Raypak 106, 156 User's Installation And Operation Manual

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INSTALLATION AND OPERATION MANUAL

Atmospheric Above-Ground

Pool & Spa Heater

(Chaue-Piscine)

Models 106 and 156

English/French

WARNING: If the information in these

instructions are not followed exactly, a re or

explosion may result causing property damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use

gasoline or other ammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or re.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

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

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re department.

Installation and service must be performed by a qualied installer, service agency or the gas

supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.

AVERTISSEMENT: Assurez-vous de bien

suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inammables à proximité de cet appareil ou de tout autre appareil.

CE FAIRE SI VOUS SENTEZ UNE ODEUR

DE GAZ:

• Ne pas tenter d’allumer d’appareil.

• Ne touchez á aucun interrupteur; ne pas vous servir des téléphones se trouvant dans la bâtiment.

• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivre les instructions du fournisseur.

• Si vous ne pouvez rejoindere le fournisseur, appelez le service es incendies.

L’installation et l’entretien doivent être assurés par un installeur qualié ou par le fournisseur de gaz.

CATALOG NO. 6100.62G Eective: 06-08-18 Replaces: 04-15-18 P/N 241519 Rev. 8

Revision 8 reects the following changes:

Manual updated to the new format style. Removed California Proposition 65 warning on pages 4 and 7. Replaced "analog/electronic" with 106/156 on section 3.3.1, page 6. Replaced "analog/digital" with 106/156 on section 5.5.3, page 21.

CONTENTS

1. WARNINGS ................................................................... 4

1.1. Pay Attention to These Terms ..............................4

2. WATER CHEMISTRY ................................................... 5

2.1. Automatic Chlorinators and

Chemical Feeders....................................................5

3. BEFORE INSTALLATION ............................................ 6

3.1. Safety ...........................................................................6

3.2. Water Temperature Safety ....................................6

3.3. Ratings and Certications .....................................6

3.4. General Information ................................................7

3.5. Product Receipt ........................................................ 7

4. INSTALLATION ............................................................. 7

4.1. Installation Codes .................................................... 7

4.2. Clearances .................................................................8

4.3. Base Installation .......................................................8

4.4. Outdoor Installation ............................................. 10

4.5. Indoor Installation ................................................. 10

4.6. Combustion and Ventilation Air

(Indoor Units Only) ............................................... 11

4.7. Gas Connections .................................................. 12

4.8. Electrical Connections ........................................ 15

4.9. 240 Volt Installation Instructions ................... 15

5. CONTROLS..................................................................16

5.1. P-106 Control Adjustments ............................... 16

5.2. P-156 Control Adjustments ............................... 17

5.3. P-156 Thermostat Operation ............................ 17

5.4. Status and Diagnostics ....................................... 19

5.5. Remote Control Wiring ........................................ 20

5.6. Post Start-Up Inspection .................................... 22

6. WIRING DIAGRAMS .................................................. 23

7. MAINTENANCE .........................................................24

7.1. Service ...................................................................... 24

8. TROUBLESHOOTING ................................................27

8.1. Mechanical ............................................................. 27

8.2. P-106 Control Logic Flow Chart ....................... 28

8.3. P-156 Control Logic Flow Chart ....................... 29

9. ILLUSTRATED PARTS LIST ......................................30

1. WARNINGS

1.1. Pay Attention to These Terms

DANGER

WARNING

CAUTION

NOTE

DANGER: Failure to install the drafthood on indoor

installation and properly vent the heater to the outdoors as outlined in the venting section of this manual can result in unsafe operation of the heater. To avoid the risk

of re, explosion, or asphyxiation from carbon monoxide,

never operate this heater unless it is properly vented and has an adequate air supply for proper operation. Be sure to inspect the vent system for proper installation at initial start-up, and at least annually thereafter. Refer to the venting section of this manual for more information regarding vent system inspections.

WARNING: To minimize the possibility of improper

operation, serious personal injury, re, or damage to the

heater:

• Always keep the area around the heater free of

combustible materials, gasoline, and other ammable

liquids and vapors.

• Heater should never be covered or have any blockage

to the ow of fresh air to the heater.

WARNING: Improper installation, adjustment,

alteration, service, or maintenance can cause property damage, personal injury or loss of life. Refer to the owner’s operating instructions provided in this manual.

Installation and service must be performed by a qualied

installer, service agency, or the gas supplier.

Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

WARNING: Both natural gas and propane have an

odorant added to aid in detecting a gas leak. Some people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar with the smell of natural gas or propane, ask your local gas supplier. Other conditions, such as “odorant fade,” which causes the odorant to diminish in intensity, can also hide,

camouage, or otherwise make detecting a gas leak by smell more dicult.

WARNING: UL-recognized fuel gas detectors are

recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

WARNING: Do not install within 3 feet (0.9 m) of a heat

pump or an outdoor condensing unit. Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury.

WARNING: The heater shall not be located in an area

where water sprinklers, or other devices, may cause water to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage electrical components, and void the warranty.

WARNING: Gasoline, as well as other ammable

materials and liquids (adhesives, solvents, etc.), and

the vapors they produce, are extremely dangerous. Do

not handle, use, or store gasoline or other ammable or

combustible materials in the vicinity of a heater.

2. WATER CHEMISTRY

NOTE: Corrosive water voids all warranties.

Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water chemistry according to Table A. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchanger tubes, reducing heater eciency and damaging the heater. If the pH drops below

7.2, this will cause corrosion of the heat exchanger and severely damage the heater. Heat exchanger damage

resulting from chemical imbalance is not covered by the warranty.

For your health and the protection of your pool equipment, it is essential that your water be chemically balanced. The following levels must be used as a guide for balanced water.

CAUTION: Free chlorine must not exceed 5 ppm which

can damage the heater and is not covered under warranty.

• Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced.

• Automatic chemical dosing devices and salt

chlorinators are usually more efcient in heated

water, unless controlled, they can lead to excessive chlorine level which can damage your heater.

• Further advice should be obtained from your pool or spa builder, accredited pool shop, or chemical supplier for the correct levels for your water.

2.1. Automatic Chlorinators

and Chemical Feeders

All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place sanitizing chemicals in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight).

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut o. See Figure 1.

NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the warranty.

Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa Types

Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)

pH 7.3-7.4 7.3-7.4 7.6-7.8

Total Alkalinity (ppm) 120-150 120-150 80-120

Calcium Hardness (ppm) 200-300 150-200 200-400

Salt (ppm) 4500 Maximum 4500 Maximum 4500 Maximum

Free Chlorine (ppm)* 2-3 2-3 2-3

Total Dissolved Solids (ppm) 3000 Maximum** 3000 Maximum** 3000 Maximum**

*Free Chlorine MUST NOT EXCEED 5 ppm! **In saltwater chlorinated pools, the total TDS can be as high as 6000 ppm.

Table A. Pool Water Chemistry

FILTER

PUMP

CHECK VALVE

SKIMMER

HEATER

AUTO-CHLORINATOR

SPA

CHECK VALVE

RETURN TO SPA

Figure 1. Spa Chlorinator Setup

3. BEFORE INSTALLATION

Plastic Header

R = Raypak

Model No.

Model Rev.

E = Electronic

N = Natural

C = Copper

3.1. Safety

This appliance is to be installed and operated by trained personnel in accordance with this Installation and Operation Manual. Be sure to read and understand the entire Installation and Operation Manual before attempting to install or operate this appliance. Failure to follow the warnings listed at the beginning of this manual could result in a re or explosion, causing property damage, bodily injury, or death.

Should you have any problems understanding the warnings and instructions in this manual, STOP, and get help from a qualied installer, service technician, or the gas supplier.

