WARNING: If these instructions are not followed exactly, a re or explosion may result causing property
AA
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 a safe place for future
reference.
10.2. Control Logic - Flow Chart ................................. 34
11. ILLUSTRATED PARTS LIST......................................35
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Page 4
1. WARNINGS
1.1. Pay Attention to These Terms
DANGER
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WARNING
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CAUTION
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CAUTION
NOTE
DANGER: Failure to install the drafthood on indoor
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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
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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: This unit contains refractory ceramic
AA
ber (RCF) insulation in the combustion chamber. RCF,
as manufactured, does not contain respirable crystalline
silica. However, following sustained exposure to very
high temperatures [>2192°F (1200°C)], the RCF can
transform into crystalline silica (cristabolite). The
International Agency for Research on Cancer (IARC) has
classied 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 Eciency 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 certied respiratory protection, to avoid inhalation
of airborne dust and airborne ber particles.
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: Improper installation, adjustment,
AA
alteration, service, or maintenance can cause property
damage, personal injury or loss of life. Installation and
service must be performed by a qualied installer, service
agency, or the gas supplier.
WARNING: Gasoline, as well as other ammable
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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.
WARNING: Both natural gas and propane have an
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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,
camouage, or otherwise make detecting a gas leak by
smell more dicult.
WARNING: UL-recognized fuel gas detectors are
AA
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
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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
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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.
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Page 5
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
eciency 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
AA
can damage the heater and is not covered under warranty.
• 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.
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 plumbing diagrams on Figure 29 and Figure 30.
• Occasional chemical shock dosing of the pool or
spa water should not damage the heater providing
the water is balanced.
Recommended Level(s)Fiberglass PoolsFiberglass SpasOther Pool and Spa Types
Water Temperature68-88°F (20-31°C)89-104°F (31-40°C)68-104°F (20-40°C)
pH7.3-7.47.3-7.47.6-7.8
Total Alkalinity (ppm)120-150120-15080-120
Calcium Hardness (ppm)200-300150-200200-400
Salt (ppm)4500 Maximum4500 Maximum4500 Maximum
Free Chlorine (ppm)*2-32-32-3
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
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.
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Page 6
3. OPERATING INSTRUCTIONS
3.3. Visual inspection
3.1. Start-Up Procedures
Your pool/spa heater has been designed for years of safe
and reliable pool/spa water heating. It is available with
electronic ignition. This manual provides installation,
operation, maintenance, and service information for these
heaters.
Temp Adjust Buttons
Mode Button
TEMP
LCD Display
Figure 1. Heater Control Toggle Switch
ON
MODE
OFF
If your heater has been installed correctly, operating the
heater is an easy task. The upper front panel of the heater
contains the control center that allows you to turn the
heater On or O and adjust the temperature settings for
the pool or spa. The temperature range is factory set from
65°F (18°C) to 104°F (40°C). See Figure 1 for location of
toggle switch to turn the heater On and O.
See Section 8 for additional details about the use of the
controls in the Control Adjustments subsection.
3.2. Before Start-Up
3.2.1. Burners
Clean main burners and air louvers of dust, lint and debris.
Keep heater area clear and free from combustibles,
ammable liquids and chemicals. Do not obstruct the
ow of combustion and ventilation air.
3.2.2. Water
Water must be owing through the heater during
operation. Ensure that the system is lled with water and
that the pump is operating.
3.3.1. Atmospheric Heaters
With the heater on, remove the door and make a visual
check of the pilot and burner. The ame should be blue
with a well-dened pattern.
A yellow or “oating” ame indicates restricted air
openings or incorrect orice size. Should this occur, shut
the heater o and contact your installer or gas supplier.
WARNING: Operation of the heater without water
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circulation will cause rapid and severe damage to the
heater, and will void the warranty.
3.4. Caution
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 can cause drowsiness which could
lead to unconsciousness and subsequently result in
drowning.
3. Pregnant Women Beware! Soaking in water over
102°F (39°C) can cause fetal damage during the first
three months of pregnancy resulting in the birth of a
brain-damaged or deformed child. Pregnant women
should stick to the 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 pools or hot tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihistamines, or
anticoagulants, should not use spas or hot tubs.
3.2.3. After Start-Up
Feel the inlet and outlet pipes. Outlet pipe should be only
slightly warmer than the inlet. It should not be hot.
WARNING: Should overheating occur or the gas
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supply fail to shut o, turn o the manual gas control to
the appliance.
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Page 7
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in conned
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areas, extra care should be exercised when lighting propane heaters.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
ELECTRONIC IGNITION SYSTEM
(AUTOMATICALLY LIGHTED PILOT)
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell near
the oor because some gas is heavier than
air and will settle on the oor.
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.
OPERATING INSTRUCTIONS
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 pilot. Do
not try to light the pilot by hand.
5. Remove heater door panel.
6. Turn gas control knob clockwise to
“Off”. (Honeywell VR 8300 and Robertshaw
7000)
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”. (Honeywell VR 8300 and Robertshaw
7000)
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.
*If you cannot reach your gas supplier, call the
re 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 qualied service technician.
Force or attempted repair may result in a re
or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualied
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.
HONEYWELL
VR 8300 GAS
VALVE IID
GAS
INLET
ROBERTSHAW 7000
GAS VALVE IID
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.
SHUT-OFF PROCEDURES
4. For Honeywell VR 8300 and Robertshaw
7000 gas valve.
Turn gas control knob clockwise
to “Off”. Make sure knob rest against stop.
