INSTALLATION & OPERATING
INSTRUCTIONS
CATALOG NO. 6100.59E Effective: 06-24-08 Replaces: 12-12-07 P/N 241255 Rev. 6
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death
.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
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 fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
Model 130A
Atmospheric
Above-Ground
Pool & Spa
Heater
2
Rev. 6 reflects the following: a formatting correction to the Clearances section on page 8.
WARNINGS 4
Pay Attention to These Terms 4
WATER CHEMISTRY 5
Automatic Chlorinators &
Chemical Feeders 5
SAFETY 6
Water Temperature Safety 6
INTRODUCTION 6
Ratings & Certifications 6
Model Identification 7
Specifications 7
Unpacking 7
INSTALLATION 8
Installation Codes 8
Clearances 8
Base Installation 8
Outdoor Installation 8
Indoor Installation 10
Combustion & Ventilation Air 10
Gas Connections 11
Water Connections 13
Electrical Connections 15
Control Adjustments—Millivolt 16
Wiring Diagrams 17
Post Start-Up Inspection 20
Cold Weather Operation 20
MAINTENANCE 21
SERVICE 21
Water Pressure Switch 21
Flame Roll-Out Safety Switch 22
High Limits 22
Pilot Safety—Millivolt Models 22
Burner Tray Removal 22
Gas Valve Removal 24
Main Burner & Orifice Removal 24
Igniter Removal & Cleaning (Electronic) 24
Ignition Control Fault Codes 24
Pilot Removal & Cleaning (Millivolt) 25
Heat Exchanger Removal 25
Tube Cleaning Procedure 25
De-sooting Procedure 25
Immersion Well Replacement— Millivolt 26
Replacement Parts 26
TROUBLESHOOTING 27
Mechanical 27
Electrical 28
General—Heater Will Not Fire 30
Electronic Control Logic
Flowchart 30
ILLUSTRATED PARTS LIST 31
CONTENTS
3
DANGER:
Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
WARNING:
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
CAUTION:
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
NOTE:
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DANGER: Failure to install the drafthood on indoor
installation and properly vent the heater to the
outdoors as outlined in the venting section of this
manual can result in unsafe operation of the heater.
To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the venting
section of this manual for more information regarding
vent system inspections.
WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
Do not handle, use, or store gasoline or other
flammable or combustible materials in the vicinity of
a heater.
WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the user's information manual provided with
this heater. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
CAUTION: Verify proper operation after servicing.
WARNINGS - Pay Attention to These Terms
4
WARNING: This unit contains refractory ceramic
fiber (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 classified 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 fibers. When cleaning spills,
use wet sweeping or High Efficiency Particulate Air
(HEPA) filtered 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
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
5
WATER CHEMISTRY
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 efficiency and damaging the heater. If
the pH drops below 7.2, this will cause corrosion of the
heat exchanger and severely damage the heater. Heat
exchanger damage resulting from chemical imbalance
is not covered by the warranty.
For your health and the protection of your pool equipment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
• 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 efficient in heated water,
unless controlled, they can lead to excessive chlorine level which can damage your heater.
• Further advice should be obtained from your pool
or spa builder, accredited pool shop, or chemical
supplier for the correct levels for your water.
Automatic Chlorinators &
Chemical Feeders
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemicals
in the skimmer. High chemical concentrations will
result when the pump is not running (e.g. overnight).
Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off. See
Fig. 1.
NOTE: Corrosive water voids all warranties.
CAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and void the warranty.
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) 6000 Maximum 6000 Maximum 6000 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!
Table A: Water Chemistry
6
Filter
Fig. 1: Pool/Chlorinator Setup
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 fire or explosion, causing
property damage, bodily injury, or death.
Should you have any problems understanding the
warnings and instructions in this manual, STOP, and
get help from a qualified installer, service technician,
or the gas supplier.
Water Temperature Safety
Elevated water temperature can be hazardous. The
U.S. Consumer Product Safety Commission has these
guidelines:
1. Spa water temperatures should never exceed
104°F (40°C). A temperature of 100°F (38°C) is
considered safe for a healthy adult. Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use may cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.
3. Pregnant Women Beware! Soaking in water over
102°F (39°C) may cause fetal damage during the
first three months of pregnancy resulting in the
birth of a brain-damaged or deformed child.
Pregnant women should stick to the 100°F (38°C)
maximum rule.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err
in regulating water temperatures by as much as
4°F (2.2°C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pressure
problems should obtain a physician's advice
before using spas or hot tubs.
6. Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines,
anticoagulants, or recreational drugs should not
use spas or hot tubs.
INTRODUCTION
Ratings & Certifications
This pool & spa heater is design-certified and tested
under the latest requirements of ANSI Z21.56 / CSA
4.7 Standard for Gas-Fired Pool Heaters. The heater
can be used either indoors or outdoors. If necessary,
the top of the heater can be changed after installation
to accommodate indoors or outdoors.
Heater
Auto-Chlorinator
Check Valve
Pump
Skimmer
Pool
Check Valve
Return to Pool
7
WARNING: Use of any parts not manufactured
and/or approved by the manufacturer will void the
warranty.
Ambient Temperature Rating of
Components
• Millivolt heater +32°F to +175°F
• Electronic heater only -40°F to +175°F
Model Identification
The model identification number and heater serial
number are found on the heater rating plate.
The model identification number will be similar to
PR130A- EN-X, where:
• "EP" designates an Electronic heater using Propane
gas
• "EN" designates an Electronic heater using Natural
gas
• "MP" designates a Millivolt heater using Propane gas
• "MN" designates a Millivolt heater using Natural gas
• "P" prefix designates plastic (Polymer) headers
• "X" suffix designates Cupro-Nickel tubing
• "C" suffix designates Copper tubing
Heater
Rating
Plate
Fig. 2: Location of Heater Rating Plate
Specifications
Unpacking
On receipt of the heater it is suggested that visual
checks are made for external damage to the shipping
carton. If the carton is damaged, make a note to that
effect on the Bill of Lading when signing for the shipment. Remove the heater from the shipping
packaging. Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that the
correct number of packages are received, as indicated
on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Authorization to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
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.