3.2. Water Temperature Safety

Elevated water temperature can be hazardous. The U.S. Consumer Product Safety Commission has these guidelines:

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

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

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

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

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

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

AVERTISSEMENT: La U.S. Consumer Product Safety Commission indique que des températures de l’eau élevées deuvent être dangereuses. Voir la notice d’installation et de fonctionnement pour le réglage de lat température. Suivre les instructions pour une installation appropriée.

3.3. Ratings and Certications

This pool & spa heater (chaue-piscine) is designcertied and tested under the latest requirements of ANSI Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters (Chaue-Piscines). The heater can be used either indoors or outdoors. (Installer å l’intérieur ou à l’extérieur.) If necessary, the top of the heater can be changed after installation to accommodate indoors or outdoors.

WARNING: Use of any parts not manufactured

and/or approved by the manufacturer may cause nonwarrantable damage.

3.3.1. Ambient Temperature Rating of Components

106 Heater -40°F to +175°F (-40°C to 79°C)

156 Heater -32°F to +175°F (-35°C to 79°C)

3.3.2. Model Identication

The model identication number and heater serial number are found on the heater rating plate. See Figure 2.

Figure 2. Location of Heater Rating Plate

The model identication number will be similar to the example shown in Figure 3.

P - R - E N - C

M = Rheem

D = Ruud

106 or 156 =

106 A

P = Propane

A = Analog

Figure 3. Model Identication Number

3.4. General Information

Model No. Input

Gas Conn.

(NPT)

Water Conn.

(NPT)

Shipping Weight

Std. Heater

w/ Stackless Top

Drafthood Assembly

106

156

105,000 BTU/hr.

(30.75 KW)

150,000 BTU/hr.

(43.93 KW)

1/2"

(1.27 cm)

Table B. Basic Product Data

1-1/2" or 2"

(3.8 cm or 5 cm)

3.5. Product Receipt

On receipt of the heater it is suggested that visual checks are made for external damage to the shipping carton. If the carton is damaged, make a note to that eect on the Bill of Lading when signing for the shipment. Remove the heater from the shipping packaging. Report any damage to the carrier immediately.

These items are shipped inside a bag in the carton with the heater:

1. 2” CPVC union with “O” rings (2)

2. Plastic pipe finish flange for gas line

3. Bonding lug with mounting screw

4. Installation and Operation Manual

On occasion, items are shipped loose. Be sure that the correct number of packages are received, as indicated on the Bill of Lading.

Claims for shortages and damages must be led with the carrier by consignee. Authorization to return goods must be received from the factory prior to shipping. Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted. All returned goods are subject to a restocking charge.

When ordering parts, specify the model and serial number of the heater. When ordering under warranty conditions, specify the date of installation. Records of the installation must be provided, when requested, to substantiate a claim.

Debits for defective replacement parts will not be accepted and will only be replaced in kind per the manufacturer’s standard warranties.

4. INSTALLATION

IMPORTANT NOTICE: These instructions are intended

only for the use by qualied personnel, specically trained

and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. If your state is such, be sure your contractor

bears the appropriate license. Persons not qualied shall not attempt to x this equipment nor attempt repairs

according to these instructions.

85 lbs.

(38.6 kg)

100 lbs.

(45.4 kg)

WARNING: This unit contains refractory ceramic

ber (RCF) insulation in the combustion chamber. RCF,

as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very

high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classied the inhalation of crystalline silica (cristabolite) as carcinogenic to humans.

When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid

inhaling airborne bers. When cleaning spills, use wet sweeping or High Eciency Particulate Air (HEPA) ltered vacuum to minimize airborne dust. Use feasible

engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate

NIOSH certied respiratory protection, to avoid inhalation of airborne dust and airborne ber particles.

WARNING: Improper installation, adjustment,

alteration, service or maintenance may damage the equipment, create a hazard resulting in asphyxiation,

explosion or re, and will void the warranty.

14 lbs.

(6.35 kg)

4.1. Installation Codes

Installations must be in accordance with local, state, provincial, and national codes, laws, regulations and ordinances. In the absence of local codes, installations must be in accordance with the latest editions of the:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, ANSI/NFPA 70

• For Canada only: CAN/CSA-B149 Installation Code

(B149) and CSA C22.1 C.E.C. Part 1 and Part 2

4.2. Clearances

AVERTISSEMENT: Cet appareil doit être installé

conformément au National Fuel gas Code ANSI Z223.1, et aux exigences de l’autorité competente.

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

air ow.

Heater Side

Top* Unobstructed 30" (76.2 cm)

Front 24" (61 cm) Alcove

Vent N/A 6" (15.2 cm)

Back 12" (30.5 cm) 12" (30.5 cm)

Right Side 6" (15.2 cm) 6" (15.2 cm)

Left Side 6" (15.2 cm) 6" (15.2 cm)

*Clearance from top of vent terminal.

Table C. Required Minimum Clearances from Combustible

Surfaces

Outdoor

Installations

Dégagements minimaux à assurer entre les parois de l”appareil et les contructions combustibles: 6po (15.2 cm) (côtés), 12po (30.5 cm) (arrière) et 30po (76.2 cm) (dessus).

When installed according to the listed minimum clearances from combustible construction, the pool heater can be serviced without removing permanent construction around the heater.

However for ease of servicing, we recommend a

clearance of at least 18" (45.7 cm) on the rear. This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater.

Minimum clearance from drafthood to combustible construction 6" (15.2 cm) from the vent.

Degagement minimal de 6 po (15.2 cm) requis entre le coupe-tirage et une construction combustible. 2 po du conduit de raccordement.

Clearances less than recommended may require removal of the heater to service either the heat exchanger or the burner tray. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

It is possible to reduce the clearances to combustible surfaces by protecting these surfaces as shown in table

10.2.3 of the National Fuel Code. See Table D.

Indoor

Installations

Description Location

Back 9 (229)

a. 3-1/2" (89 mm) thick

masonry walls without ventilated air space

b. 1/2" (13 mm)insulation

board over 1" (25 mm) glass ber or mineral wool batts

c. 0.024 sheet metal over

1" (25 mm) glass ber or mineral wool batts reinforced with wire on rear face with ventilated air space

d. 3-1/2" (89 mm) thick

masonry wall with ventilated air space

e. 0.024 sheet metal with

ventilated air space

f. 1/2" (13 mm) thick

insulation board with ventilated air space

g. 0.024 sheet metal with

ventilated air space over

0.024 sheet metal with ventilated air space.

h. 1" (25 mm) glass ber

or mineral wool batts sandwiched between two sheets 0.024 sheet metal with ventilated air space

Derived from National Fuel Gas Code, Table 10.2.3

Table D. Reduction of Clearances to Protected Surfaces

FLOORING: This heater can be installed on combustible

ooring.

Right 9 (229) Left 9 (229) Vent 5 (127) Indoor Top 39 (991) Outdoor Top Unobstructed Back 6 (152) Right 6 (152) Left 6 (152) Vent 3 (76) Indoor Top 30 (762) Outdoor Top Unobstructed Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed Back 6 (152) Right 6 (152) Left 6 (152) Vent 6 (152) Indoor Top 39 (991) Outdoor Top Unobstructed Back 4 (102) Right 4 (102) Left 4 (102) Vent 2 (51) Indoor Top 24 (610) Outdoor Top Unobstructed Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed Back 4 (102) Right 4 (102) Left 4 (102) Vent 3 (76) Indoor Top 24 (610) Outdoor Top Unobstructed

Distance

in. (mm)

4.3. Base Installation

Heater must be mounted on a level base, such as

cementable slab or cement blocks. Heaters may not be installed on carpeting.

Figure 4. Heater Dimensions

Amp Draw

120 Volt 240 Volt

4 2

Figure 5. Florida Building Code Tie-Down Method

This heater must b e installed at least 5' (1.52 m) from the inside wall of a pool unless separated from the pool by a solid fence, wall or other permanent solid barrier.

