Page 1
Heater Manifold
REPLACEMENT INSTRUCTIONS
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan, WI 53115
International: 262-728-5551, FAX: 262-728-7550
www.starite.com
Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA
© 2003, Sta-Rite Industries, Inc. Printed in U.S.A. S570 (Rev. 8/21/03)
Page 2
O-Ring
No. U9-226
Connector Tube Kit
No. 77707-0017
SR/SRC200 Manifold Conversion Kit
No. 77707-0014
SR/SRC333 Manifold Conversion Kit
No. 77707-0015
SR/SRC400 Manifold Conversion Kit
No. 77707-0016
Safety Precautions:
Fire or explosion hazard. Disconnect all
power to the heater and close the External Manual Gas
Valve before starting this procedure.
Compressed spring hazard. The Thermal
Regulator plug has a spring behind it. Restrain it when
removing it from the Manifold to prevent it from flying
and possibly injuring persons nearby (see Picture No. 8,
Page 3).
2
Turn off the power to the heater and
the filter pump.
0
Close water inlet and outlet valves to
isolate the heater from the system.
Close the gas valve. If it is necessary to
move the heater, disconnect the union.
Drain the Heater. Loosen the union collars. When the
heater is empty, disconnect the unions.
Separate and remove the covers.
1 2 3
4 5 6
Filter
Pump
Heater
Outlet to
Pool
3871 0101
3872 0101
Inlet from
Filter
Open
3874 0101
3873
Page 3
3
Remove the manifold and adapter.
Clean the tube sheet and O-Ring sealing surfaces thoroughly
as described above.
9
10
Remove the switch covers and disconnect the wires from the safety switches. The
wires are color coded and marked for the switches they serve.
Carefully remove the spring-loaded
thermal regulator.
7 8
*Hand-tighten all long bolts; then tighten indicated bolts enough to allow short bolts
to engage.
11A
11B
• Install O-rings on tube ends; install manifold.
• SR/SRC200 and SR/SRC400: Tighten all long bolts HAND
TIGHT; then tighten the bolts next to the short bolts a little
more with a wrench.
• Insert and start the two short bolts until they engage three
or four threads, then tighten all bolts according to the normal torque pattern shown on Page 4.
• SR/SRC300: These models use long bolts only. Tighten all
bolts HAND TIGHT; then tighten according to the normal
torque pattern shown on Page 4.
3877 0101
3879 0101
Models SR200/SRC200
Short Bolt Placement
Clean the tube sheet and O-ring
1.
sealing surface with a nylon brush,
then brighten the tube sheet
surface with 320 grit emery cloth.
NOTE: When cleaning, be careful
not to push the tube sheet into the
combustion chamber. If you do,
thread a couple of bolts into it
and pull it back in place.
Brush off all dust and debris
2.
with a brush and wipe it down
with a cloth.
Apply silicone grease (supplied)
3.
to O-Rings.
4067 0901
Models SR400/SRC400
Short Bolt Placement
2-3/4"
*
2-1/2"
*
2-3/4"
4068 0901
2-3/4"
*
2-1/2"
*
2-3/4"
2-3/4"
*
2-1/2"
2-3/4"
*
2-1/2"
Page 4
4
NOTICE NOTICE NOTICE
• Start and run the filter pump for several minutes before starting the heater in order to purge all air from the system.
Open all air vents in the system (on Filter, Strainer, etc.) while purging the air. Run the pump with the vents open
until all vents run a solid stream of water.
• Check gas union(s) for leaks with soapy water before firing the heater.
Explosion and fire hazard. Be sure that all gas connections are tight and do not leak before
attempting to start the heater.
• See Step 15, above, for switch cover installation instructions.
• Have a No. 77707-0008 Insulation Kit on hand in case the heating coil shifts during manifold installation and
requires opening the combustion chamber cover to realign it.
1. Make sure that all bolts are engaged and hand tight.
2. Torque the bolts in sequence as shown. Some noise (pop-
ping, etc.) is normal as you tighten.
3. Go around the manifold and retighten the bolts as
needed to 75-115 in.-lbs. (8.4-12.9 N-m) (you may have
to do this several times).
Install the Thermal Regulator in the Manifold.
12 13
Reconnect wires to switches.
NOTE: You may have to reroute the AGS wire to the opposite side of the manifold (depending on your heater’s production date). If so, be sure that the wire crosses ahead of
the Water Pressure Switch as shown and does not touch the
Combustion Chamber.
Install the second switch cover as shown when retrofitting a
new manifold.