5. Replace heater door panel.
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Page 8
3.5. Maintenance
DRAIN
WARNING: Check the heater for possible rodent nests
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after long periods of non-use.
To be followed one month after start-up and then semiannually.
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.
CAUTION: Soot may be combustible. Wet sooted
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surfaces completely prior to cleaning. Do not use steel
wire brush.
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.
Yellow flame means restriction of the air openings.
Lifting or blowing flame indicates high gas pressure.
Low flame means low gas pressure. Should the
latter 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.
CAUTION: Combustion air must not be contaminated
AA
by corrosive chemical fumes which can damage the
heater and void the warranty.
6. Keep area around heater clear and free from
combustible materials, gasoline and other flammable
and corrosive vapors and liquids.
If Heater Will Not Fire:
If you have no electrical power, it may be that your “circuit
breaker” has tripped. Try re-setting it.
If you have electrical power but the heater will not re
check the following or see Troubleshooting section:
1. The time clock must be in the “ON” position.
2. Your pump strainer basket may be full. If so remove
debris.
3. Your filter may be dirty. If so, backwash or clean
filter. (To tell if your 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 you are not moving water (or your
gauge is broken). Try to get the pump to run at its
normal flow rate.
5. Check flow switch operation and paddles (“F” paddle
on 268 or “A” paddle on 408).
3.6. Cold Weather Operation
3.6.1. Important Freeze Information
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
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temperatures just above freezing or for freeze protection.
When heater is used during freezing weather, care must
be taken to avoid freeze-ups. Continuous pump operation
is a must. Additional protection may be required. The
heater is not warranted against freeze-ups.
COLD CLIMATE: Prolonged operation with water
temperatures below 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.
3.6.2. Winterizing the Pool and 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 valve located on the inlet/outlet header,
(under water pipes). Remove the heat exchanger
inspection panel on the side opposite water piping
to gain access to the drain plug on the return header.
Open drain plug on return header.
Figure 2. Return Header Drain Valve
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Page 9
4. BEFORE INSTALLATION
Rating Plate
4.1. Receiving equipment
The manufacturer recommends that this manual be
reviewed thoroughly before installing the pool/spa heater.
If there are any questions that this manual does not answer,
please contact the factory or your local representative.
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill
of Lading when signing for the equipment. Remove the
heater from the carton. If it is damaged, report the damage
to the carrier immediately. Save the carton.
These items are shipped inside a box in the carton with
the heater:
1. “Pagoda” top
2. In/Out flanges (2)
3. 2" CPVC female tailpiece, ring nut and O-ring
4. 2" flange gaskets (2)
5. Flange bolts (4)
6. Pressure relief valve
7. 2" CPVC adapter
8. Plastic pipe finish flange for gas line
9. Bonding lug with mounting screw
10. 2" CPVC manifold adapter
11. Prewired 1" flow switch with outdoor cover
12. Temperature and pressure gauge
The Model and Serial No.
can also be found inside
the bezel above the display
Alternate
location
Be sure that you receive the number of packages indicated
on the Bill of Lading.
When ordering parts, you must specify the model and
serial numbers of the heater. See below for location of
serial number. When ordering under warranty conditions,
you must also specify date of installation.
4.2. Rating and certications
These heaters are design-certied and tested under the
latest requirements of the ANSI Z21.56 / CSA 4.7 Standard
for Gas-Fired Pool Heaters. All heaters can be used either
indoor or outdoors. The appropriate top designated for
each type of use is required. If necessary, the top can be
changed at a later date to change from outdoor to indoor
or vice versa.
All units have heat exchangers which are ASME-certied
(BPV Section IV part HLW) and are registered with
National Board.
4.3. Ambient Temperature Rating
of Heater Components
Electronic Ignition Heater* -32°F to + 175°F (-36°C to 79°C)
*Requires 120 or 240VAC Power Supply
4.4. Atmospheric heaters
Rated inputs are suitable for up to 2,000 ft (610 m)
elevation. For elevations above 2,000 ft (610 m), reduce
input 4% for each 1,000 ft (305 m) above sea level, as high
elevation reduces combustion performance.
5. INSTALLATION
5.1. Installation Codes
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest edition of
the National Fuel Gas Code, ANSI Z223.1/NFPA54 and
National Electrical Code, ANSI/NFPA 70, and for Canada,
the latest edition of CAN/CSA-B149 Installation Codes,
and Canadian Electrical Code, CSA C22.1 Part 1 and
Part2.
Model and Serial No.
located on Rating Plate
Figure 3. Rating Plate Location
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Page 10
5.2. Clearances
5.2.1. All Heaters
For indoor and outdoors clearances from combustible
surfaces, see the chart below.
LocationIndoor Installation
Top *30" (762 mm) Drafthood
FrontAlcove (Open)
Vent6" (152 mm)
Floor **0"
Back6" (152 mm)
Right Side12" (305 mm) Water Side
Left Side6" (152 mm) Opposite Water Side
LocationOutdoor Installation
Top *Unobstructed (Outdoor Stack)
Top ***36" (76 mm) (Stackless Top)
Right Side12" (305 mm) Water Side
Left Side6" (152 mm)
Floor0"
Back6" (152 mm)
* Clearance from top of vent terminal
** Do not install on carpeting
*** Clearance from top of heater
Table B. Minimum Clearances from Combustible Installations
4' (1.2 m)
Minimum
4' (1.2 m)
Minimum
4' (1.2 m)
Minimum
3' (0.9 m)
Minimum
10' (3 m)
Minimum
Forced Air Inlet
Figure 4. Minimum Distances to Building Openings from
Table C. Reduction of Clearances to Protected Surfaces
When installed according to the listed minimum clearances
from combustible construction, the pool heater can still
be serviced without removing permanent construction
around the heater.