Ce chaue-piscine doit êntre installè à au moins 5 peds (1.52 m) de la paroi interne de la piscine à moins d’êntre

isolé de la piscine par un clôture, un mur ou autre barrière permanente.

4.4. Outdoor Installation

WARNING: The heater should not be located in an area

where water sprinklers or other devices may cause water to spray through the cabinet louvers and into the heater. This could cause internal rusting or damage electrical components, and will not be covered under warranty.

WARNING: Do not install within 3' (0.9 m) of a heat

pump or an outdoor condensing unit. Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury.

NOTE: This heater is design-certied for outdoor installation when equipped with the approved top(s) for

outdoor use.

1' (0.3 m) above any door, window or gravity inlet into any building. The top surface of the heater shall be at least 3' (0.9 m) above any forced air inlet, or intake ducts located within 10' (3 m) horizontally. See

Figure 6.

• For installations in Canada, pool heaters shall not

be installed with the top of the vent assembly within 10' (3 m) below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/ CSA-B149. The heater must be raised 7" (0.2 m) above the surface which could support snow, ice or debris. Refer to the latest revisions of CAN1-2.21-M85.

4.4.2. Outdoor Stack

NOTE: The outdoor stack is optional equipment and does not come standard with the heater. Use part number 014718 for the 106 and 014719 for the 156.

High Wind Conditions (Outdoor Units Only)

In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' (0.9 m) from high vertical walls, or install a wind-break so the heater is not in direct wind current.

In areas of daily high winds, it may be necessary to replace the outdoor stackless top with a stack adapter in combination with a wind-resistant/weather-proof outdoor stack. See Figure 7.

4 ft (1.2 m)

3 ft (0.9 m)

10 ft (3 m)

Figure 6. Outdoor Installation Clearances

1 ft (0.3 m)

4.4.1. Heater with Outdoor Stackless Top

Heaters must not be installed under an overhang of less than 3' (0.9m) from the top of the heater. Three sides must be open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs with the use of gutters.

Ne pas installer ce chaue-piscine sous une saillie

mesurant moins de 3 pi de hauteur. La partie sous Ia saillie doit etre ouverte sur 3 côtes.

• For U.S. installations, the point from where the flue products exit the heater must be a minimum of 4' (1.2 m) below, 4' (1.2 m) horizontally from, or

OUTDOOR STACK

Figure 7. Outdoor Stack

The outdoor stack serves the same function as the low prole stackless top and should be installed in accordance with the same clearance requirements. Follow the installation instructions provided with the Outdoor Stack Kit for installation.

4.5. Indoor Installation

The heater is design-certied for indoor installation when equipped with the approved drafthood.

Locate heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside.

See Vent Piping section for details. Minimum allowable space is shown on the rating plate. Follow the installation instructions provided with the Indoor Drafthood Kit for installation.

NOTE: For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with an occupied area. Refer to the latest

edition of CAN/CSA-B149 for specic requirements.

WARNING: Indoor heaters require a drafthood that

must be connected to a vent ppe and properly vented to the outside. Failure to follow this procedure can cause

re or fatal carbon monoxide poisoning.

This drafthood must be installed without alteration. see rating plate.

Ce coupe-tirage doit être installé sans modication. Voir

Ia plaque signalétique.

4.6. Combustion and Ventilation

Air (Indoor Units Only)

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings are one opening that is 12" (30.5 cm) from the ceiling for ventilation, and one opening that is 12" (30.5 cm) from the oor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI Z223.1 (Canada-CAN/ CSA-B149) and any local codes that may have jurisdiction.

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the heater and void the warranty. Do not store chlorine, bromine, baquasil or acid in the same room as the heater.

All Air from inside the building each opening shall have a minimum net free area as noted in Table E.

Typical Screened

or Louvered

Opening

41 in²

(265 cm²)

57 in²

(368 cm²)

106

156

Unrestricted

Opening

27 in²

(174 cm²)

38 in²

(245 cm²)

Model

Table E. Minimum Air Net Free Area - Interior Source

All air from outdoors when air is supplied directly from outside the building each opening shall have a minimum net free area as noted in Table F.

Model Area

106 105 in² (677 cm²)

Typical Screened

and Louvered

Opening

54 in²

(348 cm²)

76 in²

(490 cm²)

4.6.1. Vent Piping

Appliance Categories

Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent.

Category I – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category II – A heater which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

Category III – A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

Category IV – A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

These heaters operate as venting category I atmospheric appliances.

Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (3 m) (drafthood relief opening to vent terminal), the vent pipe size may be reduced by no more than one size as specied in the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). As much as possible, avoid long horizontal runs of vent pipe and too many elbows.

If installation requires horizontal runs, the vent pipe must have a minimum of 1/4" (2 cm per m) per ft rise and should be supported at not more than ve foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the ashing and extending above the roof more than 5' (1.5 m) should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the roof and walls.

For protection against rain or blockage by snow, the vent pipe must terminate with a vent cap which complies with local codes or, in the absence of such codes, the latest edition of the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149).

The discharge opening must be a minimum of 2' (0.6 m) vertically from the roof surface and at least 2' (0.6 m) higher than any part of the building within 8' (2.4 m) vent stack shall be at least 5' (1.5 m) in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4' (1.2 m) horizontally from, and in no case below, unless a 4' (1.2 m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

156 150 in² (968 cm²)

Table F. Minimum Air Net Free Area - Exterior Source

8' (2.4 m)

HEATER JACKET

OR LESS

24" MIN

(610 mm)

VENT CAP

24" MIN

(610 mm)

5' (1.5 m)

MIN

GAS INLET

FINISH FLANGE

MANUAL SHUT-OFF VALVE

(Field supplied)

GAS VALVE

VENT PIPE

DRAFTHOOD

HEATER

Figure 8. Vent Piping Requirements

The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction.

Type “B” double-wall or equivalent vent pipe is recommended. However single-wall metal vent pipe may be used as specied in the latest edition of the National Flue Gas Code ANSI Z223.1 (Canada - CAN/CSA-B149).

4.7. Gas Connections

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-o valve located outside the heater jacket. Use the pipe nish ange to seal between the gas line and the heater jacket. See Figure

9. All gas piping should be tested after installation in

accordance with local codes.

UNION

(Field supplied)

SEDIMENT TRAP

(Field supplied)

Figure 9. Gas Line Sediment Trap

CAUTION: Only sealant tape or a pipe compound rated

for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

4.7.1. Gas Pressure Regulator

The gas pressure regulator is preset at 4" W.C. (1.0kPa) for natural gas and 10" W.C. (2.5kPa) for propane gas.

If adjustment is needed, remove plug and turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

Gas Pressure* Natural Gas Propane Gas

Max. Inlet

(Static)

Min. Inlet

(Dynamic)

Manifold Gas

(Dynamic)

*Static means without heater operating. Dynamic refers to heater operating.

Table G. Static and Dynamic Gas Pressure

10.5" WC (2.6 kPa)

5" WC

(1.2 kPa)

4" WC

(1.0 kPa)

13" WC

(3.2 kPa)

11" WC

(2.7 kPa)

10" WC

(2.5 kPa)

4.7.2. Gas Pressure Adjustment Location

CAUTION: Do not use 5, 10 or 20 gallon (19.38 to 76

Liter) propane tanks, like those used with consumer

barbecues, to supply gas to this heater.

CAUTION: The heater and its manual shut-o valve

must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess

of 1/2 psig (3.5 kPa). The heater and its gas connections

shall be leak tested before placing the appliance in operation. Use soapy water for leak test. Do not use open

ame.

