appliance if any part has been

under water. Immediately call a qualified
service engineer to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.

7. Wait five ( 5 ) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas STOP! Follow " B " in the
safety information above on this label. If you
don't smell gas, go to the next step.

8. Turn " ON " gas supply to appliance.

9. Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

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

4. Turn off gas supply to appliance.

5. Replace heater door panel.

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

CARE OF YOUR HEATER

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

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 appliance.

VISUAL INSPECTION
With the heater on, remove the door and make a
visual check of the pilot and burner.
The flame should be blue with a well-defined pattern.

MAIN BURNER FLAME

PILOT BURNER FLAME

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

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

WARNING:

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

SECTION 2/CAUTION

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

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

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

3.

Pregnant Women Beware!

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

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

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

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

SECTION 3/MAINTENANCE AND
CARE PROCEDURES

To be followed one month after start-up and then
semi-annually. A full service by a competent person
(i.e. CORGI registered) should be conducted at least
once a year.

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

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

4

03-06-99

4" MAX
100MM

flame.tif

europilot2.tif

3. Make visual check of the burner and pilot
flame. Flame pattern on the main burner
and pilot is indicated in the previous illustra­tion. Yellow flame means restriction of the
air openings. Lifting or blowing flame indi­cates high gas pressure. Low flame means
low gas pressure. Should this occur, shut
the heater off and contact your gas supplier
or qualified service agency.

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

CAUTION:

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

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

POOL & SPA WATER CHEMISTRY

IMPORTANT! These Heaters are not suitable for use

on Salt Chlorinated pools. If this is intended please
contact the Manufacturer.

Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain
your water pH between 7.4 and 7.8 and total alkalinity
between 100 and 150 p.p.m. If the mineral content
and dissolved solids in the water become too high,
scale forms inside the heat exchanger tubes, reduc­ing heater efficiency and also damaging the heater.
If the pH drops below 7.2, the heater will be severely
damaged. This will result in corrosion of the heat

exchanger. Heat exchanger damage resulting

from chemical imbalance is not covered by the
warranty.

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 chlorine
tablets or bromine sticks in the skimmer. High
chemical concentrations will result when the pump is
not running (i.e. 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.

NOTE: High chemical concentrates from feeders

and chlorinators that are out of adjustment will cause
very rapid corrosion to the heat exchanger in the
heaters. Such damage is not covered under the
warranty.

5

08-08-01

COLD WEATHER OPERATION

MODERATE CLIMATE: Heater operation can

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

CAUTION: Do not use the heater to maintain water

temperatures just above freezing or for freeze
protection. When heater is used during freezing
weather, care must be taken to avoid freeze ups.
Continuous pump operation is a must. Additional
protection may be required. The heater is not
warranted against freeze ups.

COLD CLIMATE: Prolonged operation with water

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

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

WINTERIZING THE POOL & SPA HEATER

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

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

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

Return Header

185, 265 & 405 Models

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

Drain
Plug

plug.tif

01-10-98

6

PART TWO - INSTALLATION/SERVICE INSTRUCTION

SECTION 1 / RECEIVING EQUIPMENT

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

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

1. CPVC Adaptors (2)

2. Plastic Flange (1)

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

1. In/Out Flanges (2)

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

3. 2" Flange Gaskets (2)

4. Flange Bolts (4)

5. 2" CPVC Adapters (2)

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

When ordering parts, you must specify model and serial number of heater. When ordering under warranty
conditions, you must also specify date of installation.
It is recommended that this manual be reviewed thoroughly before installing your pool/spa heater. If there
are any questions that this manual does not answer, please contact the supplier.

SECTION 2 / GENERAL SPECIFICATIONS

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

GENERAL SPECIFICATIONS

WATER CONTENT Litre Model 0.8 Model 1.1 Model 1.8

(gal) 055 (0.18) 105 (0.3) 155 (0.4)

Model 1.9 Model 1.9 Model 2.6
185 (0.4) 265 (0.4) 405 (0.5)

MAXIMUM WATER PRESSURE 8 bar (125 psi)

bar (psi)

MAXIMUM WATER FLOW TEMP 45.0

°C (°F) (110)

ELECTRICAL SUPPLY 230V 50Hz

FUSED AT 3A. POWER 100W

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

7

13-08-03

PERFORMANCE SPECIFICATIONS

GAS CATEGORY, TYPE, AND

II

2H3P

G20 @ 20 mbar (8 in. wg)

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

7

U.K. & Ireland.

PERFORMANCE SPECIFICATIONS - NATURAL GAS

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

MODEL 055 105 155 185 265 405

BURNER mbar 6.3 6.8 7.7 8.1 8.3 8.7
PRESSURE (in. wg) ( 2.5 ) ( 2.7 ) ( 3.1 ) (3.2) (3.3) (3.5)

HEAT GROSS kW 12.9 26.67 38.98 49.53 71.5 108.4
INPUT (Btu/h) (44,000) (91,000) (133,000) (169,000) (244,000) (370,000)

NET kW 11.6 24.0 35.08 44.58 64.4 97.6

(Btu/h) (39,600) (81,900) (119,700) (152,100) (219,600) (333,000)

HEAT kW 10.06 20.8 30.4 38.63 55.8 84.58
OUTPUT (Btu/h) (34,300) (71,000) (103,700) (131,820) (190,300) (288,600)

GAS RATE m

3

/h 1.22 2.5 3.7 4.6 6.6 10.28

INJECTOR DIA. mm 1.78 1.78 1.85 1.78 1.78 1.78
& (MARKING) gauge (50) (50) (49) (50) (50) (50)

NUMBER OF BURNERS 4 8 10 13 19 29
& INJECTORS

PERFORMANCE SPECIFICATIONS - PROPANE GAS

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

MODEL 055 105 155 185 265 405

BURNER mbar 23.8 19.0 21.5 28.5 29.4 29.3 30.0
PRESSURE (in. wg) (9.6) ( 7.6 ) ( 8.6 ) ( 11.4 ) (11.8) (11.7) (12.0)

HEAT GROSS kW 14.1 12.9 26.67 38.98 49.53 71.5 108.4
INPUT (Btu/h) (48,000) (44,000) (91,000) (133,000) (169,000) (244,000) (370,000)

NET kW 13.0 11.9 24.54 35.86 45.57 65.8 99.8

(Btu/h) (44,500) (40,500) (83,720) (122,360) (155,480) (224,480) (340,400)

HEAT kW 11.0 10.06 20.8 30.4 38.63 55.8 84.58
OUTPUT (Btu/h) (37,400) (34,300) (71,000) (103,700) (131,820) (190,300) (288,600)

GAS RATE m

3

/h 0.50 0.47 0.97 1.43 1.82 2.57 4.04

INJECTOR DIA. mm 1.09 1.09 1.09 1.06 1.06 1.06
& (MARKING) gauge (57) (57) (57) (59) (59) (59)

NUMBER OF BURNERS 4 8 10 13 19 29
& INJECTORS

055

Easiheat

SECTION 3 / INSTALLATION
INSTRUCTIONS

IMPORTANT NOTICE

These instructions are intended for the use of quali­fied personnel only, specifically trained and experi­enced in the installation of this type of heating equip­ment and related system components. Installation
and service personnel must be CORGI registered.
Persons not qualified must not attempt to fix this
equipment nor attempt repairs according to these
instructions.

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.

STATUTORY REQUIREMENTS

Gas Safety (Installation and Use)
Regulations, 1994

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

General Requirements

The appliance must be installed by a competent
person ie. CORGI registered in accordance with the
relevant requirements of the Gas Safety Regulations,
current I.E.E. Regulations, Model Water Byelaws,
Local Water Authority Byelaws and any relevant
requirements of the local gas supplier, local authority
and the relevant British Standard Codes of practice
and Building Regulations. Manufacturers notes must
not be taken in any way as overriding statutory
obligations. Typical documents include:

Models 055, 105 & 155

BS. 5440:1 Flues (for gas appliances of rated input not

exceeding 60 KW).