Model
No.
Input
(BTUH)
Gas
Conn.
(NPT)
Water
Conn.
Shipping
Weight, Std.
Heater
w/Stackless
Top
130A 130,000 1/2 in.
1-1/2
in. or 2
in.
NPT
140 lbs.
Table B: 130A Specifications
8
INSTALLATION
Installation Codes
Installations must be in accordance with local, state,
provincial, and national codes, laws, regulations and
ordinances. In the absence of local codes, installations
must be in accordance with the latest editions of the:
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
• National Electrical Code, ANSI/NFPA 70
• For Canada only: CAN/CGA B149 installation Code
(B149) and CSA C22.1 C.E.C. Part 1 and Part 2
Clearances
The required minimum clearances from combustible
surfaces are shown in Table C below.
When installed according to the listed minimum clearances from combustible construction, the pool heater
can be serviced without removing permanent construction around the heater.
However for ease of servicing, we recommend a clearance of at least 24" in the front, and at least 18" on the
rear. This will enable the heater to be serviced in its
installed location, that is, without movement or
removal of the heater.
Heater Side
Outdoor
Installations
Indoor
Installations
Top* Unobstructed 42 in.
Front 6 in. Alcove
Vent N/A 6 in.
Back 12 in. 12 in.
Right Side 6 in. 6 in.
Left Side 6 in. 6 in.
*Clearance from top of vent terminal.
Table C: Required Minimum Clearances from
Combustible Surfaces.
Fig. 3: Alternate Method for Providing a Non-
Combustible Base
Clearances less than these may require removal of the
heater to service either the heat exchanger or the
burner tray. In either case, the heater must be installed
in a manner that will enable the heater to be serviced
without removing any structure around the heater.
Base Installation
Heater must be mounted on a level base, such as
cementable slab, cement blocks or another non-com-
bustible surface. An alternate method for providing a
base for combustible floors is illustrated. Heaters may
not be installed on carpeting.
Outdoor Installation
NOTE: This heater is design-certified for outdoor
installation when equipped with the approved top(s)
for outdoor use.
WARNING: The heater should not be located in an
area where water sprinklers, or other devices, may
cause water to spray through the cabinet louvers
and into the heater. this could cause internal rusting
or damage electrical components, and void the
warranty.
WARNING: Do not install within 3 feet of a heat
pump or an outdoor condensing unit. strong air
intake from this type of equipment can disturb the
combustion process and cause damage or personal
injury
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 flow.
Minimum
12"
Minimum
4"
Minimum
HEATER
Sheet Metal
24 Gauge
Hollow concrete cinder block,
align holes and leave ends open.
12"
9
Fig. 4: 130A Dimensions
Heater with Outdoor Stackless Top
Heaters must not be installed under an overhang of
less than 3 ft from the top of the heater. Three sides
must be open in the area under the overhang. Roof
water drainage must be diverted away from heaters
installed under overhangs with the use of gutters.
• For U.S. installations, the point from where the flue
products exit the heater must be a minimum of 4 ft
below, 4 ft horizontally from, or 1 ft above any door,
window or gravity inlet into any building. The top surface of the heater shall be at least 3 ft above any
forced air inlet, or intake ducts located within 10 ft
horizontally. See Fig. 7
• For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10
ft below, or to either side, of any opening into the
building. Refer to the latest revisions of CAN/CGAB149
Outdoor High-Wind Top
High Wind Conditions
(Outdoor Units Only)
In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' from high
vertical walls, or install a wind-break so the heater is
not in direct wind current.
In areas of daily high winds, it may be necessary to
replace the outdoor stackless top with a stack adapter
in combination with a wind-resistant/weather-proof
outdoor stack. See Fig. 5.
The outdoor stack serves the same function as the low
profile stackless top and should be installed in accordance with the same clearance requirements. Follow
the installation instructions provided with the High
Wind Kit for installation.
NOTE: The outdoor high-wind top is optional
equipment and does not come standard with the
heater. Use the following part numbers: P/N 004301
(Green), P/N 011558 (Gray)
Fig. 5: Outdoor High-Wind Top
HIGH-WIND
TOP
10
Indoor Installation
The heater is design-certified 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 nameplate. Follow
the installation instructions provided with the Indoor
Drafthood Kit for installation.
Indoor Drafthood
Combustion & Ventilation Air
(Indoor Units Only)
The heater must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are one opening that is 12 inches from the
ceiling for ventilation, and one opening that is 12 inches from the floor for combustion air as outlined in the
latest edition of the National Fuel Gas Code, ANSI
Z223.1(Canada-CAN/CGA-B149) and any local codes
that may have jurisdiction.
NOTE: For Canada, indoor installation is restricted
to an enclosure that is not occupied and does not
directly communicate with an occupied area. Refer
to the latest edition of CAN/CGA-B149 for specific
requirements.
Fig. 6: Indoor Drafthood
NOTE: The indoor drafthood is optional equipment
and does not come standard with the heater. Use the
following part number: P/N 003723.
All Air From Inside the Building
Each opening shall have a minimum net free area of
130 sq. in.
All Air From Outdoors
When air is supplied directly from outside of building,
each opening shall have a minimum net free area of
33 sq. in.
Vent Piping
Vent piping the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least 10 ft (drafthood relief opening to vent terminal),
the vent pipe size may be reduced as specified in the
National Fuel Gas Code, ANSI Z223.1 (Canada CAN/CGA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows.
If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 in. per ft rise and should
be supported at not more than five foot intervals.