Figure 10. Honeywell Gas Valve

Model Tubing Input

In/Out Header

Hose Connector

Hose

106 Cu

156 Cu

Table capacities are based upon use of sch 40 black iron pipe. For capacities using other materials, consult local code. * Natural Gas 1000 BTU/FT * Natural Gas 2500 BTU/FT

105,000 BTU/hr

(30.8 kW)

150,000 BTU/hr

(43.9 kW)

0.60 Specic Gravity @ 0.5" WC Pressure Drop (Gaz Naturel 3154.5 W/m3 0.60 Densite @ 0.124 kPa Pressure Drop)

1.53 Specic Gravity @ 0.5" WC Pressure Drop (Gaz Naturel 7886.3 W/m3 0.60 Densite @ 0.124 kPa Pressure Drop)

1/2" (1.27 cm) 3/4" (1.91 cm) 1" (2.54 cm)

NAT LPG NAT LPG N AT LPG

26' (8 m) 65' (20 m) 99' (30 m) 252' (77 m) 350' (107 m) 892' (272 m)

13' (4 m) 34' (10 m) 51' (16 m) 130' (40 m) 180' (55 m) 459' (140 m)

Table I. Maximum Equivalent Pipe Length

4.7.3. Electronic Ignition Gas Valves

Figure 11. Location of Gas Pressure Adjustment

4.7.4. Water Connections

The heater requires water ow and positive pressure to re and operate properly. It must therefore be installed downstream of the discharge side of the lter pump. A typical installation is plumbed as follows:

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

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

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

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

Heater must be located so that any water leaks will not damage the structure of adjacent area. PVC pipe may be glued directly into supplied CPVC header unions.

4.7.5. Flow Rates

Model Minimum Maximum

106/156 20 GPM (75 L) 70 GPM (265 L)

Table H. Water Flow Rates

When the ow rates exceed the maximum 70 GPM (265L), an external auxiliary bypass valve is required. See section "External Auxiliary Bypass Valve" on page 14 for details.

4.7.6. Polymer Headers

Before attaching the supplied 2" (5 cm) CPVC unions to the In/Out header, make sure the O-rings are properly seated in the grooves. Use AquaLube or equivalent nonpetroleum-based lubricant on the O-ring. Hand tighten the unions. Glue PVC or CPVC piping directly to the unions.

In/Out Header

O-Ring

Tail Piece

Nut

2” Pipe (5cm)

Drain Plug

Figure 12. In/Out Header for 2" (5 cm) Installation

Figure 13. Optional In/Out Header for 1-1/2" (3.8 cm) or

1-1/4" (3.2 cm) Hose Connection

If there is any possibility of back-siphoning when the pump stops, it is recommended that a check valve (or valves) also be installed in the system.

4.7.7. Internal Automatic Bypass Valve

PIPE ONTO DISCHARGE SIDE OF PIPING

A built-in automatic bypass valve is provided in the In/Out header. The internal bypass valve automatically responds to changes in water pressure in the piping system. The proper amount of water ow is maintained through the heater under varying pressures dictated by the conditions of the pump and lter.

Bypass Disc

Spring

Bypass Body

4.7.10. Pressure Relief Valve Installation

To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4” (1.9 cm) pressure relief valve, having a capacity equal to or greater than the BTUH input of the heater to be installed, is recommended for this heater. The maximum pressure relief valve setting is 125 psi (862 kPa). This relief valve needs to be installed on the outlet pipe from the header as noted in Figure 16 below.

Figure 14. Internal Automatic Bypass Valve

4.7.8. External Auxiliary Bypass Valve

An auxiliary bypass valve must be used when ow rates exceed 70 GPM (265 LPM). Usually a high-performance pump size larger than one horsepower will exceed this ow rate. This valve is required to complement the function of the automatic bypass valve, particularly when starting the heater in winter or early spring when the spa or pool temperature is below 50°F (10°C). It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the ow rate to the spa jets, etc.

FROM HEATER

FULL PORT

BALL VALVE

OR GLOBE

TO POOL/SPA

BYPASS VALVE

Figure 15. Auxiliary Bypass Valve

TO HEATER

VALV E

FROM POOL/SPA

4.7.9. Auxiliary Bypass Valve Adjustment

NOTE: Do not use a gate valve as an auxiliary bypass valve.

Figure 16. Pressure Relief Valve Installed

If required, this needs to be installed in a eld-supplied tting external to the heater. The valve shall be installed in a vertical position. Do not over-tighten. Install the pressure relief valve hand tight plus 1/2 turn.

WARNING: To avoid water damage or scalding due

to relief valve operation, drain pipe must be connected to valve outlet and run to a safe place of discharge. Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch

downward from the valve. No shut-o valve shall be

installed between the relief valve and the drain line.

The valve lever should be tripped at least once a year to ensure that waterways are clear. If the relief valve does not function properly, replace it immediately.

Flow (GPM) Pressure Drop (ft of Head)

20 7.6

30 8.2

40 8.7

50 9.3

60 9.8

70 10.4

Table J. Heat Exchanger Pressure Drop

To set bypass: With clean lter, adjustment is made by

touching 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.

4.8. Electrical Connections

BONDING LUG

TER

SUPPL

Be sure that electrical service to the heater has proper overload fuse or circuit breaker protection, wire size and connections which comply with all applicable codes.

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 302°F (150°C) wire or its equivalent.

Si un des ls original fourni avec l’appareil doit être remplacé, utilisez un l 302°F (150°C), ou l’équivalent.

The heater comes standard with a 120 VAC 3-prong power cord. For 240 VAC applications, see Figure 18. Power source must be a wired ground, with ground fault circuit interruption circuitry.

Amp draw:

4 amp at 120VAC 2 amp at 240VAC

4.9. 240 Volt Installation Instructions

CAUTION: This heater has provisions to be connected

to an alternate supply source. To reduce the risk of electric shock, disconnect all connections before servicing.

1. Disconnect the 120V power cord from power source.

2. Remove knurled screw from the lower front panel.

3. Remove the front panel and set aside.

4. Remove the two stainless screws holding the control panel in place.

5. Lower the control panel and then sway it forward. The 120V wiring should be visible next to the transformer.

6. Disconnect and remove the 120V power cord from the heater.

7. Bring the 240V supply line into the control box.

8. Install a wire nut on the white transformer wire. See

Figure 18.

9. Wire nut the 240V supply lines to the red and black wires on the transformer.

10. Wire nut the supply ground line to the green transformer wire.

11. Reposition the control panel back in place and reinstall the two screws.

12. Re-install front panel and knurled screw.

Figure 17. Electronic Heater Power

ATTENTION. Au moment de l’entretien des

commandes, étiquetez tous les ls avant de les

débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux.

The heater must be electrically grounded and bonded in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70. (Canada - Canadian Electrical Code, CSA C22.1, Part 1 and Part 2.)

NOTE: Input power to the heater (120 VAC) can be supplied from the load (pump) side of time clock or

directly from the GFCI power source. It is preferred to make connection to the load/pump side of the time clock.

WARNING: Risk of electrical shock. More than one

disconnect switch may be required to de-energize the equipment before servicing.

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation.

HOT

BLACK

HOT

SIDE

Figure 18. 240V Wire Connection

RED RED

BLACK

HEA

GREENGREEN

WHITE

5. CONTROLS

HOT

Knobstop Ring

5.1. P-106 Control Adjustments

The P-106 has an analog control system. The pool or spa water temperature is controlled by the thermostat on the upper front panel of the heater. The control center contains an On/O toggle switch and a thermostat. The switch functions as a means for turning the heater On or O.

The thermostat is tted with a means of limiting the upper temperature limit below the maximum level. The knob stop adjustment ring shown in Figure 19 is adjustable by loosening the set screw, rotating the knobstop ring to the desired location, and tightening the set screw.

COOL

Knobstop Set Screw

Figure 19. Water Temperature Thermostat

NOTE: Maximum setpoint is 104°F (40°C).