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

exceeding 60KW).
BS. 5449 Forced circulation hot water systems.
BS. 6798 Installation of gas fired hot water boilers of

rated input not exceeding 60 KW.
BS. 6891: Installation of low pressure pipework.
Health & Safety Document No. 635.
The Electricity at Work regulations, 1989.
CP341; Water Supply.
British Gas Publications:
IM2; Purging Procedures of Non-domestic Gas Installations
IM5, Soundness Testing Procedures for Industrial and
Commercial Gas Installations.

8

01-10-98

Sheet Metal
24 Gauge

0.7mm

12" Min.
300mm

12" Min.
300mm

4" Min.
100mm

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

Models 185, 265 & 405

BS. 6891; Installation of low pressure pipework.
BS. 6644; Installation of Gas Fired Hot Water

Boilers 60kW to 2MW.
CP 341; Water Supply.
British Gas Publications:
IM2; Purging Procedures on Non-domestic

Gas Installations.
IM5; Soundness Testing Procedures for

Industrial and Commercial Gas Installations.
IM11; Flues for Commercial and Industrial

Gas Fired Boilers and Air Heaters.
Model Water Byelaws.

This appliance must be installed externally in open air
(without a flue) or indoors (with a suitable flue system)
in a room separated from living rooms and provided
with appropriate ventilation direct to the outside.

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

Conversion Instructions.

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

NOTE:

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

BASE INSTALLATION

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

Heaters must not be installed on carpeting.

base.tif

9

01-10-98

CLEARANCES

ALL HEATERS
For clearances from combustible surfaces, see the
chart below.

CLEARANCE FROM COMBUSTIBLE
MATERIAL (mm)

Plant Room Installation

Model Top Back Right Left Front
055 900 50 150 150 Clear
105 900 50 150 150 Clear
155 1050 300 150 300 Clear
185-405 750 150 300 150 Clear

Outdoor Installation

Model Top Back Right Left Front
055 Clear 50 150 150 Clear
105 Clear 50 150 150 Clear
155 Clear 300 150 150 Clear
185-405 Clear 150 150 150 Clear

4'
Min

4'
Min

Forced Air
Inlet

4' Min

10'
Min.

1' Min

1.0m 3' Min

3.0m

1.25m

1.25m

1.25m

0.3m

For servicing, provide at least 600mm (24") in front of
the heater for burner tray removal, and at least
450mm (18") on water connection side of the heater
to inspect and delime the heat exchanger.

Heaters must not be installed under an overhang of
less than 1.0m (3 feet) from the top of the heater.
Three (3) sides must be open in the area under the
overhang. Roof water drainage must be diverted
away from the heaters installed under overhangs
with the use of gutters:
The point from where the flue products exit the heater
must be a minimum of 1.25m (4 feet ) below, four (4)
feet horizontally from or 0.3m (1 foot) above any
door, window or gravity inlet to a building. The top
surface of the heater shall be at least 1.0m (3 feet)
above any forced air inlet, or intake ducts located
within 3.0m (10 feet) horizontally.

HIGH WIND CONDITIONS
(OUTDOOR HEATERS ONLY)

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

clear.tif

10

08-08-01

Heater with
Outdoor
Stackless Top

Press tab
to locate

Pagoda Top

(Shipped

Loose with

Heater)

105 & 155 Models

FLUE TERMINAL (Outdoor) Stackless Top Illustra­tion

Top Vent
Opening

Heater Vent Opening

Jacket Top

185, 265 & 405 Models

FLUE TERMINAL (Outdoor) Stackless Top Illustra­tion

1. Insert tabs into keyhole (4 places).

2. Snap tabs into keyholes so as not to pull out.

tab2.tif

tab1.tif

055expl1.tif

OUTDOOR HEATERS

These heaters are certified by British Gas plc 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 louvres and into
the heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.

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

FLUE CONNECTIONS AND DIMENSIONS

055 Models

FLUE TERMINAL (Outdoor) Stackless Top Illustra­tion

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

to heater.

2: Line up top vent opening over heater vent

opening

3: Lower outdoor top onto unit lining up slots in

outdoor top with screw holes in jacket top.

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

outdoor top to unit.

11

01-10-98

185, 265 & 405 Models

FLUE TERMINAL (Indoor) Draught Diverter

Illustration

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

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

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

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

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

6. Attach the three (3) mounting brackets to the
stack using the screws provided and the holes

that are pre-drilled in the stack. Make sure the

brackets are positioned with the flange near

the top side of the stack (see illustration

below).

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

7. Turn the assembled stack and jacket top, right
side up. The jacket top will be trapped
between the brackets and the top of the stack.
Place the stack over the inner adapter panel
flanged hole and lower the louvered jacket top
panel back into its original position. Reinstall the
four (4) No.10 flat head screws removed in
step 1 above.

S8960

Draught
Diverter

Jacket
Top

Mounting

Screws (8)

Screw Hole
Location

3.25"

82.5mm

Draught
Diverter

No.10 Screw (3)

Flue Collector
(Part of Heater)

Inner Stack
Adapter Panel

Jacket Top Panel
(Part of Heater)

Mounting Bracket (3)

INDOOR HEATER

The design is also certified by British Gas plc for
indoor installation when fitted with the appropriate
draught diverter and a suitable flue system to outside.
Note that the heater must be in a room separated
from living rooms and provided with appropriate
ventilation direct to the outside.

055 Models

FLUE TERMINAL (Indoor) Draught Diverter
Illustration

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

105 & 155 Models

FLUE TERMINAL (Indoor) Draught Diverter
Illustration

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

Draught
Diverter

055expl2.tif

405term.tif

term.tif

Mounting
Screws

12

10-12-01

SPECIFICATIONS & DIMENSIONS 055 - 105 - 155

MODEL FLUE DIA WATER CONNECTIONS SHIPPING WEIGHT

kg (lbs)

mm (in.) APPLIANCE DIVERTER

055 100 (4) 1-1/2" NPT 31.8 (70) 2.3 (5)
105 127 (5) 1- 1/2" NPT 48 (105) 3.5 (8)
155 152 (6) 2" NPT 62 (135) 3.5 (8)

825mm
(32 - 1/2")

Gas Connection

60mm
(2 - 3/8")

525mm
(20 - 3/4")

455mm
(18")

620mm
(24 - 1/2")

130mm
(5 -1/8")

325mm
(12 - 7/8")

475mm
(18 - 3/4")

65mm
(2 - 1/2")

85mm
(3 - 3/8")

190mm
(7 - 1/2")

Gas

Connection

65mm
(2 - 1/2")

325mm
(12 - 3/4")

510mm

(20")

690mm
(27 - 1/4")

1070mm
(42")

610mm
(24")

DIMENSIONS -

105 Model Only

DIMENSIONS -

055 Model Only

dim055.tif

dim105.tif

835mm

(32 - 7/8")

13

10-12-01

A

*Electrical Connection On Left Side is 486mm (19-1/8")

(38")

Gas Connection (13-1/4")

(C)

Indoor

Draft

(40")

(7-1/2")

(3-3/8")

86mm

191mm

1015mm

675mm (26-1/2")

(*21-1/4")

*540mm

(26 ½")

673mm

965mm

336mm

Dim405.tif

(C)

INDOOR DRAUGHT

HOOD

185 1590MM (62

5/8

")

265 1597mm (62

7/8

")

405 1570mm (65

3/8

")

SPECIFICATIONS & DIMENSIONS 185 - 265 - 405

MODEL WIDTH FLUE DIA WATER SHIPPING WEIGHT

(A) CONNECTIONS kg (lbs)

mm (in.) mm (in.) APPLIANCE DIVERTER

185 464 (18 1/4) 150 (6) 2" NPT 86.8 (191) 5.5 (12)
265 568 (22 3/8) 175 (7) 2" NPT 97 (214) 7 (15)
405 743 (29 1/4) 230 (9) 2" NPT 115 (253) 9 (20)

DIMENSIONS -

155 Model Only

610mm

(24")

1140mm
(44 - 7/8")

770mm

(30 - 3/8")

390mm

(15 - 3/8")

370mm

(14 - 1/2")

680mm

(26 - 3/4")

900mm

(35 - 1/2")

220mm
(8 - 3/4")

85mm

(3 - 3/8")

Gas
Connection

14

18-11-02

VENTILATION REQUIREMENTS

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

Position grilles to avoid the risk of accidental
blockage or flooding. Further guidance is given in
BS6644.