However for ease of servicing, we recommend a clearance
of at least 24" (610 mm) in the front, and at least 18" (457
mm) on the water connection side.
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This will enable the heater to be serviced in its installed
PAGODA TOP
location, that is, without movement or removal of the heater.
Clearances less than these (6" [152 mm] minimum), 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.
5.2.2. Flooring
This heater can be installed on combustible ooring.
The combustible clearances listed can be reduced by
protecting the exposed combustible surfaces as shown in
Table C.
5.3. Outdoor Heater Installation
These heaters are design-certied for outdoor installation,
when equipped with the approved tops designated for
outdoor use.
WARNING: The heater shall not be located in an area
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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.
For U.S. installations, the point from where the ue
products exit the heater must be a minimum of 4' (1.2m)
below, 4' (1.2 m) horizontally from, or 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.
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.
5.3.1. Pagoda Top Installation
1. Insert tabs into keyhole (4 places). See Figure 6,
detail A.
2. Snap tabs into keyholes so as not to pull out. See
Figure 6, detail B.
WARNING: Do not install within 3' (914 mm) of a heat
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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.
Figure 5. Heater with Outdoor Stackless Top
Heaters must not be installed under an overhang of less
than three 3' (0.9 m) 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 the heaters installed
under overhangs with the use of gutters.
DETAIL ADETAIL B
OUTDOOR TOP
(SHIPPED LOOSE WITH HEATER)
Figure 6. Outdoor Top Installation
For installations in Florida and Texas, that must
comply with the Florida or Texas Building Code, follow
the directions shown in Figure 9 for the installation of
hurricane tie-down brackets for all models.
5.3.2. Indoor Heater Installation
The heater is also design-certied for indoor installation
when equipped with the approved drafthood.
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 specic requirements. Locate heater as
close as is practical to a chimney or gas vent. Heater must
always be vented to the outside. See section "Vent Piping" on page 15 for details. Minimum allowable space is
shown on the nameplate.
WARNING: Indoor heaters require a drafthood that
AA
must be connected to a vent pipe and properly vented to
the outside. Failure to follow this procedure can cause
re or fatal carbon monoxide poisoning.
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Page 12
5.3.3. Outdoor and Indoor Stack
The outdoor and indoor stacks are optional equipment
and do not come standard with the heater. Refer to
installation instructions inside box for instructions on how
to install outdoor/indoor stack.
ModelOutdoor StackIndoor Stack
268009835009839
408009837009841
Table D. Outdoor and Indoor Stack Kit Number
OUTDOOR STACK KIT
(1) Drafthood, painted
(1) Adapter plate
(3) Mounting brackets (clips)
(1) Top panel cover
(2) 1-foot sections of metal tape
(3) Screws
(1) Instructions
Clips
5.4. Combustion and Ventilation Air
5.4.1. 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" (305 mm) from the ceiling for
ventilation, and one opening that is 12" (305 mm) 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.
All Air from Inside the Building:
Each opening shall have a minimum net free area as noted:
ModelSquare InchesModelSquare Inches
268266408399
Table E. Opening Minimum Net Free Requirements
All Air from Outdoors:
When air is supplied directly from outside the building,
each opening shall have a minimum net free area as noted:
Model
Unrestricted
Opening
(sq. in.)
Typical Screened
or Louvered
Opening (sq. in.)
Typical Screened
and Louvered
Opening (sq. in.)
Figure 7. Outdoor Stack Kit Components
NOTE: The outdoor drafthood kit does not require any
additional vent pipe for proper operation. This drafthood
functions as the vent termination.
INDOOR STACK KIT
(1) Drafthood, unpainted
(1) Adapter plate
(3) Mounting brackets (clips)
(3) Screws
(1) Instructions
Clips
26867101134
408100150200
Table F. Opening Minimum Net Free Requirements
CAUTION: Combustion air must not be contaminated
AA
by corrosive chemical fumes which can damage the
heater and void the warranty.
Figure 8. Indoor Stack Kit Components
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Page 13
FLORIDA AND TEXAS BUILDING CODES
WIND SPEED = 150 MPH, 3 SECOND GUST
ModelB
26823" (583 mm)
40829" (735 mm)
2" x 6" x 1/8" Pallet
Anchor Bracket (4 Total) (Kit# 011636)
EXPOSURE = C
268/408 ATMOSPHERIC
B
40"
(1 m)
28"
(709 mm)
3" (76 mm)
Min. Conc.
Pad by others
Min. Edge
Distance
6"
(152 mm)
(1)–1/4" x 1-3/4" S.S. T
apcon Bolt & Washer (Field Supplied)
Ea. Pallet Anchor Bracket
Use hole closest to unit (4 total)
1/4" x 1-3/4" S.S.
Tapcon Bolt and Washer (Field Supplied)
NOTE: Use hole closest to unit with
washer overlapping edge of unit.
3" (76 mm)
Min. Conc.
Pad by others
(1)–1/4" x 1-3/4" S.S.
Tapcon Bolt & Washer (Field Supplied)
Ea. Pallet Anchor Bracket
Use hole closest to unit (4 total)
Min. Edge
Distance
6"
(152 mm)
TOH
Figure 9. Florida And Texas Building Codes
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Page 14
B
A
(709 mm)
FLUE
Amp Draw
120 Volt 240 Volt
42
10"
(253 mm)
C
INDOOR
DRAFTHOOD
(963 mm)
Heater
Model
BTUH
Input
(000)
38"
13-1/4"
(336 mm)
CONNECTION
GAS
(A)
Cabinet
Width
in. (mm)
D
(B)
Flue
Dia.
in.