5.2. P-156 Control Adjustments

Program Mode Button (SW1)

The P-156 has a digital control system. The pool heater (chaue-piscine) touchpad, located on the upper front panel of the heater, allows the user to select either POOL or SPA operation, and to adjust the setpoint temperature. The LCD display window indicates the mode (OFF, SPA, POOL) and the actual water temperature. A manual power switch provided below the touchpad turns the control power ON or OFF.

Figure 20. Digital Control Adjustment

5.2.1. MENU/SET Button

The MENU/SET button is used to select POOL or SPA operation. It allows the user to turn the heater o electronically. The LCD remains energized and displays OFF, while continues to show the actual water temperature.

5.3. P-156 Thermostat Operation

Figure 22. Thermostat Program Button (SW1)

5.3.1. Service Menu and Fault History

To access the Service Menu and fault history, press the MENU/SET and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate while in the Service Menu. The rst screen displayed is the Flame Strength indicator, which indicates the pilot ame current using a bar graph and numerical display. A signal of less than 4 bars indicates a weak ame signal and may require service. Refer to the Troubleshooting section for possible causes and corrections.

5.2.2. Temp Buttons

If the heater is in POOL or SPA mode, the desired water temperature (SETPOINT) will be displayed and may be adjusted using the UP or DOWN buttons.

5.2.3. Operation

In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SETPOINT). When the water temperature is above the setpoint, “Water Temp” will alternate with “No Demand.” When the water temperature is below the setpoint and the heater is ring, “Water Temp” will alternate with “Heating.”

To adjust the setpoint temperature, make sure the control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons.

Figure 21. Alternating Display During Heating

Figure 23. Flame Strength Indicator

Press the DOWN button. The Supply Voltage screen indicates the voltage supplied to the control board. Normal readings range from 24 to 29 volts.

Figure 24. Supply Voltage Indicator

Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured by the amount of time that the main gas valve has been powered. The Cycle count indicates the number of on/o cycles of the heater, as measured by the number of times the pilot valve has been powered.

Figure 25. Run Time Indicator

Press the DOWN button. The Fault History displays up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, and proceeds through ten most recent messages in chronological order. The second line of the display shows the fault message. If there are no faults in the history buer, the second line reads “All Faults Clear.”

Figure 26. Fault History Indicator

5.3.2. Program Button

1. Remove the two screws holding the control cover, and swing the panel down so the back side of the board is visible. Locate the Program Mode button (SW1) as shown in Figure 22. Press and hold the button for 5-7 seconds until Set Factory Defaults appears on the display. Release the program button.

2. Press the MENU/SET button sequentially until the desired program event is reached. There are 5 different events that can be programmed. They appear in the sequence listed in Figure 27:

Resets board to factory default settings.

Resets faults in the History File.

Both the POOL and SPA setpoints will revert to 65°F (18°C) and both POOL and SPA maximum temperature settings will be 104°F (40°C). The Control Lockout PIN will be cleared and the control will resume normal operation.

Clear Faults

Refer to step one above to access the program screen. Press the MENU/SET button until Clear Faults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Faults Cleared appears. This operation resets the Fault History le to “0” and clears all the stored faults.

Fahrenheit or Celsius

Refer to step one above to access the program screen. Press the MENU/SET button until Fahrenheit or Celsius appears on the digital display. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale.

Spa Max Temp – Spa Set Point Maximum Adjustment

Refer to step one above to access the program screen. Press the MENU/SET button until Spa Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F (42°C).

Pool Max Temp – Pool Set Point Maximum Adjustment

Refer to step one above access into the program screen. Press the MENU/SET button until Pool Max Temp appears on the digital display. Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value. The control can be set for a maximum of 107°F (42°C).

Change from Fahrenheit to Celsius.

SPA setpoint maximum adjustment.

POOL setpoint maximum adjustment.

Figure 27. Programmable Events

Set Factory Defaults

Refer to step one above to access the program screen. Set Factory Defaults should appear on the screen. If it does not, press the MENU/SET button until it appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Defaults Set appears. This operation resets the operating program to its factory default values.

5.3.3. Control Lockout

The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings. To lock out the controls, press the DOWN button and MENU/SET button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the MENU/SET button to lock in selections. Conrm your selection and record your PIN.

To unlock the controls, press any button to bring up the Enter PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Successfully unlocking the control will display “Lockout Cleared.” Failure to enter the correct PIN will display “Invalid PIN.”

In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to Set Factory Defaults. This will clear the PIN and allow normal operation and selection of a new PIN if desired.

NOTE: Both the POOL and SPA setpoints will revert back to

65°F (18°C) and the POOL and SPA maximum temperature settings will be 104°F (40°C). These setpoints will need to

be readjusted to desired settings.

NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the

water temperature at the inlet to the heater may dier

from that observed at a given location in the pool or spa.

The following conditions are displayed only while there is a demand for heat present.

Display Condition

Water Sw Open Water pressure switch open.

Vent/Field Sw #1

Hi Limit 1 Fault High limit 1 open.

Hi Limit 2 Fault High limit 2 open.

Rollout Sw Open Rollout switch open.

Vent spill switch/eld switch #1 open.

5.4. Status and Diagnostics

The P-156 has a digital thermostat that is programmed to display a variety of status and diagnostic messages, depending on the operating conditions.

The following heat status messages are displayed in Pool, Spa, and Remote modes when there are no active fault conditions.

Display Condition

Heating Call for heat established, ame present.

Spark Spark operating.

No Demand Heat demand is satised.

Table K. Heat Status Messages - No Active Faults

The following conditions are displayed in Pool, Spa and Remote modes.

Display Condition

Sensor Failure

Sensor Open

Sensor Short

Flame w/o CFH

PV Output Fault

MV Output Fault

Internal Fault Board fault, replace board.

EEPROM Fault

Clock/Fireman Sw

Low Temp Lockout

Thermistor temperatures disagree by more than 2°F (1°C)

Thermistor sensor failed open. Below

-20°F (-29°C).

Thermistor sensor failed short. Above 217°F (103°C).

Board is sensing ame when both main and pilot valves are commanded shut.

Pilot gas valve output is not in commanded state.

Main gas valve output is not in commanded state.

Memory fault, reset set points, replace board if fault does not clear.

Time clock/reman switch circuit is open.

Water temperature below 36°F (2°C).

Flow/Field SW #2

Ignition Lockout (Propane Tab

Broken)

Ignition Failure (Propane Tab Not

Broken)

Ign 6min Delay (Propane Tab Not

Broken)

Table M. Heat Status Messages - Demand for Heat

Field-supplied ow switch/eld switch #2 open.

Alternating with “No pilot sensed” Pilot ame not established within the required time (15 sec or 90 sec).

Alternating with “Main Ign Failure”

- Pilot ame lost during the 8 second trial to ignite the main burner.

Alternating with “No pilot sensed” Pilot ame not established within 90 seconds.

Alternating with “Main Ign Failure”

- Pilot ame lost 4 times within the 8 second trial to ignite the main burner. Heater will lockout for 6 minutes before retrying.

Table L. Heat Status Messages - Active Faults

5.4.1. Remote Control Installation and

Operation

CAUTION: Before installing remote controls to the P-156 heaters, read the following: The digital thermostat

model is remote-ready in most cases. The digital liquid

crystal display (LCD) shows the actual pool temperature,

operating status, and service codes. See Figure 28. The touch pad on the control panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is controlling the heater by displaying Remote in the display. When connecting the heater to a remote system, identify whether it is a two- or three-wire remote system. Select the appropriate instruction listed below to properly install the remote to the heater.

5.4.2. Remote Operation

The P-156 heaters are equipped with the ability to work with external remote controls. The supplied 7-pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote. See Figure 30. The remote works by either making or breaking the circuit created by the remote wiring. Typically, a remote does not supply power to the heater, it only provides a switching function to turn the heater On or O. If your

remote is supplying its own voltage to the heater, it will not work with this heater and may damage the digital circuit board.

For operation of the heater using the onboard thermostatic controls with a time clock, see the “Time Clock/Fireman’s Switch” section.