CAUTION: Combustion air must not be

contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.

NOTE: The design is also certified by British Gas

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

FLUE SYSTEM
WARNING:

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

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

The chimney must terminate in a downdraught free
zone.

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

The draught diverter supplied with the heater must be
used.

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

Any terminal fitted must be of a type acceptable to
British Gas plc.

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

Flue.pcx

Model Input Plant Room (cm²) ref. BS5440 for models under 60kW

(kW) Inside Outside

High Low High Low

055

13 117 234 59 117

105

27 243 486 122 243

155

39 351 702 176 351

185

50 450 900 225 450

265

72 --297 600

405

108 --378 756

ref. BS6644 for models over 60kW

Compliance with the recom­mendations made in BS 6644;
British Gas publication IM11
"Flues for Commercial and
Industrial Gas fired boilers and
air heaters" and the "Third
Edition of the 1956 Clean Air Act
memorandum" should be strictly
observed where applicable.

15

18-11-02

GAS SUPPLY CONNECTIONS

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

CAUTION:

The heater and its manual shut off valve
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in
excess of 150mbar (2.2psi). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRESSURED
GAS VALVES ARE NOT COVERED BY 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.

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

A minimum of 17 mbar (6.8”) WG and a maximum of
25 mbar (10”) W.G.upstream pressure under load,
and no load conditions are provided for natural gas or
a minimum of 25 mbar (10”) W.G.and a maximum of
45 mbar (18”) W.G for propane gas.

GAS PRESSURE REGULATOR

The gas pressure regulator is preset in the factory.
If an adjustment is needed, remove cap and turn
adjustment screw clockwise to
increase pressure or counterclockwise
to decrease pressure.

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

Burner Pressure

Adjustment

Vr8600.tif

Honeywell Gas Valve

PIPE SIZING FOR GAS CONNECTIONS

MAXIMUM EQUIVALENT PIPE LENGTH METRES

N

- NATURAL GAS @ 1.0 mbar PRESSURE DROP

P

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

10mm 15mm 22mm 28mm

MODEL N P N P N P N

055

61215

105

3520

155

10.5 >24 36

185

8 >24 29

265

4.5 18 14.5

405

8.5 7

16

01-10-98

PLUMBING FOR WATER CONNECTIONS

LEFT SIDE WATER CONNECTION CONVERSION

185, 265 & 405 Models Only

Dis-assembly:

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

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

to the vertical surface behind the control
compartment.

b) Remove four (4) screws attaching the rain

shield to the rear vertical support panel.

c) Remove front and side rain shield panels,

leaving the back shield in place.

3. Remove the flue collector housing
(see figure 3).

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

5. Remove pressure switch as follows:
(see figure 4).
a) Disconnect wires to pressure switch.
b) Disconnect tube fitting from header casting.
c) Remove pressure switch with tubing through

the front of the heater.

6. Remove thermostat temperature sensor
(see figure 4).

Rain Shield

Side Panel

Figure 2

Left Side
Access
Panels

Figure 4

Figure 3

Figure 1

fig3.tif

Flue

Collector

Front Screws

Rain Shield Front Panel

fig2.tif

Four (4) Rear Screws

(2 per side)

fig4.tif

A.G.S.

High
Limit

Wires

Inner Jacket

Panel

Pressure
Switch
Tube

High
Limit Wires

Upper Side

Panel

Jacket Top

Panel

fig1.tif

Thermostat

Temperature

Sensor

Re-Route
Sensor Bulb
Through Hole

17

01-10-98

CIRCUIT
BOARD

Wire Hole In Rear
Panel Of Control Box

Three (3) Pin
Sensor Plug

Control Panel Door
(Shown In Open Position)

7. a) Disconnect the three (3) pin sensor plug

from the poolstat circuit board (see figure

5).

b) Push the connector plug and wires down

through the control box holes (see figure 5)
and then through the inner jacket panel hole
into the heat exchange area (see figure 4).

Reverse Heat Exchanger:

8. Lift the complete heat exchanger straight up and

out of the unit.Use care not to damage the
combustion chamber blocks.

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

10.Rotate the heat exchanger (inlet/outlet casting

will be on the left) and lower it back into place
above the combustion chamber. Again, be careful
not to damage the combustion chamber blocks.

Assembly:

11. Re-route the three (3) pin plug and sensor wires

from the heat exchange area through the
hole in on the right side of the inner cabinet panel
then up into the control box. Plug the three (3)
pin connector back into the poolstat circuit board
(see figure 5).

12. Connect the pressure switch tube to the same

hole it was removed from in the return header.

13. Re-route the pressure switch wires to the right

side and connect them to the pressure switch.

14. OPTIONAL, re-route the AGS wires to the left

side and overheat thermostat capillary to the
right side. Connect the wires to the sensors in
the header castings.

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

16. Replace the rain shield and screws (see figure

2).

17. Reverse and replace right and left access panels

18. Replace top side panels and jacket top panel.

board.tif

18

18-11-02

PVC Pipe

2" CPVC Adapters

Inlet/Outlet Header

CONNECTIONS

All Models

LOCATION

The heater requires water flow and pressure to
operate properly. It must therefore be installed
downstream of the discharge side of the filter pump.
A typical installation is plumbed as follows:

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

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

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

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

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

PRESSURE LOSS CHART 055 / 105 / 155 MODEL ONLY

500

400

300

200

100

0

0 100 200 300 400

LITRES / MIN

PRESSURE LOSS CHART 185 / 265 / 405 MODELS ONLY

600

500

400

300

200

100

0 100 200 300 400

LITRES / MIN

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

NOTE:If operating pressure above 2 bar (30psi) are

encountered then connection pipes must either be
screwed into the flange or suitably anchored.

CAUTION:

NEVER install PVC directly into header

flanges.

FLOW RATES

MINIMUM/min. MAXIMUM/min.

MODEL PIPE SIZE Litres (Gals) Litres (Gals)

055 1

-1/4"-1-1/2" 77 (17) 225 (50)

105 1-1/4"-1-1/2" 77 (17) 430 (95)
155 1-1/4"-1-1/2" -2" 77 (17) 430 (95)
185 1-1/4"-1-1/2" -2" 77 (17) 470 (104)
265 1-1/4"-1-1/2" -2" 95 (21) 470 (104)
405 1

-1/4"-1-1/2" -2" 150 (33) 470 (104)

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

COMPANION FLANGE CONNECTIONS

DO NOT use petroleum base assembly fluids (such

as Petroleum Jelly or lubricating oil). If assembly lube
is required, use a silicone base such as Amoral etc.

055 Model Only

The inlet/outlet header flange accepts a 1 ½"

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

M
B
A
R

M
B
A
R

mbsmall.tif

19

10-12-01

155, 185, 265 & 405 Models Only

Inlet/Outlet Header

DAN MAINES

Flange Gasket

Header Flange

1 2

155, 185, 265 & 405 Models Only

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

GASKET DESIGN 1: Accepts 1-1/2" copper tube or
1-1/4" galvanized pipe as a slip connection.