Plumbers tape, criss-crossed, will serve to space
both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof
more than five feet should be securely guyed or
braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the
roof and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies with local codes or, in the absence of such codes,
the latest edition of the National Fuel Gas Code, ANSI
Z223.1 (Canada - CAN/CGA-B149).
The discharge opening must be a minimum of 2 ft vertically from the roof surface and at least 2 ft higher than
any part of the building within 10 ft. Vent stack shall be
at least 5 ft in vertical height above the drafthood outlet. The vent cap location shall have a minimum
clearance of 4 ft horizontally from, and in no case
below, unless a 4 ft horizontal distance is maintained,
from electric meters, gas meters, regulators and relief
equipment.
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.
Indoor
Drafthood
11
4 ft
Fig. 7: Outdoor Installation Clearances
Fig. 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 specified in the latest edition of the National
Flue Gas Code ANSI Z223.1 (Canada - CAN/CGAB149).
Gas Connections
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve located outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
CAUTION: Do not use 5, 10 or 20 gallon propane
tanks, like those used with consumer bar-b-ques, to
supply gas to this heater.
CAUTION: The heater and its manual shut-off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa). The heater
and its gas connections shall be leak tested before
placing the appliance in operation. Use soapy water
for leak test. do not use open flame.
Minimum
3 ft
Minimum
Forced Air Inlet
Minimum
10 ft
Minimum
4 ft
4 ft
Minimum
1 ft
Minimum
12
Fig. 9: Gas Line Sediment Trap
NOTE: Do not use Teflon tape on gas line pipe
thread. A flexible pipe sealant suitable for LP gases
is recommended.
Gas Pressure Regulator
If adjustment is needed, remove seal and turn adjustment screw clockwise to increase pressure or
counter-clockwise to decrease pressure.
Gas Pressure* Natural Gas Propane Gas
Max. Inlet
(static)
10.5 in. WC 13 in. WC
Min. Inlet
(dynamic)
7 in. WC 11 in. WC
Manifold Gas
(dynamic)
3.5 in. WC 10 in. WC
*Static means without heater operating, dynamic refers to heater
operating.
Table D: Gas Pressure
Gas Pressure Adjustment Locations
Fig. 10A: Honeywell DSI VR 8205 Gas Valve
Fig. 10B: Robertshaw MV Gas Valve
Fig. 10C: Honeywell MV Gas Valve
(field supplied)
(field supplied)
(field supplied)
Gas Pressure Adjustment
A.
Gas Pressure Adjustment
B.
Gas Pressure Adjustment
C.
13
Electronic Ignition Gas Valves
Manual
Shut-Off
Valve
Manometer
Gas Pressure Test at
Gas Valve
Fig. 11: Location of Gas Pressure Adjustment
Pipe Sizing for Gas Connections
Water Connections
The heater requires water flow and positive pressure
to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:
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.
Model
No.
Input
(KBTU)
1/2 in. 3/4 in. 1 in.
N P N P N P
130A 130 15 35 60 145 200 500
Natural Gas 1000 BTU/FT3 0.60
Specific Gravity @ 0.5 in. WC Pressure Drop
Propane Gas 2500 BTU/FT3 1.53
Specific Gravity @ 0.5 in. WC Pressure Drop
Table E: Maximum Equivalent Pipe Length
Plumbing from the heater back to the pool or spa must
not have any valves or restriction that could prevent
flow 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 optional or field-supplied header
unions.
Flow Rates
Polymer Headers
Before attaching the optional 2-inch unions to the
In/Out header, make sure the O-rings are properly
seated in the grooves. Use AquaLube or equivalent
non-petroleum-based lubricant on the O-ring. Hand
tighten the unions. Glue PVC piping directly to the
unions.
Model No. Min. gpm Max gpm*
130A 20 70
*When flow rates exceed maximum 70 gpm, an external auxiliary
bypass valve is required. See External Auxiliary Bypass Valve section for details.
Table F: Water Flow Rates
Fig. 12: Optional In/Out Header for 2" Installation
Fig. 13: In/Out Header for 1-1/2" or 1-1/4" Hose
Connection
Drain Plug
In/Out Header
O-Ring
Tail Piece
Nut
In/Out Header
Hose Connector
2“ Pipe
Hose
14
High-temperature CPVC header flanges and header
flange nuts are available as an option. If there is any
possibility of back-siphoning when the pump stops, it
is recommended that a check valve (or valves) also be
installed in the system.
Internal Automatic Bypass Valve
A built-in automatic bypass valve is provided in the
In/Out header. The internal bypass valve automatically responds to changes in water pressure in the piping
system. The proper amount of water flow is maintained
through the heater under varying pressures dictated
by the conditions of the pump and filter.
External Auxiliary Bypass Valve
An auxiliary bypass valve must be used when flow
rates exceed 70 gpm. Usually a high-performance
pump size larger than one horsepower will exceed this
flow rate. This valve is required to complement the
function of the automatic bypass valve, particularly
when starting the heater in winter or early spring when
the spa or pool temperature is below 50°F. It also
serves to eliminate needless pressure drop through
the heater and accompanying reduction in the flow
rate to the spa jets, etc.
Fig. 14: Internal Automatic Bypass Valve
Fig. 15: Auxiliary Bypass Valve
NOTE: Do not use a gate valve as an auxiliary
bypass valve.
Auxiliary Bypass Valve Adjustment
To set bypass: With clean filter, adjustment is made by
feeling the inlet and outlet pipes at the heater. Outlet
pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold,
open bypass.
Pressure Relief Valve Installation
To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure
relief valve, having a capacity equal to the BTUH output of the heater to be installed, is recommended for
this heater. The maximum pressure relief valve setting
is 125 psi. This relief valve needs to be installed on the
outlet pipe from the header as noted in Fig. 16 below.