OFF Mode

5.4.3. Activating the Remote

To activate or deactivate the remote function, follow these steps:

1. Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds.

2. The second line of the display will alternate even when the unit is off (“No Demand”).

NOTE: When in remote operation, the keypad mode and temp buttons are disabled.

Figure 29. Remote Control Menu - Activation

5.5. Remote Control Wiring

ATTENTION

OBSERVE PRECAUTIONS

ELECTROSTATIC

SENSITIVES DEVICES

CAUTION: Electrostatic Discharge (ESD) damage can

be caused by direct or indirect contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact

of a nger allows the body to discharge, possibly causing

device damage. This damage can be limited if the service person discharges himself, following ESD preventive/ removal practices, and holds on to the heater enclosure for 5 seconds before proceeding.

Heating in the POOL Mode

Heating in the SPA Mode

Remote Mode

Figure 28. Remote Control Menu - Remote Operation

Important Installation Notes for Remote or External

Wiring Conguration:

• Remote wiring must be run in a separate conduit.

• Remote wiring must not be run parallel to high

voltage lines.

• For runs of under 30' (9.1 m), remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5" to 2.5" (3.8 to 6.4 cm) lay and jacketed.

• For runs over 30' (9.1 m), the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5" to 2.5" (3.8 to 6.4 cm) lay that is shielded and jacketed.

• Maximum cable length is 200' (61 m).

• For both two- and three-wire remote systems, the

provided 7-pin wiring connector must be utilized.

NOTE: The remote wires must be connected to the 7-pin

Pool Common

(BLU)

connector before the connector is plugged into the board.

5.5.1. 2-Wire Remote Control (On-Off)

This application assumes that only one heating function (pool or spa) is required.

1. Turn on power to the heater.

2. For a 2-Wire Remote Control from a remote without

its own sensor, push the MENU/SET button to the “POOL” or “SPA” mode and set the desired setpoint (eg. 102 °F (39°C) for Spa).

3. For a 2-Wire Remote Control from a remote with its own sensor, push the MENU/SET button “POOL” or “SPA” mode and set the temperature to the highest setting available on the control. The actual setpoint will be controlled by the remote control.

4. Turn the MENU/SET button to “OFF” and remove power from the heater.

5. On the “Remote Interface Harness”, connect the BLUE wire to one side of the “REMOTE” switch and connect the other side to either the ORANGE/ BLACK wire for “SPA” operation or the BLACK/ ORANGE wire for “POOL” operation. See Figure 30.

BLU - 24VAC

ORN/BLK - To Spa (COMM)

Wire Nut BLK/ORN - To Pool (COMM)

Figure 31. 2-Wire Remote Harness Installation on the P8

Connector of the ATF Board

(BLK/ORN)

Spa Common (ORN/BLK)

24VAC HOT

Figure 30. 7-Pin Remote Interface Harness

6. Attach wire nut on unused wire to the “Remote Interface Harness.”

7. Install the “7-Pin Remote Interface Harness” to the P8 connector and turn power “On” to the heater. SeeFigure 31.

8. For activation of the remote control, see "Activating the Remote" on page 20.

5.5.2. 3-Wire Remote Control Using

Three-Position Switch (Pool-OffSpa, or Low-Off-High)

1. This application assumes that both heating functions (pool and spa) are required.

1. Turn on power to the heater.

2. Push the menu/set button to the “POOL” or “SPA”

mode and set the desired temperature for each (eg. 80°F (27°C) for Pool and 102°F (39°C) for Spa).

3. Turn the MENU/SET button to “OFF” and remove power from the heater.

BLU - 24VAC

ORN/BLK - To Spa (COMM)

BLK/ORN - To Pool (COMM)

Figure 32. 3-Wire Remote Harness Installation on the P8

Connector of the ATF Board

4. On the “Remote Interface Harness” connect the BLUE wire to one side of the “REMOTE” switch and connect the ORANGE/BLACK wire for “SPA” operation and the BLACK/ORANGE wire for the “POOL” operation. See Figure 30.

5. Install the “Remote Interface Harness” to the P8 connector and turn power “ON” to the heater. SeeFigure 32.

6. For activation of the remote control, see "Activating the Remote" on page 20.

5.5.3. Time Clock/Fireman’s Switch

To operate the heater with a time clock, connect the timer to the reman’s switch connection in the heater’s wiring. The time clock should be of the dual switch type and set to shut o the call for heat to the pool heater (chaue-piscine) 15 to 20 minutes prior to shutting down the pool pump.

On P-106 heaters, splice into the red/white wire to connect the time clock. For P-156 heaters the reman’s switch connection is located on the 14-pin header connected to the digital control board. Splice into the red wire jumper tagged “Where necessary add “Fireman’s” switch circuit here” to connect the time clock.

The reman’s switch connection on both heaters

must be a dry contact and must not supply power to

the heater. Powering the reman’s switch connection

externally may damage the heater, and is not covered by warranty.

P-156 heaters: Do not exceed 50' (15.2 m) of total wiring using 18 AWG stranded copper wire rated for 221°F (105°C) minimum.

5.6.1. Cold Weather Operation

Moderate Climate

Heater operation can continue during short-term cold spells. When temperatures are between 0° (-17°C) and 32°F (0°C), ow (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.

NOTE: When using a time clock, the heater will display

“Clock/Fireman Sw” when the reman’s switch is open, indicating that the time clock has shut o the call for heat.

5.6. Post Start-Up Inspection

Do not use this heater if any part has been under water. Immediately call a qualied service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water.

N’utilisez pas cet appareil s’il a ete plonge dans l’eau,

meme partiellement. Faites inspecter l’appareil par un technicien qualie et remplacez toute partie du systeme

de controle et toute commande qui ont ete plonges dans l’eau.

WARNING: Should overheating occur or the gas

supply fail to shut o, turn o the manual gas control to

the appliance.

AVERTISSEMENT: En cas de surchaue ou si

l’alimentation en gaz ne s’arrete pas, fermez manueiiement ie robinet d’arret de l’admission de gaz.

Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot.

With the heater on, remove the door and make a visual check of the burner.

PILOT

Cold Climate

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

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

5.6.2. Winterizing the Heater

Heaters installed outdoors in freezing climate areas may be shut down for the winter. Observe the following procedure for winterizing the heater.

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

2. Open the drain plug located on the In/Out header, under the water pipes.

3. Remove the 2 wires from the water pressure switch and unscrew the water pressure switch to break any vacuum in the system. Remove the pressure switch and dry it before re-installing. Excessive moisture in the pressure switch may freeze, damaging the switch.

Figure 33. IID Pilot Location

In/Out Header

Drain Plug

Figure 34. In/Out Header Drain Plug Location

6. WIRING DIAGRAMS

Figure 35. P-106 Heater Wiring

Figure 36. P-156 Heater Wiring

7. MAINTENANCE

The following preventative maintenance is to be performed one month after start-up and semi-annually thereafter.

1. Inspect top of heater and drafthood for soot, a sticky black substance around finned tubes and “V” baffles, and open flue gas passageways. Any visible soot should be cleaned for proper operation. See "De-sooting Procedure" on page 26.

2. Clean main burners and pilot burner of dust and lint.

3. Inspect and operate all controls, gas valve and pressure relief valve (if equipped).

4. Make visual check of the burner and pilot flames. Flame pattern on the main burner and pilot is illustrated in the Post Start-Up Inspection section. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should these occur, shut the heater off and contact your gas supplier or qualified service agency.

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

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

7.1. Service

Verify proper operation after servicing.

S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé.

7.1.1. Water Pressure Switch

The water pressure switch, ensures that the heater operates only when the lter pump is in operation. It is located on the In/Out header. It is factory set at 1.75 PSI (12kPa) for deck-level installations. When the heater is located below the level of the spa or pool, it may be necessary to adjust the pressure switch to compensate for the no-ow static head. If it is necessary to adjust the water pressure switch, utilize the following procedure.