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

UNITHERM GOVERNOR OPERATION

Does not apply to 105 Model

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

46.1°C despite continually changing flow rates from

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

INTERNAL AUTOMATIC BY-PASS VALVE

Does not apply to 055 Model

In addition to the Unitherm Governor, a built-in auto­matic by-pass valve is provided in the in/out header.
While the Unitherm Governor responds to the
changes in water temperature in the heater, the
internal by-pass valve automatically responds to
changes in water pressure in the piping system.
Proper amount of water flow is maintained through
the heater under varying pressures dictated by the
conditions of the pump and filter.

055 Models Only

055hdr.tif

Inout.tif

gasket.tif

ugov.tif

IN

OUT

IN

OUT

105 Model Only

The 105 accepts direct connection to 1½" plastic pipe

using the adapters provided.

105 headers.tif

Inlet/Outlet Header

1½" NPT

Inlet/Outlet
Connections

EXTERNAL AUXILIARY BYPASS VALVE
(Where Required)

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

From Heater To Heater

To Pool From

Pool

AUXILLARY BYPASS VALVE
(DO NOT USE GATE VALVE)

AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is made
by feeling the inlet and outlet pipes at the heater.
Outlet pipes should be slightly warmer than inlet and
comfortable to the touch. If pipe is hot, close bypass;
if cold, open bypass.

20

09-12-99

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

A 3 pin unswitched shuttered socket outlet, fused at
3A must be provided near to the heater, this should
serve only the heater together with its controls and
pumps.

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

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

NOTE: Input power to the heater (220V) should be

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

The

Electronic Intermittent Ignition Device

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

NOTE:

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

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

Robertshaw Intermittent
Ignition Device.

ELECTRICAL WIRING

NOTE:

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

NOTE: Heaters are factory wired for 230V power

supply.

NOTE: 22mm Dia. holes not utilized on jacket and

control box can be used for fireman switch or auxiliary
control interface wiring.

INSTALLER WIRING

GREEN/YELLOW

BLUE

BROWN

INTERNAL WIRING

N

L

pass.tif

ignbrd.tif

mainsin.tif

21

08-08-01

KEY

24V 150ºC

BK- BLACK
BR- BROWN
R- RED
Y- YELLOW
G/Y- GREEN &

YELLOW

BL- BLUE

08-08-01

WIRING DIAGRAM 055-105-155 MODELS ONLY

IGNITION DEVICE-ROBERTSHAW

versa_wiring_08.01.tif

WIRING DIAGRAM 185-265-405 MODELS ONLY

IGNITION DEVICE-ROBERTSHAW

22

08-08-01

Rpwiring.tif

SECTION 4 / SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

055 MODEL

105 MODEL

155 MODEL

Manual High Limit
Reset Button

Pressure Switch

Burners & Pilot

Gas Valve

Solid State Thermostat &

Ignition Control

Drain Valve

Unitherm
Governor
(Bronze Units Only)

Bypass Valve

High Limits
& Overheat
Thermostats

High Limits &

Overheat

Thermostats

Unitherm Governor

Drain Valve

Solid State
Thermostat Control

Ignition Control

Pressure Switch

Gas Valve

Thermal Fuse

Pilot

23

01-10-98

105cont.tif

8110.tif

24

01-10-98

Overheat Thermostat Capillary
(Located in Return Header)

Drain Plug
(Located in Return Header)

Ignition Control (IID)

Solid State Thermostat Module

Ranco LM7
Overheat Thermostat

Pressure Switch

Roll-Out Safety Switch

Pilot

GENERAL LOCATION OF CONTROLS - continued.

185-265-405 MODEL

Bypass

AGS Hi-Limit

(Located in

Inlet/Outlet Header)

Unitherm Governor

Drain Valve

Transformer

Gas Valve

155 Model

CONTROL PANEL REMOVAL

1. Remove lower door.

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

3. Slide down control panel to clear jacket top

panel.

4. Rotate control panel down until panel stops.

Do not force.

NOTE: Caution must be taken not to damage

controls or wiring.

Jacket Top Panel

Control Panel

Mounting Screws (2)

185,265 & 405 Models

CONTROL PANEL REMOVAL

1. Remove (4) screws from sides of control
panel.

2. Rotate control panel down until panel stops.
Do not force.

NOTE:

Caution must be taken not to damage

controls or wiring.

CONTROL PANEL

MOUNTING SCREWS (4)

rpdoor.tif

8267.tif

rpunit.tif

25

01-10-98

On/Off
Switch

Thermostat
Knob &
Knobstop
Ring

185,265 & 405 Models

Knobstop Ring

Set Screw

Pool Temperature

Range

Spa Temperature
Range

Standby

Temperature

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

1. The “Power” (green) lamp is on when power is
applied to the RP 2100 Spa/Pool heater.
Green ON – Power to Heater Normal

2. The “Call For Heat ” (green) is on when
thermostat is functionally calling for heat.
Green ON – Call for Heater Normal

3. The “Pressure/High Limit” (red) indicates

"safety" failure.

Red ON – Pressure/High

Limit Failure Service Required

4. The “Service” (red) indicates failure of control/
limit circuit.
Red ON – Service Required

NOTE:

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

All Models

PRESSURE SWITCH

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

185,265 & 405 Models

All Models

TEMPERATURE CONTROLS

The pool or spa water temperature is controlled by the
pool heater thermostat on the upper front panel of the
heater. The control centre contains an On/Off switch

and one thermostat (055,105 &155 models) or two
thermostats (185,265 & 405 models). Heaters fitted

with two thermostats may be set up for one tempera­ture setting when heating a spa and a second tem­perature setting for heating a swimming pool. The
switch functions as a means for turning the heater on
or off, and for switching between thermostats when
fitted with two thermostats.
Thermostats are fitted with a means of limiting the
upper temperature limit below the maximum level.
The knob stop adjustment ring illustrated below is
adjustable by loosening the set screw, rotating the
knobstop ring to the desired location and retightening
the set screw.

kstop.tif

Service

Pressure/High Limit

Call forHeat

Power

E L E C T R O N I C

O F F

P O O L

S P A

rpcont.tif

405view.tif

26

17-08-00

All Models

PRESSURE SWITCH ADJUSTMENT

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

2. Turn adjustment knob (counter clockwise)

1/4 turn.

3. Turn pump off and on several times.
Heater should shut off immediately. If it does
not,repeat steps above until proper
adjustments is made.

Adjustment
Knob

PRESSURE SWITCH ADJUSTMENT RANGE

NOTE:

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

TWO SPEED PUMPS

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

CAUTION:

Do not operate the heater without the
function of a properly adjusted pressure switch or flow
switch.

1.5 m Max

1.5 m Max

FLAME ROLL-OUT SAFETY SWITCH

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

HIGH LIMITS

The heater is equipped with one manual reset over­heat thermostat located in the return header, set to
open at approx. 100°C. the other is the Automatic
Gas Shut-off limit, set to open at 57°C and located in
the Inlet/Outlet header.

NOTE:

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

055, 105 & 155 Models

HIGH LIMIT & MANUAL RESET HIGH LIMIT THER­MOSTAT REMOVAL

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

1. Remove Jacket Top,Flue Collector and Baffle.

2. Remove defective high limit and replace with

new high limit.

Manual Reset
High Limit
Thermostat

Automatic

Gas Shut-off High

Limit Thermostat

rollout.tif

ags.tif

lm7.tif

press.tif

range.tif

autoreset.tif

Automatic

Reset

Thermostat

27

01-10-98

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

4. Reverse above procedure to reinstall.

185, 265 & 405 Models

MANUAL RESET HIGH LIMIT REMOVAL

1. Shut off main electrical power switch to

heater.

2. Remove inspection panels.

3. Disconnect electrical connections from

thermostat.

4. Remove defective high limit and replace

with a new high limit. Secure bulb in
pocket with chip provided.