Pipe onto Discharge Side of Piping
Fig. 16: Pressure Relief Valve Installed
Bypass Disc
Spring
From Heater
Full Port
Ball Valve
or Globe
To Pool/Spa
To Heater
Valve
From
Pool/Spa
Bypass Valve
Bypass Body
15
If required, this needs to be installed in a field-supplied
fitting external to the heater. The valve shall be
installed in a vertical position. Do not over-tighten.
Install pressure relief valve hand tight plus 1/2 turn.
Valve lever should be tripped at least once a year to
ensure that waterways are clear. if relief valve does
not function properly, replace it immediately.
Heat Exchanger Pressure Drop
Table
Electrical Connections
Be sure that electrical service to the heater has proper overload fuse or circuit breaker protection, wire size
and connections which comply with all applicable
codes.
Millivolt Heaters
The Millivolt models are equipped with a self-generating electrical system in which the electrical current is
provided by a pilot generator. No external electrical
connections are required.
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-off valve shall be installed between the relief
valve and the drain line.
Flow (gpm) Pressure Drop (ft of Head)
20 1.3
30 1.7
40 2.0
50 2.7
60 3.5
70 4.2
Table G: 130A Pressure Drop
When installing a remote switch, do not exceed 10 ft of
wiring from the heater. Use 18-gauge stranded wire.
Electronic Heaters
The Direct Spark Ignition Device automatically lights
the main burners upon a call for heat. The heater is
supplied with a dual voltage transformer for 120/240
VAC input power hookup.
Heater must be electrically grounded and bonded in
accordance with local codes, or, in the absence of
local codes, with the latest edition of the National
Electrical Code, ANSI/NFPA 70. (Canada - Canadian
Electrical Code, CSA C22.1, Part 1 and Part 2.)
NOTE: If it is necessary to replace any of the
original wiring, use 105°C wire or its equivalent,
and/or 150°C wire or its equivalent, like the original
wiring. See Figures 19 and 20 for wire ratings.
NOTE: Electronic heaters come standard with a 120
VAC 3-prong power cord. For 240 VAC applications,
see instructions below. Power source must be a
wired ground, with ground fault circuit interruption
circuitry.
Fig. 17: Electronic Heater Power
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 deenergize the equipment before servicing.
CAUTION: Label all wires prior to disconnection
when servicing controls. wiring errors can cause
improper and dangerous operation.
16
Installation Instructions—240 Volt
1. Disconnect and remove 120 volt power cord.
2. Install wire nut on white transformer wire.
3. Wire nut 240 volt supply lines to the red and black
wire on the transformer.
4. Wire nut green supply ground line to green transformer wire
CAUTION: This appliance has provisions to be
connected to an alternate supply source. To reduce
the risk of electric shock, disconnect all connections
before servicing.
Fig. 18: 240V Hook-Up
Control Adjustments—Millivolt
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/Off toggle switch and a
thermostat. The switch functions as a means for turning the heater On or Off.
The thermostat is fitted with a means of limiting the
upper temperature limit below the maximum level. The
knob stop adjustment ring shown in Fig. 19 is
adjustable by loosening the set screw, rotating the
knobstop ring to the desired location, and retightening
the set screw.
Fig. 19: Water Temperature Thermostat
NOTE: Maximum temperature is 104°F.
240V HOOK-UP
HOT
L1
SUPPLY
SIDE
BLACK
HOT
L2
RED RED
BLACK
HEATER
HOT
COOL
GREENGREEN
WHITE
Knobstop Set Screw
Knobstop Ring
17
Wiring Diagrams
Fig. 20: Wiring Diagram—Millivolt Models
Fig. 21: Wiring Diagram—Electronic Models
HI Limit HI Limit
BK
(In/Out) (In/Out)
AGS
Thermostat Manual
BK
Y/BK
V/BK
Switch
O
Water
Press
O
Switch Switch
Gas Valve
Roll Out
R
TH/PP
W
-
Val ve
Pilot
TH
PP
R
+
Generator
To Firemans Switch
(field installed)
Optional
V/BK
18
FOR YOUR SAFETY READ BEFORE OPERATING
A. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell near
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners by hand.
5. Remove heater door panel.
6. Turn gas control knob clockwise to
"Off".
7. Wait 5 minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to
the next step.
8. Turn gas control knob counter-clockwise
to "On".
9. Replace heater door panel.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
1. Set the thermostat at the lowest setting.
2. Turn off all the electrical power to the appliance if service is to be performed.
3. Remove heater door panel.
4. Turn gas control knob clockwise
to "Off."
5. Replace heater door panel.
SHUT-OFF PROCEDURES
HONEYWELL
VR 8205 GAS
VALVE
GAS
INLET
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
19
A. This appliance has a pilot that must be lit by
hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTING, smell all around the
appliance area for gas. Be sure to smell near
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. Force or
attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been under water.
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On/Off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn
clockwise to "Off".
NOTE:
Knob cannot be turned from "Pilot" to Off"
unless knob is pushed in slightly. Do not
force.
6. Wait 5 minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the
safety information above. If you don't smell
gas, go to the next step.
7. Locate pilot mounted on the right side panel of
the burner tray.
LIGHTING INSTRUCTIONS
8. Turn gas control knob counter-clockwise
to "Pilot"
9. Place flame to end of pilot tube. Push in
control knob all the way and hold to light pilot.
Continue to hold control knob in for about one
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
If knob does not pop up when released, stop
and immediately call your service technician or
gas supplier.
10. Stand to the side of the heater and turn the
gas control knob counter-clockwise
to "On".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
SHUT-OFF PROCEDURE
HONEYWELL
MILLIVOLT
GAS VALVE
INVENSYS/
ROBERTSHAW
MILLIVOLT
GAS VALVE
HONEYWELL PILOT
ROBERTSHAW PILOT
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
Gas Pressure
Adjustment
20
Post Start-Up Inspection
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 pilot and burner. The flame should be
blue with a well-defined pattern.