(mm)
(C)
Indoor
Drafthood
in. (mm)
(D)
in. (mm)
J*
28-5/8"
(725 mm)
(J)
Min.
in. (mm)
32-11/16"
(830 mm)
ELECTRICAL
CONNECTION
Gas
Conn.
Water
Conn.
3-3/8"
(85 mm)
28"
Shipping Weights - lbs (kg)
Standard
Heater
w/Stackless
ASME
Heater
w/Stackless
Top
Top
6-5/8"
(167 mm)
40"
(1,016 mm)
ELECTRICAL
CONNECTION
Indoor
Draft-
hood
R268266.0
R408399.0
Designation for a heater using propane gas is “EP”; a heater using natural gas is “EN”.
Reduce input 4% for each 1000 ft (305 m) above sea level when installed above 2000 ft (610 m) elevation.
For Canada, no de-rating is required for elevations up to 4500 ft (1,372 m)
*Note: For outdoor stack, use J dimension in the table above for appropriate size plus 6" (152 mm).
23
(584)
29
(737)
7
(178)
9
(229)
62 (1574)
64-9/16
(1640)
Figure 10. Heater Specication and Dimensions
14
11.5
(292)
14.5
(368)
11
(279)
12-1/8
(307)
3/4"2"
3/4"2"
210
(95)
249
(113)
229
(104)
268
(121)
16
(7)
21
(9)
Page 15
5.5. Vent Piping
WARNING: Indoor heaters require a drafthood that
AA
must be connected to a vent pipe and properly vented to
the outside. Failure to follow this procedure can cause
re or fatal carbon monoxide poisoning.
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 by no more than one (1)
size as specied in Chapter 13 of 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 in. 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
ve feet should be securely guyed or braced to withstand
snow and wind loads. We recommend use of insulated
vent pipe spacers through the roofs and walls. Another
option for installation that requires horizontal runs is
using the D-2 power vent kit option.
Model120 VAC P/N240 VAC P/N
268010744009832
408010745009833
Table G. Power Vent Kit Part Number
For protection against rain or blockage by snow, the vent
pipe must terminate with a vent cap which complies with
the local codes or, in the absence of such codes, to 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.
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. This
unit operates under venting Category I conditions, with
natural draft.
Type “B” double-wall or equivalent vent pipe is
recommended. However single-wall metal vent pipe may
be used as specied in the latest edition of the National
Flue Gas Code ANSI Z223.1 (Canada - CAN/CSA-B149).
8' (2.4 m)
OR LESS
2' MIN
(610 mm)
VENT CAP
NOTE: The D-2 Power Vent operates with a positve
vent static pressure and with a vent gas temperature
that prevents excessive condensate production in the
vent, and as such, is a CATEGORY III appliance. For
more information consult the D-2 Power Vent manual
6000.57.1.
Figure 11. Optional Raypak D-2 Power Vent
The unit, when installed as directed, is capable of
operating in applications such as through-the-wall venting
and reduced horizontal and vertical vent pipe sizes in new
and current installations. The unit is factory-wired for 240
VAC, with capability of rewiring for 120 VAC.
2' MIN
(610 mm)
5' MIN
(1.5 m)
VENT PIPE
DRAFT HOOD
HEATER
Figure 12. Venting Clearances
NOTE: With venting application of two or more heaters,
contact the factory.
15
Page 16
5.5.1. Appliance Categories
HEATER JACKET
MANOMETER
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.
5.6. Gas Supply Connections
5.6.1. Supply Pressure
CAUTION: Only sealant tape or a pipe compound rated
AA
for use with natural and propane gases is recommended.
Apply sparingly only on male pipe ends, leaving the two
end threads bare.
A minimum of 6 in. WC and a maximum of 14 in. WC
upstream pressure under load and no-load conditions
must be provided for natural gas. A minimum of 12 in. WC
and a maximum of 14 in. WC are required for propane gas
under load and no-load conditions.
5.6.2. Gas Pressure Regulator
The gas pressure regulator is preset at 4.0 in. WC
throughout for natural gas, and 10.5 in. WC. for propane
gas. The pressure at the gas valve, taken with a manometer,
should be about 4.0 in. WC natural gas and 10.5 in. WC
propane gas. If an adjustment is needed, remove seal and
turn adjustment screw clockwise to increase pressure or
counter-clockwise to decrease pressure.
GAS INLET
Figure 13. Gas Supply Plumbing
MANUAL SHUT-OFF VALVE
(Field supplied)
GAS VALVE
FINISH FLANGE
UNION
(Field supplied)
SEDIMENT TRAP
(Field supplied)
Gas piping must have a sediment trap ahead of the heater
gas controls, and a manual shut-o valve located outside
the heater jacket. All gas piping should be tested after
installation in accordance with local codes.
CAUTION: The heater and its manual shut-o valve
AA
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in excess
of 1/2 psi (3.45 kPa). Dissipate test pressure in the gas
supply line before reconnecting the heater and its manual
shut o valve to gas supply line. FAILURE TO FOLLOW
THIS PROCEDURE MAY DAMAGE THE GAS VALVE.
OVER PRESSURIZED GAS VALVES ARE NOT COVERED
BY WARRANTY. The heater and its gas connections shall
be leak tested before placing the appliance in operation.
Use soapy water for leak test. DO NOT use open ame.