5. Reverse above procedure to reinstall.

HIGH LIMIT REMOVAL (A.G.S.)

1. Shut off main electrical power

switch to heater.

2. Remove inspection panels.

3. Drain heater.

4. Remove defective high limit

and replace with a new high limit.

5. Reverse above procedure to reinstall.

All Models

PILOT SAFETY IGNITION

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

BURNER DRAWER 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.

6. Disconnect wires that terminate at gas valve.

7. Slide out burner tray.

8. Reverse above procedure to re-install.

NOTE:-

IMPORTANT Reconnect Earth Connection

055, 105 & 155 Models

GAS VALVE REMOVAL

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

2. Disconnect pilot tubing from gas valve.

3. Remove gas valve with manifold from burner
tray.

4. Remove manifold from gas valve.

5. Reverse above procedure to re-install.

185, 265 & 405 Models

GAS VALVE REMOVAL

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

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

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

4. Reverse above procedure to re-install.

All Models

MAIN BURNER AND INJECTOR REMOVAL

1. Remove burner drawer. See burner
drawer removal procedure.

2. Remove screws and 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 a drill shank through orifice. Do not
enlarge hole. To remove orifice, use a
socket wrench and remove from manifold.

DO NOT overtighten when reinstalling.

055, 105 & 155 Models

PILOT REMOVAL AND CLEANING

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

2. Disconnect pilot tubing, disconnect wires
from gas valve.

3. Disconnect pilot bracket from burner shield.

4. Remove pilot from bracket.

5. Remove pilot orifice, and clean with wire or

small brush. CAUTION! DO NOT enlarge

hole in pilot orifice.

6. Reverse above procedure to re-install.

01-10-98

28

185, 265 & 405 Models

PILOT REMOVAL AND CLEANING

1. Disconnect pilot tubing, and wires from
gas valve.

2. Remove pilot assembly from burner tray.

3. Remove pilot from bracket.

4. Remove pilot injector and clean with

wire or small brush. CAUTION! Do not

enlarge hole in pilot orifice.

5. Reverse above procedure to re-install.

HEAT EXCHANGER REMOVAL

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

2. Remove top holding screws.

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

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

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

6. Reverse above procedure to reinstall.

055, 105 & 155 Models

HEAT EXCHANGER REMOVAL

1. Shut water, gas, and electricity off, close
valves andrelieve pressure.

2. Drain heat exchanger.

3. Loosen and remove flange bolts.

4. Remove flange and inlet/outlet pipes from
the header.

5. Remove outdoor stackless top or indoor
stack top from unit.

6. Remove jacket top, flue collector, and
baffles.

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

8. Remove capillary bulb from inlet/outlet
header.

9. Disconnect press switch tube from return
header.

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

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

12. Reverse above procedure to re-install.

All Models

CONTROL IMMERSION WELL REPLACEMENT

1. Shut water off to heater and drain heat
exchanger.

2. Remove jacket top panel.

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

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

TUBE CLEANING PROCEDURE (Typical)

Establish a regular inspection schedule, frequency
depending on local water condition and severity of
service. Do not let the tubes clog up solidly. Clean out
deposits over 1.5 mm in thickness.
The heater must be cleaned from the rear as shown.
It is preferable, however, to remove the heat
exchanger and the in/out header for better visibility
through the tubes and to be sure the ground-up lime
dust does not get into the system,
Note that you do not remove the top panel or the heat
exchanger, generally.
After reaming, mount the wire brush in place of the
auger and clean out debris remaining in the tubes.
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-

inhibited de-scale solvent.

Well Assembly

Olive

well.tif

drill.tif

29

08-08-01

All Models

DESOOTING PROCEDURE

CAUTION:

SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE. NEVER USE A WIRE BRUSH.

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

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

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

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

NOTE:

DO NOT WIRE BRUSH.

155, 185, 265 & 405 Models

UNITHERM GOVERNOR (U.G.) REPLACEMENT

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

2. Drain heat exchanger.

3. Remove retainer plug located under outlet
pipe connection.

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

new U.G.

5. Reverse above procedure to reinstall.

Gasket

U.G.

Retainer Plug

Spring

Extension Pieces (2) Auger with Carbide Tip Wire Brush

To test the operation of the Unitherm Governor, place
in hot water (over 43°C) and watch for movement

against spring. If there is no movement, replace unit.

055, 105 & 155 Models

COMBUSTION CHAMBER REMOVAL

1. Remove heat exchanger (See heat
exchanger removal procedure).

2. Lift up and remove front and rear refractory

shield.

3. Remove refractory panels.

4. Reverse above procedure to re-install.

185, 265 & 405 Models

COMBUSTION CHAMBER REMOVAL

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

Refractory Panels Top View

Refractory Panels Top View

ref265.dwg

ugrep.tif

soot.tif

Ensure no gaps
in corners

Ensure no gaps in corners

30

SECTION 5 / TROUBLE SHOOTING GUIDE

IMPORTANT NOTICE: These instructions are primarily intended for the use of qualified personnel specifically

trained and experienced in the installation of this type of heating equipment and related system components.
Installation and service personnel must be Corgi Registered. Persons not qualified shall not attempt to install
this equipment nor attempt repairs according to these instructions.

All Models

MECHANICAL ( FOR QUALIFIED SERVICE PERSONNEL ONLY )

PROBLEM CAUSE SOLUTION

Harmonics, or whining noise. U.G. inoperative........................ Check movement by putting into hot

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

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

Flush system and clean.

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

Low flow................................... Scale forming in heat exchanger - clean

heat exchanger and check pool pH and
total alkalinity.

Heater going on and off Dirty filter..................................Backwash 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 on Pool water.................................Recommended pH should be between

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

Sooting High flow rates.......................... Reduce by adding manual bypass valve

and adjust by putting thermometer in
header (1/4" NPT) drain opening. Set
bypass so thermometer reads between
40°C and 43°C.

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

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

*Air starvation.......................... Refer to installation instructions.

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

instructions.

*Insects or debris clogging

burner intake ports.....................Clean burners.

08-08-01

(* Usually occurs on initial start-up.)

31

08-08-01

PROBLEM CAUSE SOLUTION

Pilot outage. Low gas pressure..................... Adjust gas pressure.

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

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

Faulty Detection Electrode
or PCB

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

*Insects or debris clogging

burner intake ports.....................Clean burners.

Inner & Outer panels very hot *Gaps in corner of refractory
(paint blistered - thermal fuse Broken refractory caused by
in transformer failed) shipping damage or improper

combustion............................... Replace or re-align refractory to seal

gaps. Replace transformer.

Excessive sooting of heat

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

Takes long time to heat Calculate temperature in °/hr...... Heat rise (°/hr.)= Heater Output

pool or spa. Pool gallonage x 8.33

or refer to heater sizing chart.
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.

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

movement, replace.

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

Leaking at well. Overacid.................................. Replace well and maintain water

chemistry properly.

Leaking at heat exchanger. Overacid.................................. Replace heat exchanger and maintain

chemistry properly.
Gasket brittle and leaking - Heater running after pump

(overheated). shuts off................................... See pressure switch adjustment.

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

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

(* Usually occurs on initial start-up.)

055, 105 & 155 Models

ELECTRICAL (ELECTRONIC IGNITION IID)

START

SET THERMOSTAT

TO CALL FOR HEAT

DOES THE GREEN

DIAGNOSTIC

LED STAY ON?

YES

AFTER PREPURGE

IS THERE SPARK

AT THE PILOT

ASSEMBLY?

YES

PILOT BURNER

LIGHTS

YES

SPARK STOPS WHEN

PILOT IS LIT

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

CALL FOR HEAT OVER

SYSTEM SHUTS OFF

YES

END TROUBLESHOOTING

NO

NO

NO

NO

NO

CHECK LINE VOLTAGE POWER.
CONFIRM TRANSFORMER OUTPUT,
LIMIT CONTROLLERS, THERMOSTAT
AND WIRING. ALSO, INDUCED
DRAFT FAN AND AIR PROVING
SWITCH ON INDUCED DRAFT

SYSTEMS.