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact the installer or gas supplier.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.
Fig. 22: Correct Main Burner Flame Pattern
Fig. 23: Millivolt Pilot Burner Flame
Fig. 24: DSI Igniter Location
Cold Weather Operation
Moderate Climate
Heater operation can continue during short-term cold
spells. When temperatures are between 0° and 32°F,
flow (continuous pump operation) must be maintained.
Cold Climate
Prolonged operation with water temperatures below
50°F is not recommended. When starting the heater
with water temperatures below 50°F, operate the
heater continuously until higher temperatures are
reached. Operating the heater for prolonged periods
with pool water below 50°F 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.
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.
Igniter
Minimum Spark Gap is 0.15” - 0.18”
3/8” Nominally from burner surface
4“ MAX
Head of Pilot
must be above
Burner Deck.
21
Winterizing the Pool/Spa 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 drain plug located on the In/Out header,
under the water pipes.
3. Open the union fittings on the In/Out water lines to
break any vacuum in the system. Alternatively,
remove the 2 wires from the water pressure switch
and unscrew the water pressure switch to break
any vacuum in the system.
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 the De-sooting Procedure in the Service
Section.
2. Clean main burners and pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve (if equipped).
4. Make visual check of the burner and pilot flames.
Flame pattern on the main burner and pilot is illustrated in the Post Start-Up Inspection section.
Fig. 25: In/Out Header Drain Plug Location
Yellow flame means restriction of the air openings.
Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should
these occur, shut the heater off and contact your
gas supplier or qualified service agency.
5. On indoor heaters, clean room intake openings to
ensure adequate flow of combustion and ventilation air.
6. Keep area around heater clear and free from combustible materials, gasoline and other flammable
and corrosive vapors and liquids.
SERVICE
Water Pressure Switch
The water pressure switch, ensures that the heater
operates only when the filter pump is in operation. It is
located on the In/Out header. It is factory set at 1.75
PSI for deck-level installations. When the heater is
located below the level of the spa or pool, it may be
necessary to adjust the pressure switch to compensate for the no-flow static head. If it is necessary to
adjust the water pressure switch, utilize the following
procedure.
Water Pressure Switch Adjustment
1. With pump and heater on, turn adjustment knob
clockwise until a click is heard from the gas valve.
CAUTION: Do not adjust the pressure switch until
all air has been evacuated from the system and the
water flow rate meets the requirements listed in
Table F.
Fig. 26: Water Pressure Switch Adjustment
In/Out Header
Drain Plug
Adjustment Knob
22
2. Turn adjustment knob counter-clockwise 1/4 turn.
3. Turn pump off and on several times. Heater should
shut off immediately. If it does not, repeat the
above steps.
Two-Speed Pumps
In some cases, the flow on the low-speed is insufficient to operate the heater. This is apparent when the
water pressure switch cannot be further adjusted or if
the heater makes banging noises or shuts off on high
limit. In these cases, the pump must be run at high
speed when heating the water.
Flame Roll-Out Safety Switch
Heaters are equipped with a thermal cutoff device to
prevent flame roll-out in the event the heat exchanger
becomes blocked. This is a "single-use" type fusible
link or thermal fuse, that must be replaced when disabled by an over-temperature condition, caused by
excessive restriction in the heat exchanger flue passage, roll-out, high winds, etc.
NOTE: If heater is installed outside of the limits
shown, a higher pressure rated (11 psi) switch may
be used. A flow switch, mounted and wired adjacent
to the heater, may be used in place of the factory
mounted pressure switch. See Illustrated Parts List
for 11 psi water pressure switch.
CAUTION: Do not operate the heater without the
function of a properly adjusted water pressure switch
or flow switch.
Fig. 27: Flame Roll-Out Safety Switch
High Limits
The heater is equipped with two automatic high limits.
Both are located in the In/Out header. Both are set to
open at 135°F.
High Limit Removal
1. Shut off main electrical power switch to heater.
2. Remove In/Out inspection panel.
3. Remove defective high limit and replace with a
new high limit.
4. Replace inspection panel.
Pilot Safety—Millivolt Models
Heaters equipped with the standing pilot (Millivolt system) have pilot generators which act as a safety
device to shut off the flow of gas to the main burners
and the pilot burner in case the pilot flame is extinguished. The pilot burner must be manually re-lighted
to place the heater in operation again. Refer to the
lighting instructions provided on the heater label.
Burner Tray Removal
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
NOTE: An erratic high limit is often characteristic of
an internal heat exchanger problem, e.g. scale buildup, defective bypass. Refer to Troubleshooting
section.
Fig. 28: High Limit Switch
23
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit,
and (2) screws that secure gas valve to jacket.
6. Disconnect wires that terminate at gas valve.
7. Disconnect hi-tension wire from igniter.
8. Remove (1) screw that mounts ground wire to
burner tray.
9. Slide out burner tray.
10. Reverse above procedure to reinstall.
Fig. 29: Millivolt Burner Tray Assembly
Fig. 30: DSI Burner Tray Assembly
Orifice
Rear Hold Down Bracket
Burner
Pilot
Shield
Millivolt Pilot Assembly
(under Pilot Shield)
Millivolt Gas Valve
(Invensys shown)
Manifold
Pilot Lighter Tube
Orifice Placement Bracket
Pilot Bracket
Burner Tray Panel
Igniter
Orifice
Rear Hold Down Bracket
Burner
DSI Gas Valve
(Honeywell shown)
Manifold
Orifice Placement Bracket
Burner Tray Panel
24
Gas Valve Removal
1. Remove burner tray from heater as described in
the Burner Tray Removal section.