MANUAL
SHUT-OFF
VALV E
UNION
Figure 14. Manual Shut-O Valve Installation
5.6.3. Gas Pressure Adjustment Locations
16
Gas Pressure Adjustment
Figure 15. Robertshaw 7000 BDER (Heater Model 268)
Page 17
Gas Pressure Adjustment
Figure 16. Robertshaw 7000 DERHC (Heater Model 408)
* When ow rates exceed maximum GPM (lpm) an external auxiliary bypass valve
is required. See external bypass valve section for details.
Table I. Flow Rates
Figure 17. Honeywell VR8304 (Heater Models 268 and 408)
5.6.4. Pipe Sizing for Gas Connection
These capacities shown below based on using SCH 40
black iron pipe. For capacities using other materials,
consult local code.
Input3/4"1"1-1/4"1-1/2"
Model
(KBTU) NPNPNPNP
268266.0
408399.0*
Natural Gas 1000 BTU/FT3 0.60 specic Gravity @ 0.5 in. WC Pressure Drop
Propane Gas 2500 BTU/FT
* A 3/4" gas line can be used for up to 5' (1.5 m) maximum length from the gas valve
in addition to the sediment trap.
15
(5)35(11)50(15)
15
(5)20(6)55(17)95(29)
3
1.53 specic Gravity @ 0.5 in. WC Pressure Drop
Table H. Maximum Equivalent Pipe Length (ft/m)Flow
Rates
125
(38)
210
(64)
480
(146)
225
(69)
445
(136)
215
(66)
480
(146)
Figure 18. External Bypass Valve
Flow
GPM (lpm)
Pressure Drop (Ft of Head)
268408
30 (114)8.0
40 (151)9.09.0
50 (189)9.89.8
60 (227)10.510.5
70 (265)11.011.0
80 (302)11.511.5
90 (341)14.014.0
100 (378)17.017.0
Table J. Heat Exchanger Pressure Drop
17
Page 18
5.7. Water Connection Installation
UG SPRING
Gather the loose items that were shipped with the heater.
Figure 19. Water Connection Components
The components should be assembled onto the inlet and
outlet header of the unit as shown below.
The heater must be located so that any water leaks will not
damage the structure of adjacent area. High temperature
2" plastic pipe (CPVC) may be threaded directly into the
header anges. This is not the same as the Schedule 80
PVC pipe which is also gray. PVC may be used immediately
after the supplied CPVC adapters.
DO NOT use petroleum-based assembly uids (such
as petroleum jelly or lubricating oil). If assembly lube is
required, use a silicon base such as AquaLube etc.
5.8. Unitherm Governor Operation
CAUTION: The patented Unitherm Governor is a
AA
thermostatic mixing valve specically designed to
maintain constant heater internal temperature between
105° (41°C) and 115°F (46°C) despite continually changing
ow rates from the lter and changing pool temperatures.
This narrow range is needed to prevent damaging
condensation on the burners which will occur if the
heater runs for any length of time below 100°F (38°C). It
is also needed to inhibit scale formation in the tubes by
maintaining temperatures well below accelerated scaling
temperatures.
Figure 20. Water Connection Assembly
Once all components are in place and installed properly,
the water connections will appear as shown below:
Figure 21. Water Connection Installation
GASKET
(BEHIND UG)
UNITHERM
UG PLUG
Figure 22. Unitherm Governor Valve
GOVERNOR
5.9. Internal Automatic Bypass Valve
In addition to the Unitherm Governor, a built-in automatic
bypass valve is provided in the in/out header. While the
Unitherm Governor responds to the changes in water
temperature in the heater, the internal bypass valve
automatically responds to changes in water pressure in the
piping system. Proper amount of water ow is maintained
through the heater under varying pressures dictated by
the conditions of the pump and lter.
18
Page 19
T
BYPASS VALVE
BYPASS SPRING
Figure 23. Internal Automatic Bypass Valve
BYPASS
PLUG & SHAF
5.10. External Auxiliary Bypass Valve
Where Required - An auxiliary bypass valve should
be used when ow rates exceed 125 GPM (473 lpm).
Usually a high-performance pump size larger than
two 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 HEATER
VALVE
5.12. 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
model to be installed, is recommended for this heater.
The maximum acceptable pressure relief valve setting is
125 psi.
PRV
Figure 25. Pressure Relief Valve
NOTE: To avoid water damage or scalding due to 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. Valve lever should be tripped at
least once a year to ensure that waterways are clear.
TO POOL/SPA
BYPASS VALVE
Figure 24. Auxiliary Bypass Valve
5.11. Auxiliary Bypass Valve
Adjustment
To set bypass - With clean lter, 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.
FROM POOL/SPA
5.13. Plumbing
5.13.1. Water Connection
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.
SeeFigure 29 and Figure 30.
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 (Salt generators and
chemical feeders must be down stream of the pool
heater).
19
Page 20
Plumbing from the heater back to the pool or spa must
SWAY BRACE
not have any valves or restriction that could prevent ow
when the pump is operating.
CAUTION: An additional source of heated water, e.g. a
AA
solar system, must be connected to the main line ahead
of the heater inlet pipe in order for it to act as the primary
heat source. If the primary system provides adequate heat
to maintain set-point, the heater will not re. Be advised
that the control panel will then display sensed water
temperatures downstream of the primary heating system,
rather than the temperature of the water exiting the pool.
Heater must be located so that any water leaks will not
damage the structure of adjacent area.
6.1. Electrical Power Draw
CAUTION: Heater must be electrically grounded and
AA
bonded. Bonding lug is provided loose with the heater.
