Maxitrol SR400 Installation Manual

Heater Manifold

REPLACEMENT INSTRUCTIONS

Sta-Rite Pool/Spa Group

293 Wright Street, Delavan, WI 53115

International: 262-728-5551, FAX: [phone]
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)

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

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"

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

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

6

7

▲ 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