CHECK IGNITION CABLE, GROUND
WIRING, PILOT ASSEMBLY
INSULATOR AND GAP. CHECK
CABLE FOR SIGNS OF MELTING.

CHECK VALVE, VALVE WIRING, GAS
SHUT OFF VALVES.

CHECK FLAME SENSE WIRE AND GROUND
WIRE. CHECK PILOT FLAME COVERS SENSE
ROD. CLEAN SENSE ROD.

CHECK VALVE, VALVE WIRING.

CHECK LIMITS AND CIRCULATION FAN. CHECK
CONTINUITY OF SENSOR CABLE AND GROUND
WIRE. POOR GROUNDING MAY CAUSE
OCCASIONAL SHUTDOWNS. CHECK FOR EXCESSIVE
HEAT AT FLAME SENSOR INSULATOR.

CHECK THERMOSTAT
CHECK VALVE

CHECK FOR 25VAC

NOMINAL AT TH & TR

TERMINALS

YES

REPLACE CONTROL

IS THERE ANY

AUDIBLE SPARK

NOISE @ 5 SPARKS/

SEC?

NO

REPLACE CONTROL

NO NO

NO

YES

WARNING

HIGH VOLTAGE

For qualified Technicians ONLY

*NOTE: This heater is equipped with an

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

32

30-09-99

*

33

08-08-01

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.

Check transformer, 23•20 V supply, correct as
necessary.If 230 V side of transformer is open circuit,
check combustion chamber for heat leaks
Check 3 Amp fuse.

TEMPERATURE 40°C-40.5° C.
Control ok.

RESISTANCE 0 OHMS (SHORT CIRCUIT)
Check system for shorted wires or open circuits.
Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Replace sensor. Reconnect all leads and check
out system.

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V.
Set control to max. temperature. After 2-3
cycles, check water temperature.

TEMPERATURE ABOVE 42°C
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected
sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance
is:

0-100 ohms at minimum setting:
9k to 11k at maximum setting,
replace circuit board.

Above 11k ohms, replace potentiometer.

0 ohms (short circuit), replace potentiometer.

Reconnect all leads and check out system.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V.

Check transformer, 230 V supply, correct as necessary.
If 230 V side of transformer is open circuit, check
combustion chamber for heat leaks
Check 3 Amp fuse.

TEMPERATURE 40°C-40.5° C
Control ok.

RESISTANCE ABOVE 15k OHMS (OPEN
CIRCUIT) OR SHORT CIRCUIT.
Fix loose or broken wires. Replace sensor if
necessary.

MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Replace sensor. Reconnect all leads and check
out system.

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V.
Set control to max. temperature. After 2-3
cycles, check water temperature.

TEMPERATURE BELOW 40°C
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected sensor
resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting;
9k to 11k at maximum setting,
replace circuit board.
Above 11k ohms but less than
15 k ohms, replace potentiometer.
Above 15k ohms, fix loose or broken wires;
replace potentiometer if necessary.

Reconnect all leads and check out system.

ELECTRICAL (SOLID STATE THERMOSTAT IID)

055, 105 & 155 Models

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

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

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

Temperature (deg C) 16°C 20°C 21°C 25°C 30°C 31°C 35°C 40°C 41°C

(deg. F) 61 68 70 77 86 88 95 104 106

Resistance (k ohms) 14.9 12.5 11.9 10.0 8.1 7.7 6.5 5.3 5.1

• Check that All Manual Gas Valves
Are Open, Supply Tubing & Gas
Pressure Good.

• Check "PV" Power Monitor On
Back of Control Board (24 VAC
From IID to Pilot Gas Valve). If
No Power, Replace IID.

• Check for Gas to Pilot (Crack
Fitting on Gas Valve Pilot Tube
Connection-Clear Tube/Pilot
Orifice as Necessary)

• Verify Pilot Rectification (Pilot On

- Spark Off)

• Check "MV" Power Monitor on
Back of heater Control Board
(24 VAC from IID to Main Gas
Valve) If No Power, Replace IID.

• If All Okay, Replace Gas Valve.

YES

Sensor "Fail"

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

• Using andOhmmeter, measure resistance from Red (ST) to
Back (Com) and Red (SR) to Black (Com), if not within 5% of
each other replace Thermister.

• Check resistance value of Thermister. Reference to chart below.
Replace Thermister in not within 10% of values shown.

• If all okay, replace heater Control Board.

SENSOR RESISTANCE AT VARIOUS TEMPERATURES
TEMP
°C DEGREES 22 27 33 39 44 50 55 59
Resistance (K ) 26.11 19.90 15.31 11.88 9.30 7.33 5.83 5.10
If All Okay, Replace heater Control Board

OVERTEMP "FAIL"

Fail May indicate temporary residual

heat in heat exchanger. Reset &
repeat. If problem continues, call
service agent

- OR -

Fail May indicate failure of heater

Control Board. If power to heater
must be interrupted to reset,
replace heater Control Board.

YES

• Check for "Fail" of Limit/Switch LED
Lights on back of heater Control Board.
Identify and Verify Fault. Replace Switch/
Control as Necessary.

• Check for "Fail" of "Overtemp" or
"Sensor" LED Lights on Back of
heater Control Board.

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

YES

Temporary Condition may
have caused problem.
Does Heater Now Operate
Normally?

NO (Pg 35)

YES

Interrupt Power to
Heater. Wait 10
Seconds, Re-apply
Power (to Reset
Poly Fuse) Green
"Call For Heat "On?

NO

Heater Sparks ?

YES

NO (Or
Flashes
On-Off)

NO

NO ( Or Flashes On-Off)

NO

185, 265 & 405 Models

- IID DIAGNOSTIC FLOW CHART

HEATER WILL NOT FIRE

34

08-08-01

START

"Green" Power Light "ON"

YES

"Green" Call-For-Heat
Light "ON"

YES

"Red" Service Light "ON"

YES

"Red" Pressure/Hi-Limit
Light"ON"

YES

• Check for "Fail" Pressure or High
Limit. Lights on Back of heater
Control Board.

Verify Proper Water Flow/
Pressure.Identify and Replace
Faulty Limit/Switch as Necessary.

If All Okay, Replace heater

Control Board

• Check for 230 V Power to Transformer
(Circuit Breaker,Time Clock, Wire Connections)

• Check for Fireman Switch/Remote Thermostat
Operation (Red Jumper Wire from TP4 to TP5)
Bypass If Necessary.

• Check for 24 VAC from TP6 to TP7
(Transformer Output) If No Power, Replace
Transformer.

• Check Combustion chamber for heat leaks

• Check Fuse F1 on Back of heater Control Board.
If Fuse is Open, Replace with Auto Reset Poly Fuse,
Proceed.

• Check Toggle Switch for "Pool" or "Spa" Selec­tion. Set Temperature Control Knob to
Maximum (Counter-Clockwise)

• Check Water Temperature - Must be Less than
40°C ( Maximum Call-For Heat)

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

Is Green "Call For Heat" And/Or Red "Service"
Light On?

NO

NO (Pg 35)

Probable Component or Wire Short to Ground.

• Interrupt power to heater.

• Remove Molex Connectors P1, P2, P3 and
P4 on heater Control Board

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

Replace heater
Control Board

• Check for 24 VAC Power to IID - (24 V to
24V GND Terminals on IID). If No Power,
Replace heater Control Board, or wire
harness to IID.

• Check for Spark at IID Spark Terminal
(Remove Hi-Tension Lead from IID Module­Position end near spark terminal. Turn control
on. If spark jumps to wire, check Hi-Tension
wire, insulators, ceramic ignitor and gap. If no
spark jumps to wire, replace IID Module.