Install bonding lug on lower right or left side of jacket
as necessary for bonding the heater. Mounting hole is
provided on the jacket.
NOTE: Failure to ground the heater electrically could
aect the heater’s electronics.
NOTE: See "Time Clock/Fireman’s Switch" on page 29
for further instructions if using a time clock/reman’s
switch.
6. ELECTRICAL WIRING
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.
WARNING: Heaters are factory-wired for 240 VAC
AA
power supply. DO NOT attempt to operate at 208 VAC.
The standard eld-wiring connection is on the right side
of the heater.
To wire the heater from the left side, follow these steps:
1. Remove the two (2) screws that hold the front door
to the heater. Remove and set aside door for better
access to wiring.
2. Remove the four (4) screws that hold down the
junction box to the sway brace.
3. Remove the transformer cover located on the far
right by removing one (1) screw.
4. Remove the two (2) screws that hold down the
transformer.
5. Remove the one (1) screw that holds down the
ground wires.
6. Disconnect P6 connector from PC board.
7. Remove transformer from its current location and
relocate it on the far left side of the heater.
8. Re-route all high-voltage wires and ground wires
through the left jacket side of heater.
9. Re-install P6 connector, ground wires (SPG),
transformer, junction box, front door, and plug right
side with the left side’s grommet plug.
The Electronic Intermittent Ignition Device automatically
lights the pilot and main burners upon a call for heat. The
heater is supplied with a dual-voltage transformer for 120
VAC or 240 VAC input power hookup.
4 amps at 120VAC
2 amps at 240VAC
OPTION LOCATION
LEFT SIDE FIELD WIRING
CONTROL BOX
(FACTORY MOUNTED
LOCATION)
NOTE: 7/8" diameter holes not utilized on jacket and
control box can be used for reman switch, auxiliary
control interface or power vent (D-2) wiring.
20
Figure 26. Heater Wiring Locations
Page 21
6.2. Transformer Wiring
RED
HOT
HOT
WHITE
6.2.1. 120 VAC Wiring
For 120 VAC input power to the unit, connect the black
wire to the “L1” or hot leg of the power supply. Connect
the white wire to the “Ret” or neutral leg of the power
supply. Attach the wire nut to the red wire. There should
be no connection to the red wire for 120 VAC operation.
L1
BLACK
RETURN
or
SUPPLY
NEUTRAL
SIDE
GROUND
Figure 27. 120 VAC Wire Connection
6.2.2. 240 VAC Wiring
For 240 VAC input power to the unit, connect the black
wire to the “L1” or hot leg of the power supply. Connect the
red wire to the “L2” or second hot leg of the power supply.
Attach the wire nut to the white wire. There should be no
connection to the white wire for 240 VAC operation.
BLACK
WHITEWHITE
GREENGREEN
HEATER
4 WIRES
NOTE: If the transformer’s primary side is wired for 120
VAC and 240 VAC is applied, damage to the transformer
and PC board may result. Such damages are not covered
under manufacturer’s limited warranty.
Input power to the heater (120 or 240 VAC) can be supplied
from the load (pump) side of time clock or directly from the
GFCI power source. It is preferred that full-time power
be supplied to the heater from the GFCI power source,
and that the heater be controlled by the reman’s
switch connection or using a two or three-wire remote.
If using a switched GFCI power source, the heater could
display false service indicators on the display panel if the
pump is turned o.
WARNING: DO NOT attempt to operate the heater at
AA
208 VAC.
L1
BLACK
L2
SUPPLY
HOT
REDRED
SIDE
Figure 28. 240 VAC Wire Connection
BLACK
HEATER
4 WIRES
GREENGREEN
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.)
21
Page 22
THIS DIAGRAM IS RAYPAK’S RECOMMENDATION
THIS DIAGRAM IS RA
AND IS NO
PIPING S
AND IS NOT INTENDED TO REPLACE AN ENGINEERED
PIPING SYSTEM BY A PROFESSIONAL ENGINEER.
Figure 29. Single Pool Heater Installation
YPAK’S RECOMMENDATION
T INTENDED TO REPLACE AN ENGINEERED
YSTEM BY A PROFESSIONAL ENGINEER.
Figure 30. Multiple Pool Heater Installation
22
Page 23
7. WIRING DIAGRAM
23
Page 24
8. CONTROLS
MOUNTED ON RETURN
HEADER
HL2 - HIGH LIMIT
DRAIN PLUG
AFT THERMOSTAT
CIRCUIT BOARD
ROLL-OUT
SWITCH
GAS VALVE
PILOT
MOUNTED ON IN/OUT
HL1 - HIGH LIMIT
TEMP SENSOR/WELL
TRANSFORMER
(BEHIND PANEL)
HEADER
UNITHERM
GOVERNOR
DRAIN VALVE
8.2. Control Adjustments
The pool heater 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.
Temp Adjust Buttons
Mode Button
TEMP
MODE
Figure 31. General Location of Controls
8.1. Control Panel Removal
1. Remove screw from front door. Set aside door for
serviceability.
2. Remove (4) screws from sides of control panel.
3. Rotate control panel down until panel stops. Do not
force.
NOTE: Caution must be used to not damage controls or
wiring.
KNURLED
SCREW
LCD Display
Figure 33. Digital Control Adjustment
ON
OFF
8.2.1. 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.
8.2.2. 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.
8.3. 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 32. Knurled Screw Location
24
Page 25
Figure 34. Alternating Display During Heating
Program Mode Button (SW1)
Figure 38. 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 buer, the second line
reads “All Faults Clear.”