2. Disconnect pilot tubing (if removing a Millivolt
valve).
3. Disconnect wires to gas valve.
4. Unscrew gas valve from manifold.
5. Reverse above procedure to reinstall.
Main Burner & Orifice Removal
1. Remove burner tray.
2. Remove screws from rear burner hold-down
bracket.
3. Lift burners from slotted spacers and slide from ori-
fices. Clean with a wire brush.
4. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood toothpick
through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from
manifold. Do not over-tighten when reinstalling.
5. Reverse above procedure to reinstall.
NOTE: If the heat exchanger is sooted badly, the
burner hold-down bracket and spacer can become
distorted from direct-flame impingement and this
usually necessitates replacement of these parts.
Fig. 31: Igniter Position to Burners
Igniter Removal & Cleaning
(Electronic)
1. Disconnect high tension wire from igniter.
2. Remove (2) screws that mount the igniter to the
burner tray.
3. Remove igniter from burner tray.
4. Reverse above procedure to reinstall.
Ignition Control Fault Codes
The ignition control fault codes listed in Table H can be
used to troubleshoot ignition problems.
Fig. 32: Direct Spark Igniter
Code Condition
Steady On Power applied, control OK
Steady Off No power or control hardware fault
1 Flash Ignition lockout from too many trials
2 Flashes
Ignition lockout from too many flame
losses in single call for heat
3 Flashes
Control hardware/software fault
detected
Table H: Ignition Control Fault Codes
ORIFICES MUST BE PARALLEL WITH BASE
TOLERANCE OF +2° -0°
IGNITER
BETWEEN IGNTER & BURNER
PORTS 0.375” ± 0.125”
BURNER PORTS
25
Pilot Removal & Cleaning
(Millivolt)
1. Disconnect pilot tubing and wires from gas valve.
2. Remove pilot assembly from burner tray.
3. Remove pilot from bracket.
4. Remove pilot orifice and air opening (Honeywell
MV unit only), and clean with wire or small brush.
5. Reverse above procedure to reinstall.
Heat Exchanger Removal
1. Shut water, gas and electricity off, close valves
and relieve pressure, then remove relief valve.
Remove side inspection panels.
2. Remove top jacket holding screws. Remove the
jacket top.
3. Remove the four (4) screws holding down the flue
collector. Remove the flue collector.
4. Remove upper in/out access panel.
A
Fig. 33: Honeywell Millivolt Pilot
5. Disconnect all electrical wiring from in/out header.
6. Remove temperature sensor from in/out header.
7. Disconnect flange nuts on In/Out header.
8. Set aside heat exchanger side baffles.
9. Lift heat exchanger straight up using caution not to
damage refractory.
10. Reverse above procedure to reinstall.
Tube Cleaning Procedure
Establish a regular inspection schedule, the frequency
depending on the local water conditions and the severity of service. Do not let the tubes clog up solidly.
Clean out deposits over 1/16" in thickness.
After reaming, mount the wire brush in place of the
auger and clean out debris remaining in the tubes.
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-inhibited de-scale solvent for severe scale build-up.
De-sooting Procedure
Soot will clog areas between fins and cause eventual
tube failure. Any sign of soot at the base of the burners or around the outer jacket indicates a need for
cleaning.
1. Remove top and flue collector from cabinet.
2. Remove "V" baffles from heat exchanger, including side baffles.
3. Remove burner tray.
CAUTION: Do not enlarge hole in pilot orifice.
Fig. 34: Tube Cleaning Kit
NOTE: Please remove heat exchanger from heater
prior to reaming or removing debris.
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
Thermopile
Pilot
ir Opening
Orifice
Extension Pieces (2)
Auger with Carbide Tip
Wire Brush
26
4. Remove heat exchanger from the heater and
wash with a garden hose, making sure soot is
removed from spaces between fins.
5. Reverse above procedure to reinstall.
Immersion Well Replacement—
Millivolt
1. Shut off water to heater and drain heat exchanger.
2. Remove access panel on water connection side.
3. Remove old immersion well with bushing and
sleeve.
4. Install replacement well in header.
NOTE: In extreme cases it may be necessary to do
high-pressure cleaning at a local car wash. DO NOT
WIRE BRUSH.
Fig. 35: Immersion Well Assembly
Replacement Parts
Any part returned for replacement under standard
company warranties must be properly tagged with a
return parts tag, completely filled in with the heater
serial number, model number, etc., and shipped to the
Company freight prepaid.
If determined defective by the Company and within
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: Installation in polymer header should be
hand tight plus 1/2 turn.
NOTE: When ordering parts, it is important that the
heater model number, serial number, and type of gas
are specified.
27
TROUBLESHOOTING
Mechanical
PROBLEM CAUSE SOLUTION
Harmonics, or whining noise *Debris or restriction in system............ Locate the restriction and remove. Flush system and clean.
Low flow............................................... Scale forming in heat exchanger - clean heat exchanger and
check pool pH and total alkalinity.
Outlet pipes hot to touch Low flow.............................................. Scale forming in heat exchanger - clean heat exchanger and
check pool pH and total alkalinity.
Heater going on and off Dirty filter.............................................. Clean or replace filter.
continuously Low water level in pool........................ Raise water level.
External bypass setting out of
adjustment............................................ Adjust bypass.
*Pressure switch out of adjustment..... Adjust pressure switch.
Liming or scale forming in Pool water............................................ See Water Chemistry section.
exchanger Bypassing too much water................... Inspect bypass for movement, if no movement, replace.
Sooting High flow rates..................................... Reduce by adding manual bypass valve.
Adjust manual bypass valve until heater outlet water
temperature is between 105°F and 110°F. (Refer to Figure 15.)
*Air starvation....................................... Refer to installation instructions.
*Improper venting................................ Follow recommended installation instructions.