NO

YES

NO

NO

NO

Replace
Temp Sensor

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

NO

• Remove Molex Connector Plug
P2 on heater Control Board.

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

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

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

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

• If connections okay, replace gas
valve.

• Reconnect temp.sensor plug
at connector P1

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

YES

Verify "Call For Heat" light

(Front Panel)

• Reconnect safety circuit
plug at connector P2.
Does "Power" and"Service"
light stay on? (Front Panel)

YES

• Reconnect IID Module plug
at connector P3
Does "Power" and "Call for
Heat" Light stay on? (Front
Panel)

YES

• Place cabinet door on
heater. Check for adequate
clearance from door to
terminals on gas valve.
Remove door, correct if
necessary.

• Reconnect gas valve plug

P4 on heater Control
Board

Does "Power" and "Call for
Heat" Light stay on?

YES

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

35

01-10-98

(Or Flashes On-Off)

From Pg 34

From Pg 34

36

17-08-00

SECTION 6
REPLACEMENT PARTS LIST

055 Model

NOTE:

To supply the correct part it is important that you state the model number, serial number and type

of gas when applicable.

4-P 3-P

2-P

1-P

inject.tif

spares2.pcx

Pilot ( Silver ) Pilot ( Black )

7-P

8-P

6-P

5-P

europilot.tif

2-G

softlite.tif

37

19-08-03

Key Description - 055 Model Part Code

B BURNER TRAY
1-B Burner Tray w/Gas Valve Natural -

Burner Tray w/Gas Valve Propane ­2-B Burner 301210
3-B Burner Injector Natural No.50 350079

Burner Injector Propane No.57 350083

C CONTROLS
2-C High Limit 57ºC (135ºF) 600889B

3-C High Limit Manual Reset 102ºC M3029
4-C Thermostat Control (Solid State) 600960

6-C Potentiometer 600961
7-C Temperature Sensor 600962
8-C Ignition Control Robertshaw 100-00834 NL-3-L

SPMB502 Ignition Control, Abbey SPMB502/1

G GAS VALVE
1-G Honeywell Gas Valve M3265
2-G L.P.G. Softlight Adapter M3694

H HEAT EXCHANGER
1-H Heat Exchanger Assembly (Complete) 063780
2-H Header / Tubed Kit 004695F
3-H Baffle Kit 306790
4-H Unitherm Governer 600885
5-H U.G. Cap 400734
6-H U.G. Spring 850247
7-H Drain Valve 500719
8-H Sensor Well, High Limit M3028
9-H Bulb Retainer Clip 300203
10-H U.G Gasket 800276
11-H Inlet/Outlet Flange 350746
12-H Flange Gasket 800013B
13-H Bypass Baffle 306079

M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 650634
2-M Pressure Switch Tube Assembly 062212
3-M Thermostat Knob 800201
4-M Knob Stop 305138
5-M Dial Plate M3060
6-M Transformer M650531
7-M Toggle Switch 650595
8-M Wire Harness IID M3552
9-M Thermal Fuse 651360

P PILOT (Silver)

Part Code

PILOT (Black)

1-P Pilot Natural/Propane 600799 5-P Pilot Natural/Propane M3685
2-P Pilot Injector Natural M3274 6-P Pilot Injector Natural M3687

Pilot Injector Propane 601218 Pilot Injector Propane M3688
3-P Pilot Tube 400013 7-P Pilot Tube M3705
4-P Hi-Tension Wire 651012 8-P Hi-Tension Wire M3695

R REFRACTORY
1-R Refractory Kit FT/RR M700348

LT/RR M700349

S SHEETMETAL
1-S Jacket Top 305658
2-S Flue Collector -
3-S Door Assembly 063783
4-S Upper Jacket Control Panel M306120
5-S Cable Clamp Bracket M3299

V VENTING
1-V Stackless Top (Outdoor) 003709
2-V Drafthood (Indoor) 003722

1-V

2-V

1-S

2-S

6-C

16-H

2-C

6-H

7-H

11-H

3-J

2-M

3-H

1-M

5-C

1-H

5-M

5-S

3-M

4-M

12-H

4-S

1-R

2-B

3-B

1-G

2-J

4-C

3-S

1-B

4-H

8-H

6-S

6-S

4-J

3-C

9-M

REPLACEMENT PARTS LIST

38

10-12-01

105 Model

spares105_2.tif

4-P

3-P

2-P

1-P

inject.tif

Pilot (Silver)

Pilot (Black)

7-P

8-P

6-P

5-P

europilot.tif

10-M

2-G

2-H

2-G

softlite.tif

14-H

10-12-01

39

Key Description - 105 Model Part Code

B BURNER TRAY
1-B Burner Tray w/Gas Valve Natural -

Burner Tray w/Gas Valve Propane ­2-B Burner 301210
3-B Burner Orifice Natural No.50 350079

Burner Orifice Propane No.59 350350

C CONTROLS

2-C Automatic Reset Thermostat 601549
3-C High Limit Manual Reset 102ºC M3029
4-C Thermostat Control (Solid State) 600960
5-C Potentiometer 600961
6-C Temperature Sensor 600962

G GAS VALVE
1-G Honeywell Gas Valve M3265
2-G L.P.G. Softlight Adapter M3694

H HEAT EXCHANGER
1-H Heat Exchanger Assembly (Complete) 064187
2-H Inlet/Outlet Header 006887F
3-H Return Header 351047
4-H Tube Bundle 006889F
6-H Baffle Kit 306255
7-H Bolt Kit 006890F
8-H Header Gasket 800014B
11-H Bypass Valve 006716F
12-H Bypass Spring 850252

Drain Valve (not shown) 500719
14-H Sensor Well, Pool Temperature M3028
15-H Well Retaining Clip 300203
16-H Sensor Well, High Limit M3028

J J BOX/CONTROL BOX
2-J Ignition Control Robertshaw 100-00834 NL-3-L M3031
3-J Transformer 230V/24V M650531
4-J Toggle Switch 650595

M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 650634
2-M Pressure Switch Tube Assembly 064685
3-M Thermostat Knob 800201
4-M Knob Stop 305138
5-M DialPlate M3060
8-M Wire Harness M3551
9-M Thermal Fuse 651360
10-M Elbow Adapter M4031

P PILOT (Silver)

Part Code

PILOT (Black)

1-P Pilot Natural/Propane 600799 5-P Pilot Natural/Propane M3699
2-P Pilot Injector Natural M3274 6-P Pilot Injector Natural M3687

Pilot Injector Propane 601218 Pilot Injector Propane M3688
3-P Pilot Tube 400013 7-P Pilot Tube M3700
4-P Hi-Tension Wire 651012 8-P Hi-Tension Wire M3695

R REFRACTORY
1-R Refractory Kit FT/RR 700443

LT/RT 700444

S SHEETMETAL
1-S Jacket Top 306894
2-S Flue Collector 064624
3-S Door Assembly M306893
4-S Upper Jacket Control Panel M306892
5-S Control Panel IID Pilot M306895

V VENTING
1-V Stackless Top (Outdoor) 004898
2-V Drafthood (Indoor) 004897

40

REPLACEMENT PARTS LIST

155 Model

4-P 3-P

2-P

1-P

17-08-00

inject.tif

bits.tif

Pilot (Silver) Pilot (Black)

7-P

8-P

6-P

5-P

europilot.tif

2-G

softlite.tif

2-C

12-H

41

10-12-01

Key Description - 155 Model Part Code

B BURNER TRAY
1-B Burner Tray w/Gas Valve Natural -

Burner Tray w/Gas Valve Propane ­3-B Burner 301210
4-B Burner Orifice Natural No.49 350078