14 15
To rque Pattern - All Models
98
54
12
3 6
710
75-115 in.-lbs./8.4-12.9 N-m
4071 0901
3/8"
Drill Hole
1/4" Dia.,
Centered
Cut away to
clear Switch Cover
3884 0101
Page 5
5
3
200 Manifold 333 Manifold 400 Manifold
Key Part Conversion Kit Conversion Kit Conversion Kit
No. Description Qty. 77707-0014 77707-0015 77707-0016
1 Coil/Tube Sheet Seal O-ring () 35505-7222 (6) 35505-7222 (10) 35505-7222 (12)
• Manifold O-Ring 1 35505-7437 35505-7437 35505-7437
3 Water Pressure Switch 1 42001-0060T 42001-0060T 42001-0060T
2 Manifold/Connector Tube Assembly 1 * * *
4Flat Washer 10 U43-41SS U43-41SS U43-41SS
5 5/16x2-3/4” SS Hx Hd Capscrew () 37007-0214(8) 37007-0214(10) 37007-0214(8)
6 Switch Cover 1 42001-0007 42001-0007 42001-0007
• Switch Cover Screw 1 U30-742SS U30-742SS U30-742SS
7 Thermal Regulator Assembly
(Purchase Separately; Includes
Key Nos. 8,9,10,11) 1 77707-0010 77707-0010 77707-0010
8 Thermal Regulator 1
9 Thermal Regulator Spring 1
10 Thermal Regulator Cap O-Ring 1
11 Thermal Regulator Cap 1
12 Drain Plug 1 U178-920P U178-920P U178-920P
13 5/16x2-1/2” SS Hx Hd Capscrew 2 37007-0213 – 37007-0213
13 3/4” NPT Pipe Plug 1 WC78-38AT WC78-38AT WC78-38AT
• Relief Valve † 38674-0719 38674-0719 38674-0719
• Connector Tube Kit (Includes O-Ring) 2 77707-0017 77707-0017 77707-0017
• Connector Tube O-Ring 2 U9-226 U9-226 U9-226
• Not illustrated.
* Not available separately. If the manifold body fails, purchase a complete Manifold Conversion Kit, which includes all safety
switches and all internal components except the Thermal Regulator (Key No. 7, above). Does not include relief valve.
† Purchase separately; required on Canadian installations.
Repair Parts List
1
2
6
4
5
8
7
14
9
10
11
4
13
12
4074 1001
Page 6
6
Page 7
7
Page 8
▲ Retain Warranty Certificate (upper portion) in a safe and convenient location for your records.
DETACH HERE: Fill out bottom portion completely and mail within 10 days of purchase/installation to:
▼ Sta-Rite, Attn: Warranty Dept., 293 Wright St., Delavan, WI 53115
Pumps, filters, skimmers, underwater lights (except bulbs),
accessories and fittings manufactured by Sta-Rite are warranted to be free of defects in material and workmanship for
one (1) year from date of installation.
Product specific warranties:
Year from date
of installation
HRPB, DEPB, System 3, System 2 and Posi-Clear
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 years
Internal filter components and valves . . . . . . . . . 1 year
Max-E-Therm – Pool/Spa Heaters . . . . . . . . . . . . . 2 years
Heater Enclosure only (Upper RH & LH;
lower enclosure; and control board enclosure)… 10 years
Automatic Pool Cleaners including Hose . . . . . . . 2 years
Cristal-Flo filters – Tanks . . . . . . . . . . . .10 years pro-rated*
Valve and internal components. . . . . . . . . . . . . . . . 1 year
Posi-Flo II – Tanks . . . . . . . . . . . . . . . . . . . . . . . . . .10 years
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year
PRC Cartridge –
Filter Tanks . . . . . . . . . .5 years pro-rated (1st 2 years full)
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year
System 2 Above Ground Systems – Tanks . . . . . . .10 years
Pumps / Platform and Internals . . . . . . . . . . . . . . . 1 year
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year
When equipped with A.O. Smith
2-compartment motors (Does not include
pumps sold as part of a systems package) . . . . . . 2 years
Traps / In-Line Strainers . . . . . . . . . . . . . . . . . . . . . 1 year
Vertical Commercial Filter – Tanks . . . . . . . . . . . .10 years
Internals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year
Horizontal Commercial Filter
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 years
(Years 6-9, Prorated declining 20%/year, Yr. 10 - 10%)
Internals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year
* Full warranty coverage is in effect for one year after installation. The pro-rated warranty covers the tank only during
the 2nd through 10th year after installation. The amount covered decreases by 10% each year. (ie., 2nd year 90% covered,
3rd year 80% covered, etc.).
The foregoing warranties relate to the original consumer purchaser (“Purchaser”) only. Sta-Rite shall have the option to repair or replace the defective product, at its sole discre-
tion. Purchasers must pay all labor and shipping charges necessary to replace the product covered by this warranty.
Requests for warranty service must be made through the installing dealer. This warranty shall not apply to any product
that has been subject to negligence, misapplication, improper
installation or maintenance, or other circumstances which are
not in Sta-Rite’s direct control.
This warranty sets forth Sta-Rite’s sole obligation and
Purchaser’s exclusive remedy for defective products.
STA-RITE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL,
INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE
DURATION OF THE APPLICABLE EXPRESS WARRANTIES
PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long
an implied warranty lasts, so the above limitations or exclusion may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which vary
from state to state.
Supersedes all previous publications.
Sta-Rite Industries, Inc.,
293 Wright St., Delavan, WI 53115
Warranty Registration Card
Name
Address
City State Zip
Purchase Date
Product Purchased
■■ New installation ■■ Replacement
Type of Pool ■■ Inground ■■ Vinyl ■■ Fiberglass ■■ Gunite
Size of Pool
Years pool has been in service ■■ less than 1 ■■ 1-3 ■■ 3-5 ■■ 5-10
Purchased from:
Company name
Address
City State Zip
Please send me more information on these
other products from Sta-Rite.
■■ Pumps ■■ Filters ■■ Automatic Pool Cleaners
■■ Maintenance Equipment ■■ Test Strips
■■ Heaters
S4877PS (Rev. 2/4/03)
STA-RITE LIMITED WARRANTY
Loading...