*Insects or debris clogging
burner intake ports............................. Clean burners.
Pilot outage Low gas pressure................................ Adjust gas pressure.
Restricted pilot..................................... Clean pilot.
Weak pilot generator............................ Replace pilot.
Yellow lazy flame Low gas pressure................................ Adjust gas pressure.
*Insects or debris clogging
burner intake ports............................... Clean burners.
Outer jacket very hot *Broken refractory caused by
(paint blistered) shipping damage or improper
combustion......................................... Replace refractory panels.
Excessive sooting of heat exchanger.. Determine cause of sooting & correct.
Takes too long to heat Under-sized heater............................... Calculate heating capacity of heater:
pool or spa Htr. output(BTUH)
Pool gallonage x 8.33
This does not take into account heat loss due to weather.
Filter not running long enough............. Reset time clock.
Dirty filter.............................................. Clean filter.
Gas line or meter undersized............... Refer to installation instructions.
*Debris in gas line................................ Remove debris or blow out gas line.
Leaking at well Overacid............................................... Replace well and maintain proper water chemistry.
Over chlorination.................................... Check location of chlorinator and backflow preventer.
Leaking at heat exchanger Overacid............................................... Replace heat exchanger and maintain proper water chemistry.
Over chlorination.................................... Check location of chlorinator and backflow preventer.
Gasket brittle and leaking - Heater running after pump shuts off.... See Pressure Switch Adjustment.
(overheated) Refractory damage.............................. Replace refractory.
Sooted heater....................................... Determine cause of sooting and correct.
* Indicates symptom which usually occurs on initial start-up.
These instructions are intended for use by qualified personnel who are specifically trained and experienced in
the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this
equipment nor attempt repairs according to these instructions.
28
Electrical
Standing Pilot Millivolt
The following information is presented for use by qualified service personnel only.
1. Filter must be on with adequate water flow through heater.
2. Gas valve must be in "ON" position. Thermostat set higher than pool water temperature.
3. Jumpers are for temporary check only. If left in place, they could cause the heater to burn up.
Light pilot
If pilot burner remains lit
Jump across both "TH"
wires on gas valves
If main burner fires,
remove jumper
Jump across pressure
If main burner fires,
remove jumper
Clean filter
Check for adequate water
flow from filter
Replace pressure switch
If main burner does not
switch terminals
fire, remove jumper
If main burner does not
fire, remove jumper
Jump across thermostat
If main burner fires,
remove jumper
Replace thermostat
If pilot burner goes out
when main burner lights
or when gas valve knob
Replace
gas
valve
If pilot burner stays on
Problem is a wire or
If main burner does
NOT fire...
Jump across each
high limit and remove
jumper
Replace high limit that
prevented from firing
Remove both "TH"
wires from gas valve.
component short to
cabinet or low gas
pressure
is released
Relight pilot
If pilot burner
does not light
Check gas supply, gas
line size, gas pressure.
Also check for insects
or debris in pilot assy.
If burner does not remain
lit, attach millivolt meter
and read pilot output
If above 500mV,
replace gas valve
If below 500mV, check
gas pressure. Also check
for insects or debris in
the pilot assembly
If output is still low,
replace pilot generator
29
Terminal Block Wiring
Fig. 36: Terminal Block Wiring
1. Raw Output (700mV± 100)
Pilot generator disconnected from valve (knob must be held down to keep pilot on).
White – Negative
Red + Positive
2. Pilot Load (500mV± 100)
Pilot generator connected to valve-Power applied to pilot solenoid.
TP(Thermopile-Robertshaw)
PP(Power Pile-Honeywell)
TH TP – Common (Invensys)
TH PP – Common (Honeywell)
3. Main Valve Load (200mV± 100)
Control/Limit circuit closed (All switches "ON")
TP(Thermopile-Robertshaw)
PP(Power Pile-Honeywell)
TH TP – Common (Invensys)
TH PP – Common (Honeywell)
30
Electronic Control Logic Flowchart
Fig. 37: Control Logic Flowchart
General—Heater Will Not Fire
If there is no electrical power, it may be that the home "circuit breaker" has tripped. Try re-setting it.
If there is electrical power but the heater will not fire check the following:
1. The time clock must be in the "ON" position.
2. The pump strainer basket may be full. If so remove debris.
3. The filter may be dirty. If so, backwash or clean filter. (To tell if the filter is dirty, look to see if the filter pressure will be higher than usual).
4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure; then there is not enough moving water (or the gauge is broken). Try to get the pump to run at its normal
flow rate.
START
Turn knob to a
desired temperature
zone.
Turn switch ON.
After (6)
seconds, does
the igniter
spark?
Yes
Does the
burner tray
light?
Yes
Does the
burner tray
stay lit?
Yes
END
No
No
No
•Check water flow. Pressure switch is set for 1.75 PSI.
•Turn knob counterclockwise (setpoint may be lower
than actual temperature)
•Check High Limit. Both are normally closed.
•Check Roll-Out switch. Must be normally closed.
•Check wiring in control box against wiring diagram.
Ensure the heater is OFF. Attempt each step individually and
manually restart the heater after each attempt.
•Check gas line. There may be some air in the system.
•Make sure high tension wire is not grounding out to metal
or other voltage wire.
•Make sure high tension wire is properly connected to the
igniter.
•Check the gas valve. There must be 24VAC while the ignition
module is sparking.
•Check the igniter. Igniter may not be sensing correctly.
Check that the spark plug gap is ~.18”.