Burner Orifice Propane No.57 350083

C CONTROLS
1-C Thermostat Pocket, High Limit M3028
2-C High Limit 60ºC (140ºF) 600893B
3-C High Limit Manual Reset 102ºC M3029
5-C Thermostat Control (Solid State) 600960
6-C Potentiometer 600961
7-C Temperature Sensor 600962

G GAS VALVE
1-G Honeywell Gas Valve M3265
2-G L.P.G. Softlight Adapter M3694

H HEAT EXCHANGER
1-H Heat Exchanger Assembly (Complete) 066126
2-H Inlet/Outlet Header 004963F
3-H Return Header 004964F
4-H Tube Bundle 004896F
6-H Baffle Kit 303232
7-H Bolt Kit 004889F
8-H Header Gasket 800086B
9-H Unitherm Governor 062234B
10-H U.G. Retainer Spring 850254
11-H Bypass Valve 062235B
12-H Bypass Spring 850252
13-H Drain Valve 500719
14-H Sensor Well, Pool Temperature 003765F
15-H Well Retaining Clip 300203
16-H Inlet & Outlet Flange 003766F
17-H Flange Gasket 1-1/2" Connections 800217

Flange Gasket 2" Connections 800080B

J J BOX/CONTROL BOX
2-J Ignition Control IID Robertshaw 100-00834 NL-3-L M3031
3-J Transformer 230V/24V M650531
4-J Toggle Switch 650761

M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 650634
2-M Pressure Switch Tube Assembly 054374
3-M Thermostat Knob 800201
4-M Knob Stop 305138
5-M DialPlate M3060
8-M Wire Harness IID M3553
9-M Thermal Fuse 651360

P PILOT (Silver)

Part Code

PILOT (Black)

1-P Pilot Natural/Propane 600799 5-P Pilot Natural/Propane M3685
2-P Pilot Injector Natural M3274 6-P Pilot Injector Natural M3687

Pilot Injector Propane 601218 Pilot Injector Propane M3688
3-P Pilot Tube 400381 7-P Pilot Tube M3703
4-P Hi-Tension Wire 651013 8-P Hi-Tension Wire M3696

R-1 REFRACTORY
1-R Refractory Kit FT/RR M700341

LT/RT M700114

S SHEETMETAL
1-S Jacket Top 305703
2-S Flue Collector 053243
3-S Door Assembly 060146
4-S Access Panel Group -
5-S Control Panel IID Pilot 063243

V VENTING
1-V Stackless Top (Outdoor) 003710
2-V Drafthood (Indoor) 003723

REPLACEMENT PARTS LIST

185, 265 & 405 Model

42

08-08-01

5-C

15-H

14-H

2-H

14-M

7-H

4-H

6-H

2-C

8-H

3-H

8-S

18-H

1-V

2-M

1-M

18-H

4-S

1-J

2-J

6-S

5-M

3-B

4-B

1-G

3-S

1-B

7-S

10-S

4-S

12-S

13-M

11-M

4-J

4-M

3-M

3-C

4-P 3-P

2-P

1-P

3-V

inject.tif

17-H

16-H

1-C

11-H

12-H

9-H

10-H

13-H

2-S

5-S

Pilot (Silver)

Pilot (Black)

7-P

8-P

6-P

5-P

europilot.tif

2-G

softlite.tif

6-C

43

10-12-01

Key Description - 185, 265 & 405 Models 185 265 405

B BURNER TRAY
1-B Burner Tray w/Burners

Burner Tray w/o Burners
Burner Tray w/Gas Valve Natural SPMB405
Burner Tray w/Gas Valve Propane SPMB403

3-B Burner 301210 301210 301210
4-B Burner Orifice Natural No.50 350079 350079 350079

Burner Orifice Propane No.59 350350 350350 350350

C CONTROLS
1-C Thermostat Pocket, High Limit M3028 M3028 M3028
2-C High Limit 60ºC (140ºF) 600893B 600893B 600893B
3-C P.C Board Control Units 601213 601213 601213
5-C Temperature Sensor Units 601226 601226 601226
6-C High Limit Manual Reset 102ºC M3029 M3029 M3029

G GAS VALVE
1-G Honeywell Gas Valve M3265 M3265 M3265
2-G L.P.G. Softlight Adapter M3694 M3694 M3694

H HEAT EXCHANGER
1-H Heat Exchanger Assembly CI(Complete) 065254 065258 065266
2-H Inlet/Outlet Header CI 003759F 003759F 003759F
3-H Return Header CI 002450F 002450F 002450F
4-H Tube Bundle 005252F 005253F 005255F
6-H Baffle Kit (8) 307237 307238 307240
7-H Bolt Kit 001303F 001303F 001303F
8-H Header Gasket 800014B 800014B 800014B
9-H Unitherm Governor 062234B 062234B 062234B
10-H U.G. Retainer Spring 850254 850254 850254
11-H Bypass Valve 062235B 062235B 062235B
12-H Bypass Spring 850252 850253 850253
13-H Drain Valve 500719 500719 500719
14-H Sensor Well, Pool Temperature 003765F 003765F 003765F
15-H Well Retaining Clip 300203 300203 300203
16-H Inlet & Outlet Flange 003766F 003766F 003766F
17-H Flange Gasket 1-1/2" Connections 800217 800217 800217

Flange Gasket 2" Connections 800080B 800080B 800080B

18-H Rear Drain Plug & Cover 005264F 005264F 005264F

J J BOX/CONTROL BOX
1-J Ignition Control

Robertshaw 100-00834 NL-3-L M3031 M3031 M3031
2-J Transformer 230V/24V M650531 M650531 M650531
4-J Rocker Switch Units 650903 650903 650903

M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 650634 650634 650634
2-M Pressure Switch Tube Assembly 065391 065391 065391
3-M Thermostat Knob (1) 800303 800303 800303
4-M Knob Stop (1) 305138 305138 305138
5-M Thermal Fuse 651360 651360 651360
8-M Wire Harness IID M3554 M3555 M3555
11-M Control Panel IID 800312 800312 800312
13-M Thermostat Shaft IID 800304 800304 800304
14-M CPVC Adapter 501750 501750 501750

Parts list is continued on next page

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44

19-03-03

185, 265 & 405 Replacement Parts List (continued)

Key Description 185 265 405

P PILOT (Silver)
1-P Pilot Natural/Propane 600799 600799 600799
2-P Pilot Orifice Natural M3274 M3274 M3274

Pilot Orifice Propane 601218 601218 601218
3-P Pilot Tube 400607 400607 400607
4-P Hi-Tension Wire 650998 650998 650998

P PILOT (Black)
5-P Pilot Natural/Propane M3685 M3685 M3685
6-P Pilot Orifice Natural M3687 M3687 M3687

Pilot Orifice Propane M3688 M3688 M3688
7-P Pilot Tube M3690 M3690 M3690
8-P Hi-Tension Wire M3696 M3696 M3696

R-1 REFRACTORY
1-R Refractory Common (Left & Right) 700461 700461 700461
2-R Refractory Uncommon M700462 M700463 700465

S SHEETMETAL
1-S Jacket Top (Louvred) 065218 065219 065221
2-S Flue Collecter 065148 065149 065151
3-S Door Assembly 065162 065163 065364
4-S Access Panel Set (3 Pcs.) - - -
5-S Side Panel Right 307099 307099 307099
6-S Side Panel Left 307100 307100 307100
7-S Side Panel Cap 307098 307098 307098
8-S Rear Panel Kit (2 Pcs.) - - -

10-S High Limit Cover 307280 307280 307280
12-S Up-Front Control Panel 065170 065171 065173

V VENTING
1-V Indoor Stack Kit

(Includes inner adapter panel) 006696 006697 006699
3-V "Pagoda" Top 065310 065312 065311

Station Lane

Industrial Estate

Witney

Oxon.

Tel. [phone]

Fax. [phone]

Booklet issue 12 27-08-03