Figure 39. Fault History Indicator
Figure 35. Thermostat Program Button (SW1)
8.3.1. 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.
Figure 36. 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.
8.3.2. 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 35. 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 40:
Resets board to factory default
settings.
Resets faults in the History File.
Change from Fahrenheit to
Celsius.
Figure 37. 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.
SPA setpoint maximum
adjustment.
POOL setpoint maximum
adjustment.
Figure 40. Programmable Events
25
Page 26
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.
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.
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 dier
from that observed at a given location in the pool or spa.
8.4. Status and Diagnostics
The digital thermostat models are 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.
DisplayCondition
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).
8.3.3. 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.
Conrm 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
HeatingCall for heat established, ame present.
SparkSpark operating.
No DemandHeat demand is satised.
Table K. Heat Status Messages - No Active Faults
26
Page 27
The following conditions are displayed in Pool, Spa and
Remote modes.
DisplayCondition
Sensor Failure
Sensor Open
Sensor Short
Flame w/o CFH
PV Output Fault
MV Output Fault
Internal FaultBoard fault, replace board.
EEPROM Fault
Clock/Fireman Sw
Low Temp
Lockout
Table L. Heat Status Messages - Active Faults
Thermistor temperatures disagree by
more than 2°F (1°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).
The following conditions are displayed only while there is
a demand for heat present.
DisplayCondition
8.4.1. Remote Control Installation and
Operation
CAUTION:Before installing remote controls to the
AA
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 41. 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.
8.4.2. Remote Operation
The 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. 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 "Time Clock/Fireman’s
Switch" on page 29.
Water Sw OpenWater pressure switch open.
Vent/Field
Sw #1
Hi Limit 1 FaultHigh limit 1 open.
Hi Limit 2 FaultHigh limit 2 open.
Rollout Sw OpenRollout switch open.
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
Vent spill switch/eld switch #1 open.
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.
OFF Mode
Heating in the POOL Mode
Heating in the SPA Mode
Remote Mode
Figure 41. Remote Control Menu - Remote Operation
27
Page 28
8.4.3. 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 42. Remote Control Menu - Activation
8.5. Remote Control Wiring
ATTENTION
OBSERVE PRECAUTIONS
ELECTROSTATIC
SENSITIVES DEVICES
NOTE: The remote wires must be connected to the 7-pin
connector before the connector is plugged into the board.
8.5.1. 2-Wire Remote Control (On-O)
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 43.
Pool Common
(BLK/ORN)
Spa Common
(ORN/BLK)
CAUTION: Electrostatic Discharge (ESD) damage can
AA
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.
Important Installation Notes for Remote or External
Wiring Conguration:
• 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.
24VAC HOT
(BLU)
Figure 43. 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.
SeeFigure 44.
8. For activation of the remote control, see section 8.4.3
on page 28.
8.5.2. 3-Wire Remote Control Using
Three-Position Switch (Pool-OSpa, or Low-O-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.
28
Page 29
BLU - 24VAC
ORN/BLK - To Spa (COMM)
Wire Nut BLK/ORN - To Pool (COMM)
Figure 44. 2-Wire Remote Harness Installation on the P8
Connector of the ATF Board
On heaters, splice into the red/white wire to connect the
time clock. For 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.
Do not exceed 50' (15.2 m) of total wiring using 18 AWG
stranded copper wire rated for 221°F (105°C) minimum.
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.
8.5.4. Water Flow Switch
The water ow switch ensures that the heater operates
only when the lter pump is in operation. It is located on
the outlet side of the In/Out header. It is factory pre-wired
and pre-set with a minimum water ow paddle. Install
conduit to the upper jacket hole. Connect two wires from
the conduit to the appropriate terminal wires behind the
transformer cover (i.e. orange to orange and orange/black
to orange/black). No further adjustment is needed.
BLU - 24VAC
ORN/BLK - To Spa (COMM)
BLK/ORN - To Pool (COMM)
Figure 45. 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 43.
5. Install the “Remote Interface Harness” to the P8
connector and turn power “ON” to the heater.
SeeFigure 45.
6. For activation of the remote control, see section 8.4.3
on page 28.
8.5.3. 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 (chaue-piscine)
15 to 20 minutes prior to shutting down the pool pump.
Figure 46. Water Flow Switch Assembly
NOTE: The sheet metal cover should be in place at all
times to protect the ow switch from rain and other
environmental factors.
CAUTION: Do not operate the heater without the
AA
function of a properly adjusted ow switch.
29
Page 30
GAS VALVE
8.5.5. Flame Roll-Out Safety Switch
The heater is 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.
Figure 47. Flame Roll-Out Safety Switch
8.5.6. High Limits
The heater is equipped with two automatic high limits.
One is located in the inlet/outlet header, and the other is
located in the return 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.
2. Shut off gas upstream of heater.
3. Remove front door.
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit,
and (2) screws that secure gas valve to jacket.
6. Disconnect wires that terminate at gas valve.
7. Disconnect hi-tension wire from PC board.
8. Slide out burner tray.
9. Reverse above procedure to reinstall.
8.5.9. Gas Valve Removal
1. Shut off gas supply to the heater. Remove gas piping
to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Remove burner tray from heater.
4. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
5. Reverse above procedure to reinstall.
8.5.10. Main Burner And Orice Removal
1. Remove burner tray.
2. Remove screws and burner hold-down bracket.
Figure 48. High Limit Switch
High Limit Removal
1. Shut off main electrical power switch to heater.
3. Remove defective high limit and replace with a new
high limit.
4. Replace inspection panel.
8.5.7. 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.