3. Turn pump off and on several times. Heater should shut off immediately. If it does not, repeat the above steps.

NOTE: If heater is installed outside of the limits shown, a

higher pressure rated 11 psi (76 kPa) switch may be used. A ow switch, mounted and wired adjacent to the heater,

may be used in place of the factory mounted pressure

switch. See Illustrated Parts List for 11 psi (76 kPa) water

pressure switch.

Adjustment Knob

Figure 37. Water Pressure Switch Adjustment

7.1.2. Two-Speed Pumps

In some cases, the ow on the low-speed is insucient to operate the heater. This is apparent when the water pressure switch cannot be further adjusted or if the heater makes banging noises or shuts o on high limit. In these cases, the pump must be run at high speed when heating the water.

CAUTION: Do not operate the heater without the

function of a properly adjusted water pressure switch or

ow switch.

7.1.3. Pilot Safety

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

CAUTION: Do not adjust the pressure switch until all

air has been evacuated from the system and the water

ow rate meets the requirements listed in Table I.

Water Pressure Switch Adjustment

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

2. Turn adjustment knob counter-clockwise 1/4 turn.

Figure 38. Flame Roll-Out Safety Switch

7.1.4. Flame Roll-Out Safety Switch

Heaters are equipped with a thermal cuto device to prevent ame roll-out in the event the heat exchanger becomes blocked. This is a “single-use” type fusible link or thermal fuse, that must be replaced when disabled by an over-temperature condition, caused by excessive restriction in the heat exchanger ue passage, roll-out, high winds, etc.

7.1.5. High Limits

The heater is equipped with two automatic high limits. Both are located in the In/Out header. Both are set to open at 135°F (57°C).

NOTE: An erratic high limit is often characteristic of an internal heat exchanger problem, e.g. scale build-up, defective bypass. Refer to Troubleshooting section.

7.1.6. High Limit Removal

1. Shut off main electrical power switch to heater.

2. Remove rear In/Out inspection panel.

3. Remove defective high limit and replace with a new high limit.

4. Replace inspection panel.

12. Reverse above procedure to reinstall.

Figure 40. Burner Tray Assembly

7.1.8. Gas Valve Removal

1. Remove burner tray.

2. Disconnect pilot tubing from gas valve

3. Rotate the gas valve counter clockwise to remove valve from nipple.

4. Reverse above procedure to reinstall.

Figure 39. High Limit Switch

7.1.7. Burner Tray Removal

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door

4. Disconnect gas line from gas valve.

5. Remove (3) screws holding the anti-rotation bracket in place.

6. Remove bracket an set aside.

7. Remove (4) screws as shown in the image.

8. Disconnect wiring from gas valve.

9. Remove (2) screws holding the control panel up.

10. Flip the control panel forward.

11. Disconnect ignition wire and remove with burner

tray.

SCREWS HOLDING

TRAY IN PLACE

Figure 41. Gas Valve Removal

7.1.9. Pilot Removal and Cleaning

1. Remove burner tray from heater

2. Disconnect tubing from gas valve.

3. Remove (2) screws holding pilot bracket in place.

4. Remove the pilot assembly by pushing the pilot

5. Remove the locating pilot screw from the bracket to release the pilot assembly.

6. Reverse above procedure to reinstall

7.1.10. Heat Exchanger Removal

PILOT BRACKET SCREWS

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

2. Remove the (8) top jacket holding screws. Remove the jacket top.

3. Remove the screws holding down the flue collector. Remove the flue collector.

4. Remove upper in/out access panel.

5. Disconnect all electrical wiring from in/out header.

6. Remove temperature sensor from in/out header.

7. Disconnect flange nuts on In/Out header.

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

9. Reverse above procedure to reinstall.

Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in non-inhibited descale solvent for severe scale build-up.

7.1.12. De-sooting Procedure

CAUTION: Soot may be combustible. Wet sooted

surfaces completely prior to cleaning. Do not use steel wire brush.

Soot will clog areas between ns and cause eventual

tube failure. Any sign of soot at the base of the burners or around the outer jacket indicates a need for cleaning.

1. Remove top and flue collector from cabinet.

2. Remove burner tray.

3. Remove heat exchanger from the heater and wash with a garden hose, making sure soot is removed from spaces between fins.

4. Reverse above procedure to reinstall.

NOTE: In extreme cases it may be necessary to do highpressure cleaning at a local car wash. DO NOT WIRE BRUSH.

Figure 42. Spark to Hood Pilot

Figure 43. Pilot Bracket Screws

7.1.11. Tube Cleaning Procedure

Establish a regular inspection schedule, the frequency depending on the local water conditions and the severity of service. Do not let the tubes clog up solidly.

Extension Pieces (2)

Figure 44. Tube Cleaning Kit

Auger

with Carbide Tip

Wire Brush

7.1.13. Replacement Parts

NOTE: When ordering parts, it is important that the heater model number, serial number, and type of gas are

specied.

Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag, completely lled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid.

If determined defective by the Company and within warranty, a like part or equal substitution will be returned, freight collect. Credit will not be issued.

MANUFACTURER:

2151 EASTMAN AVENUE

OXNARD, CA 93030

NOTE: Please remove heat exchanger from heater prior to reaming or removing debris.

Clean out deposits over 1/16" (0.16cm) in thickness. Use the Tube Cleaning Kit #052871F to ream the tubes as necessary. After reaming, mount the wire brush in place of the auger and clean out debris remaining in the tubes.

8. TROUBLESHOOTING

8.1. Mechanical

IMPORTANT NOTICE: These instructions are intended for the use of qualied personnel who are specically trained and

experienced in the installation of this type of heating equipment and related system components. Installation and service

personnel may be required by some states to be licensed. Persons not qualied shall not attempt to install this equipment

nor attempt repairs according to these instructions.

Problem Possible Cause Corrective Action

Harmonics, or whining noise *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 ow ............................................................. Scale forming in heat exchanger - clean heat exchanger and

Heater going on and o

continuously

Liming or scale forming in exchanger

Sooting High ow rates ................................................. Reduce by adding manual bypass valve

Pilot outage or “Weak Flame” signal

Yellow lazy ame Low gas pressure ............................................ Adjust gas pressure

Outer jacket very hot (paint

blistered)

Dirty lter ........................................................... Clean or replace lter

Low water level in pool .................................. Raise water level

External bypass setting out of

adjustment ........................................................ Adjust bypass

*Pressure switch out of adjustment .......... Adjust pressure switch

Pool water .......................................................... See Water Chemistry on page 5

Bypassing too much water ........................... Inspect bypass for movement, 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

Low gas pressure ............................................ Adjust gas pressure

Restricted/dirty pilot ...................................... Clean pilot and/or electrode

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

Insects or debris clogging burner intake

ports .................................................................... Clean burners

*Broken refractory caused by shipping

damage or improper combustion .............. Replace refractory panels

Excessive sooting of heat exchanger ....... Determine cause of sooting and correct

check pool pH and total alkalinity

Adjust manual bypass valve until heater outlet water temp is between 105°F and 110°F (40.5°C and 43.3°C) If no movement, replace

Takes too long to heat pool or spa

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

Leaking at heat exchanger Overacid ............................................................. Replace heat exchanger and maintain proper water chemistry

Gasket brittle and leaking -

(overheated)

* Indicates symptom which usually occurs on initial start-up.

Under-sized heater .........................................

Filter not running long enough ................... Reset time clock

Dirty lter ........................................................... Clean lter

Gas line or meter undersized ...................... Refer to installation instructions

Heater running after pump shuts o ........ See Pressure Switch Adjustment

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

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

Calculate heating capacity of heater Htr. output (BTUH) Pool gallonage x 8.33 or refer to heater sizing chart This does not take into account heat loss due to weather

8.2. P-106 Control Logic Flow Chart

START

Turn knob to a desired

temperature zone.