31
ILLUSTRATED PARTS LIST
32
1-P
5-P
4-P
2-P
6-P
HONEYWELL MILLIVOLT PILOT
3-P
7-P
8-P
33
CALL Plastic Plastic
OUT DESCRIPTION Green Gray
B BURNER TRAY
1-B Burner Tray w/Burners (Sea Level)* 011578F 011578F
Burner Tray w/o Burners (Sea Level)* 011579F 011579F
Burner Tray w/Gas Valve Natural MV 011580F 011580F
Burner Tray w/Gas Valve Propane MV 011581F 011581F
Burner Tray w/Gas Valve Natural DSI 011582F 011582F
Burner Tray w/Gas Valve Propane DSI 011583F 011583F
2-B Burner Hold Down Kit 011584F 011584F
3-B Burner 301210/10 301210/10
4-B Burner Orifice Nat. #51 (Sea Level)* 350080F/10 350080F/10
Burner Orifice Pro. #59 (Sea Level)* 350350F/10 350350F/10
C CONTROLS
1-C Thermostat Auto Reset 135º Surface Mount 006725F 006725F
2-C Thermostat Control MV (Mechanical) 003346F 003346F
3-C Thermostat Control DSI (Solid State) 011585F 011585F
4-C PC Board 005086B 005086B
5-C Potentiometer 011586F 011586F
6-C Temperature Sensor 011587F 011587F
G GAS VALVE
1-G Combination Valve Nat. MV 011588F 011588F
Combination Valve Pro. MV 011589F 011589F
Combination Valve Nat. DSI 011590F 011590F
Combination Valve Pro. DSI 011591F 011591F
H HEAT EXCHANGER
1-H Heat Exchange Assy Copper 011592F 011592F
Heat Exchange Assy Cupro Nickel 011593F 011593F
2-H Inlet/Outlet Header Complete 011594F 011594F
Inlet/Outlet Header (Includes 6-H) 011595F 011595F
3-H Return Header (Includes 6-H) 011596F 011596F
4-H
Tube Bundle Copper **
Tube Bundle Cupro Nickel **
011597F 011597F
011598F 011598F
5-H Baffle 011599F 011599F
6-H Flange Nut Kit 008259F 008259F
7-H O Ring Gasket (2) 011600F 011600F
8-H Sensor Adapter DSI 006714F 006714F
Sensor Well Millivolt 006805F 006805F
9-H Bypass Kit 011601F 011601F
10-H Bypass Valve 006716F 006716F
11- H Bypass Dam / Shaft 006717F 006717F
12-H Bypass Spring 011602F 011602F
13-H Drain Plug 006721F 006721F
14-H Inlet/Outlet Header Dam 011603F 011603F
15-H Hose Adapter 1-1/2" MPT x 1-1/2" Hose 011635 011635
16-H 2" PVC Connector & Nut (2) Optional 006723F 006723F
17-H O Ring (2) Optional 006724F 006724F
J CONTROL BOX
1-J Control Box DSI (Includes 3-C) 011604F 011604F
2-J Transformer 120/240/24V 011605F 011605F
3-J Ignition Control Direct Spark 011606F 011606F
4-J Rocker Switch 009493F 009493F
*FOR ALTITUDES ABOVE 2,000 FEET ABOVE SEA LEVEL, CONSULT THE FACTORY.
** WARNING: The Hydraulic conditions or water chemistry that caused the tube
bundle to fail have very likely also damaged the bypass valve. We recommend you inspect
the bypass assembly. Failure to do so could cause premature failure of this replacement part.
34
CALL Plastic Plastic
OUT DESCRIPTION Green Gray
M MISCELLANEOUS COMPONENTS
1-M Pressure Switch 1.75 PSI 006737F 006737F
Pressure Switch 11 PSI Special-See Adj in Service Manual 009133F 009133F
2-M Thermostat Knob 009499F 009499F
3-M Knob Stop 006886F 006886F
4-M Dial Plate 901768 901769
5-M PRV 125 PSI (Optional) 008091F 008091F
6-M Deliming Kit 052871F 052871F
7-M Wire Harness MV 011607F 011607F
Wire Harness DSI 011608F 011608F
(not shown)
(not shown)
(not shown)
8-M Line Cord 011609F 011609F
9-M Thermal Fuse 005899F 005899F
10-M Touch-up Paint (Green) 750125
Touch-up Paint (Dark Gray) 750126
P PILOT
1-P Pilot Nat. MV 600525B 600525B
Pilot Pro. MV 600575B 600575B
2-P Pilot Orifice Nat. MV 003901F 003901F
Pilot Orifice Pro. MV 003902F 003902F
3-P Pilot Generator MV 600019B 600019B
4-P Pilot Mounting Bracket MV 011610F 011610F
5-P Lighter Tube MV 052797 052797
6-P Pilot Tube MV 004078F 004078F
7-P Ignitor DSI 011611F 011611F
8-P Hi Tension Wire DSI 011612F 011612F
R REFRACTORY
1-R Refractory Kit 011613F 011613F
2-R Refractory Retainer Kit 011614F 011614F
S SHEETMETAL
1-S Jacket Top 011615F 011616F
2-S Jacket Left 011617F 011618F
3-S Jacket Right 011619F 011620F
4-S Jacket Rear 011621F 011622F
5-S Flue Collector 011623F 011623F
6-S Door Assy. 011624F 011625F
7-S Access Panels 011626F 011627F
8-S Control Panel 011628F 011629F
9-S Poolstat Control Cover 006492 006492
V VENTING
1-V Stackless Top (Outdoor) 011630F 011631F
2-V "Pagoda" Top 010334 011632
3-V Drafthood (Indoor) 003723 003723
4-V Outdoor Stack w/Adapter (Outdoor) 004301 011558
5-V Outdoor Stack N/A N/A
CONVERSION KITS**
GAS CONVERSIONS
Natural to Propane MV 011633F
Propane to Natural MV 011634F
Natural to Propane DSI N/A
Propane to Natural DSI N/A
** Gas conversions are to be done only by a qualified agency.
For gas conversions, please consult the factory.
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