NOTE: If the heat exchanger is sooted badly, the burner
hold-down bracket and spacer can become distorted from
direct-ame impingement and this usually necessitates
replacement of these parts.
3. Lift burners from slotted spacers and slide from
orifices. Clean with a wire brush.
4. Orifices usually do not need to be replaced. To clean,
run either copper wire or wood toothpick through
orifice. Do not enlarge hole. To remove orifice, use a
socket wrench and remove from manifold. DO NOT
overtighten when reinstalling.
BURNER
BURNER
HOLD-DOWN
BRACKET
PILOT
GAS
ORIFICE
8.5.8. Burner Tray Removal
1. Shut off main electrical power switch to heater.
30
Figure 49. Burner Tray Assembly
Page 31
8.5.11. Pilot Removal And Cleaning
1. Disconnect pilot tubing and wires from gas valve.
2. Remove pilot assembly from burner tray.
3. Remove pilot from bracket.
4. Remove pilot orice and air opening, and clean with
wire or small brush.
CAUTION! Do not enlarge hole in pilot orice.
AA
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.
8.5.14. Desooting Procedure
WARNING: Soot Is Combustible. Exercise Extreme
AA
Care.
5. Reverse above procedure to reinstall.
Extension
Pieces (2)
Figure 50. Tube Cleaning Kit
Auger
with Carbide Tip
Wire Brush
8.5.12. 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.
3. Remove rear top panel.
4. Remove screws mounting the rain shield to the rear
panel. Also remove the screws that mount the rain
shield to the sway brace. Remove rain shield.
5. Remove the four (4) screws holding down the flue
collector. Remove the flue collector.
6. Disconnect flange nuts on Inlet/Outlet header,
loosen union(s) at gas pipe and slide heater away
from piping.
7. Lift heat exchanger straight up using caution not to
damage refractory.
8. Reverse above procedure to reinstall. Make sure the
insulation strips are properly replaced on top of the
refractory retainer.
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 “V” baffles from heat exchanger.
3. Remove burner tray.
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.
NOTE: In extreme cases it may be necessary to do steam
cleaning at the local car wash. DO NOT WIRE BRUSH.
8.5.15. Combustion Chamber Removal
To remove combustion chamber, you must rst have
removed the heat exchanger.
Figure 51. Atmospheric Heaters
8.5.13. 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.
The heater may be cleaned from the return header side,
without breaking pipe connections. It is preferable,
however, to remove both headers for better visibility
through the tubes and to be sure the ground-up lime dust
does not get into the system. Note that you do not remove
the top panel or the heater exchanger, generally.
8.5.16. Immersion Well Replacement
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.
Figure 52. Well Assembly
31
Page 32
8.5.17. Unitherm Governor Replacement
1. Shut water, gas and electricity off, close valves and
relieve pressure.
2. Drain heat exchanger.
3. Remove retainer plug located next to the outlet pipe
connection.
4. Unsnap old unitherm governor to remove from
retainer plug. Snap in new unitherm governor.
5. Reinstall retainer plug, taking care to lubricate
gasket with a non-petroleum based grease such as
AquaLube.
9. REPLACEMENT PARTS
NOTE: To supply you with the correct part, it is important
that you supply the heater model number, serial number
and type of gas when applicable.
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
GASKET
(BEHIND UG)
UNITHERM
UG PLUG
Figure 53. Unitherm Governor Valve
UG SPRING
GOVERNOR
To test the operation of the Unitherm Governor, place in
hot water (over 110°F [43°C]) and watch for movement
against spring. If there is no movement, replace unit.
32
Page 33
10. TROUBLESHOOTING
10.1. Mechanical
IMPORTANT NOTICE: These instructions are intended for the use of qualied personnel who are specically 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 qualied shall not attempt to install this equipment
nor attempt repairs according to these instructions.
ProblemPossible CauseCorrective Action
Harmonics, or whining noiseUnitherm governor inoperative ...................Check movement by putting in hot water (110°F [40°C] or
*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
SootingHigh ow rates .................................................Reduce by adding manual bypass valve
Pilot outage or “Weak Flame”
signal
Yellow lazy ameLow gas pressure ............................................Adjust gas pressure
Outer jacket very hot (paint
blistered)
Takes too long to heat pool or
spa
Leaking at wellOveracid .............................................................Replace well and maintain proper water chemistry
Leaking at heat exchangerOveracid .............................................................Replace heat exchanger and maintain proper water chemistry
Gasket brittle and leaking (overheated)
* Indicates symptom which usually occurs on initial start-up.
Dirty lter ...........................................................Clean or replace lter
Low water level in pool ..................................Raise water level
Sooted heater ...................................................Determine cause of sooting and correct
higher)
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
higher). If no movement, replace
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
33
Page 34
10.2. Control Logic - Flow Chart
Power On
Is the water
temperature displayed?
YES
NO
• 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?
OR
Water temp displayed?
(pilot lit and rectified)
YES
NO
NO
“Remote” and Water Temperature displayed
(a remote control is controlling the heater)
Note: Disconnect the remote by turning the
remote function off. See page 30 for instructions.
NO
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.
*FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL.
**WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also
damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and
36
Page 37
CALL
** Conversion must be made with complete burner tray with gas valve (see item 1-B).
* Gas conversions are to be done only by a qualified agency.
Pilot Orifice Pro .012004308F004308F
3-PPilot Mounting Bracket 013791F013791F
4-PPilot Tube004078F004078F
5-PHi Tension Wire with Pilot ElectrodeN/AN/A
6-PPilot Shield 010351F010351F