Turn switch on.

The home circuit breaker may have tripped.

Check and reset if necessary.

After six (6) seconds,

does the pilot spark?

YES

Is there power to the heater?

YES

1. Ve rify that the time clock is in the “ON” position.

2. Check to see if the pump strainer basket is full. Remove debris if necessary.

3. Check to see if the filter is dirty. If it is, backwash or clean the filter.

4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure, then there is not enough moving water in the system (or the gauge is broken). Attempt to make the pump run at its normal flow rate.

Does the pilot spark after performing the above steps?

1. The setpoint may be lower than the actual temperature. Turn the knob counterclockwise to raise it.

2. Check the high limits. Both are normally closed.

3. Check the rollout switch. It must be normally closed.

4. Check the wiring in the control box against the wiring diagram.

Is the pilot lit?

YES

Do the burners light?

YES

END

Ensure that the heater is OFF. Attempt each of the following steps individually, and manually restart the heater after each attempt.

1. Check the gas line for air in the system.

2. Ensure that the high tension wire is not grounding out to metal or to other voltage wiring.

3. Ve rify that the high tension wire is properly connected to the ignition module.

4. Check the gas valve. There must be 24VAC between PV and MV/PV.

Check the gas valve. There must be 24VAC

between PV and MV/PV.

8.3. P-156 Control Logic Flow Chart

Power On

Is the water

temperature displayed?

YES

• Check On/Off switch (under lid on control panel)

• Check for 120/240 volts to the transformer (time clock, circuit breaker, wire connections)

• Check for 24 volts to Circuit Board (P6 connector)

Push MODE

switch to select "Pool" or "Spa"

Push Temp

arrow to scroll to

desired temperature

Water temperature

and set

temperature

displayed?

YES

“Heating” will display briefly

“Spark”

Flame icon displayed

and flashing?

Water temp displayed?

(pilot lit and rectified)

YES

“Remote” and Water Temperature displayed

(a remote control is controlling the heater)

Note: Disconnect the remote by turning the

remote function off. See page 36 for instructions.

Is a fault code displayed and flashing?

YES

Diagnostic Readouts

“Sensor Failure,” “Sensor Open” or “Sensor Short” -

Temperature sensor out of range (replace sensor)

Sensor Failure

Inspect thermister, wires, and connector at Terminal P1 Check resistance value of the thermister. Reference to chart below. Replace thermister if not within 10% of values shown below. If okay, replace Circuit Board.

Sensor resistance at various temperatures

Temp Degrees F 40 50 60 70 80 90 100 106 Temp Degrees C 4.4 10 15.6 21.1 26.7 32.2 37.8 41.1 Resistance (k) 261.1 199.0 153.1 118.8 93.0 73.3 58.3 51.0

If okay, replace Circuit Board

“Water Sw Open” Pressure switch. Verify water flow and pressure CLEAN FILTER / STRAINER - backwash if neccessary.

“Hi Limit 1 Fault” High limit switch. Verify water flow. Inspect internal “Hi Limit 2 Fault” Thermostat (Unitherm Governor) and bypass valve.

“Rollout Sw Open” Rollout Sensor - Check for blocked heat exchanger and soot. Atmospheric Units - Replace fusible link. Lo NOx Units - Press manual reset button.

“Clock/Fireman Sw” Fireman or Remote switch connected to safety loop is in the OFF mode.

“Vent/Field Sw #1” Vent switch open. Check connections to the board. If extractor installed, troubleshoot extractor.

“Ignition Lockout” Ignition lockout. Check power at pilot valve. Check spark (bad

ignition circuit or hi-tension wire). Verify clean pilot orifice and clearance from igniter to ground hood.

“Ignition Failure” Ignition failure. Verify gas to the heater. Verify valve operation (gas present at tube fitting).

Heater Fired?

YES

END

Verify power at MV on P-4 Terminal on digital circuit board.

Verify power to valve MV voltage. (Replace valve.)

5-S

8-S

9. ILLUSTRATED PARTS LIST

2-V

1-V

1-S

4-V

3-V

2-H

7-H

6-S

6-H

4-H

2-S

1-R

11-M

12-M

6-H

3-S

1-J

5-V

5-H

7-H

4-S

3-H

7-C

2-J

6-C

5-C

9-C

8-C

1-J

10-C

3-M

2-J

2-M

2-C

3-J

10-S

3-C

9-S

4-M

4-J

4-C

9-S

8-M

4-J

9-M

1-B

3-B

10-M

1-G

7-S

5-P

1-P

3-P

2-P

4-P

15-H

(OPTIONAL)

16-H

13-H

9-C

8-H

14-H

1-C

12-H

10-H

11-H

5-M

(OPTIONAL)

1-M

17-H

1-H

Natural 1.30mm (0-4,999 ft) Propane 1.84mm (0-1,999 ft)

*FOR ALTITUDES ABOVE THOSE LISTED, CONSULT THE FACTORY.

CALL

5-VStack Adapter014910F014911F

OUT DESCRIPTION106A156A

MMISCELLANEOUS COMPONENTS

1-MPressure Switch 1.75 PSI 006737F006737F

2-MThermostat Knob 009499F009499F 3-MKnob Stop 006886F006886F 4-MDial Plat 5-MPRV 125 PSI (Optional) 008091F008091F 6-M Deliming Kit (not shown) 052871F052871F 7-MWire Harness Analog (not shown

8-M Control Bezel Digital (Includes Switch Decal)N/A 014886F 9-MSwitch/Decal-Membrane N/A014887F 10-M Control Bezel Cove 11-M Line Cor 12-M Roll-Out Safety Switch 005899F005899F 13-M To uch-up Paint

PPILOT

1-PPilot Nat

2-PPilot Orifice Nat. 003903F003903F Pilot Orifice Pro 3-PPilot Mounting Bracket 014889F014889F 4-PPilot Tube 004078F004078F 5-P Hi Tension Wire w/Pilot Electrod

RREFRACTORY

1-R Refractory Ki

SSHEETMETAL

1-SJacket To 2-SJacket Left 014894F014895F 3-SJacket Right 014896F014897F 4-SJacket Upper Front 014898F014898F 5-SJacket Lower Rea 6-S Flue Collecto 7-S Door Panel

8-SAccess Panels 014904F014904F 9-S Control Panel

10-S Control Cover

V VENTING

1-VStackless Top (Outdoor 2-VAccess Panel (Hot 3-VDrafthood w/Adapter (Indoor) 014357 014358

4-VStack N/AN/A

Pressure Switch 11 PSI Special-See Ad

Wire Harness Digital (not shown

Cool Dark Gray 750256 750256 Warm Dark Gray 750258 750258

Pilot Pro. 002003F002003F

Raypak 014902F014902F Rheem 014903F014903F Ruud 014902F014902F

Analog 014905FN/A Digita

Analog 014778 N/A Digita

Outdoor Stack w/Adapter (Outdoor

in Service Manual 009133F009133F

14912FN/A

14884FN/A

/A 014885F

/A 014888F

11609F 011609F

02003F002003F

04308F004308F

/A N/A

14890F014891F

14892F014893F

14899F014899F 14900F014901F

/A 014906F

/A N/A

14907F014908F 14909F014909F

14718 014719

For Altitudes Over 2,000 Feet Above Sea Level, Consult Factory.

Natural to Propane Copper Heat Exchanger 014914F 014915F Cupro Nickel Heat Exchanger N/AN/A Propane to Natural Copper Heat Exchanger 014918F 014919F Cupro Nickel Heat Exchanger N/AN/A

** Gas Conversions are to be done only by a qualified agency.

CONVERSION KITS** 106A 156A

NOTES

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Raypak 106, 156 User's Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual