Raypak Low NOx Series, Low NOx 267A, Low NOx 337A, Low NOx 207A, Low NOx 266L Installation And Operation Manual

...

INSTALLATION AND OPERATION MANUAL

Gas-Fired Pool and Spa Heater

Low NOx Models 207A, 266L, 267A, 337A, 399L, and 407A

WARNING: If the information is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

— 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.

Catalog No. 6000.592A

E󰀨ective: 11-15-19 Replaces: 10-01-19 P/N 241793 Rev 1

QUICK START GUIDE

CLEARANCES

 Space required: See page 11.

 Minimum and service clearances: See page 7 for

clearances table. Note that local codes prevail.

PIPING

 Pressure relief valve: See page 17 for recommended

PRV orientation.

 Flow rates: See page 15 for ow rate values.

GAS

 Distance to regulator (pipe lengths) and gas inlet

sizes: See page 14.

 Required pressure for Natural Gas:

Min = 5" WC, Max = 10.5" WC

 Sediment trap is required for all installations:

See page 13.

WATER CHEMISTRY

 Water chemistry requirements: See page 5.

POWER

 Supply voltage: See page 20 for acceptable input

voltages.

VENTING

 Materials: See pages 8, 10 and 12.

 D-2 Power Vent Kit: See page 12.

 Indoor Stack kit: See page 9.

CONTROLS INTERFACE

 Wiring diagram: See page 21.

 User interface: See page 22.

 Remote operation: See page 26.

Revision 1 reects the following changes:

Added model 266L, 399L to tables D, E, F, G, H, I, J, K, gure 7, and parts list. Removed Model Identication section. Amended text in gures 27, 28, and wiring diagram.

CONTENTS

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

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

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

Automatic Chlorinators and Chemical Feeders....... 5

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

Receiving equipment............................................... 6

Rating and certications .......................................... 6

Elevation ................................................................. 6

Ambient Temperature Rating .................................. 6

4. INSTALLATION ....................................................... 6

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

Clearances .............................................................. 7

Outdoor Heater Installation ..................................... 7

Combustion and Ventilation Air ............................... 9

Vent Piping ............................................................ 12

D-2 Power Vent Kit ................................................ 12

Gas Supply Connections....................................... 13

Flow Rates ............................................................ 14

ProTek Shield Assembly........................................ 15

Unitherm Governor Operation ............................... 16

Internal Automatic Bypass Valve ........................... 16

External Auxiliary Bypass Valve ............................ 16

Auxiliary Bypass Valve Adjustment .......................17

Pressure Relief Valve Installation .......................... 17

Plumbing Diagram................................................. 18

Heat Exchanger Reversal ..................................... 19

5. ELECTRICAL WIRING ......................................... 19

Electrical Power Draw ........................................... 20

Transformer Wiring ...............................................20

6. WIRING DIAGRAM ............................................... 21

7. CONTROLS ........................................................... 22

Control Panel Removal ......................................... 22

Control Adjustments ............................................. 22

Operation .............................................................. 23

Status and Diagnostics ......................................... 25

Remote Control Installation and Operation ........... 26

Remote Control Wiring .......................................... 26

8. OPERATING INSTRUCTIONS ............................ 32

Before Start-Up ..................................................... 32

Start-Up Procedures ............................................. 32

9. MAINTENANCE AND CARE ............................... 34

Cold Weather Operation .......................................34

10. TROUBLESHOOTING ......................................... 35

Digital - Flow Chart................................................ 36

Control Logic - Flow Chart .................................... 37

11. REPLACEMENT PARTS ..................................... 38

12. ILLUSTRATED PARTS LIST .............................. 39

1. WARNINGS

Pay Attention to These Terms

DANGER

WARNING

CAUTION

NOTE

DANGER: Failure to install the drafthood on indoor

installation and properly vent the heater to the outdoors as outlined in the venting section of this manual can result in unsafe operation of the heater. To avoid the risk of re, explosion, or asphyxiation from carbon monoxide, never operate this heater unless it is properly vented and has an adequate air supply for proper operation. Be sure to inspect the vent system for proper installation at initial start-up, and at least annually thereafter. Refer to the venting section of this manual for more information regarding vent system inspections.

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,

alteration, service, or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualied installer, service agency, or the gas supplier.

WARNING: Gasoline, as well as other ammable

materials and liquids (adhesives, solvents, etc.), and the vapors they produce, are extremely dangerous. Do not handle, use, or store gasoline or other ammable or combustible materials in the vicinity of a heater.

WARNING: To minimize the possibility of improper

operation, serious personal injury, re, or damage to the heater:

• Always keep the area around the heater free of combustible materials, gasoline, and other ammable liquids and vapors.

• Heater should never be covered or have any blockage to the ow of fresh air to the heater.

WARNING: This unit contains refractory ceramic

ber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures [greater than 2192°F (1200°C)], the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classied the inhalation of crystalline silica (cristabolite) as carcinogenic to humans.

When removing the burners or heat exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne bers. When cleaning spills, use wet sweeping or High E󰀩ciency Particulate Air (HEPA) ltered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certied respiratory protection, to avoid inhalation of airborne dust and airborne ber particles.

WARNING: Both natural gas and propane have

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

WARNING: UL-recognized fuel gas detectors are

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

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

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

WARNING: The heater shall not be located in an

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

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 rst 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

2. WATER CHEMISTRY

NOTE: Corrosive water voids all warranties.

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

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

resulting from chemical imbalance is not covered by the warranty.

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

CAUTION: Free chlorine must not exceed 5 ppm

which can damage the heater and is not covered under warranty.

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

• Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater.

• Check valve should be installed between the heater outlet and a chlorinator or other chemical dosing device.

• 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 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 Diagram" on page 18.

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

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

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

pH 7.3-7.4 7.3-7.4 7.6-7.8

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

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

Salt (ppm) 4500 Maximum 4500 Maximum 4500 Maximum

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

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

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

Table A. Pool Water Chemistry

3. BEFORE INSTALLATION

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:

Standard Unit (POLYMER HEADERS)

1. “Pagoda” top

2. 2" CPVC union half with "O" rings (2)

3. Plastic pipe finish flange for gas line

4. Bonding lug with mounting screw

ASME Unit (BRASS HEADERS)

1. “Pagoda” top

2. 2" CPVC union half with "O" rings (2)

3. Plastic pipe finish flange for gas line

4. Bonding lug with mounting screw

5. Pressure Relief Valve

6. ProTek Shield Adapter with ProTek Shield Assembly

and wing nut

THE MODEL AND SERIAL NO. CAN ALSO BE FOUND INSIDE THE BEZEL ABOVE THE DISPLAY

Be sure that you receive the number of packages indicated on the Bill of Lading.

Rating and certications

These heaters are design-certied 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 when appropriate venting is installed. 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.

Elevation

Rated inputs are suitable for up to 5,000 feet (1524 m) elevation. For elevations above 5,000 feet (1524 m), consult the factory.

Ambient Temperature Rating

Heater Components

Electronic Ignition Heater* -32°F to 175°F (-35°C to 79°C)

*Requires 120 or 240VAC, 1 Ph, 60 Hz Power Supply

4. INSTALLATION

WARNING: This unit contains refractory ceramic

ber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures (>2192°F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classied the inhalation of crystalline silica (cristabolite) as carcinogenic to humans.

MODEL AND SERIAL NO. LOCATED ON RATING PLATE

Figure 1. Rating Plate Location

F10639-1

IMPORTANT NOTICE: These instructions are intended only for the use by qualied personnel, specically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. If your state is such, be sure your contractor bears the appropriate license. Persons not qualied shall not attempt to x the equipment nor attempt repairs according to these instructions.

WARNING: Improper installation, adjustment,

alteration, service or maintenance may damage the equipment, create a hazard resulting in asphyxiation, explosion or re, and will void the warranty.

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

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 Part 2.

Clearances

All Heaters

For indoor and outdoor clearances from combustible surfaces, see the chart below.

Location Indoor Installation

Top * 30" (762 mm) Drafthood

Front Alcove (Open)

Vent 6" (152 mm)

Floor ** 0"

Back 6" (152 mm)

Right Side 12" (305 mm) Water Side

Left Side 6" (152 mm) Opposite Water Side

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. This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater.

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.

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.

Outdoor Heater Installation

These heaters are design-certied for outdoor installation, when equipped with the approved tops designated for outdoor use.

WARNING: The heater shall not be located in an

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

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

PAGODA TOP INSTALLATION

Location Outdoor Installation

Top * Unobstructed (Outdoor Stack)

Top *** 36" (914 mm) (Stackless Top)

Floor 0"

Back 6" (152 mm)

Right Side 12" (305 mm) Water Side

Left Side 6" (152 mm) Opposite Water Side

* Clearance from top of vent terminal ** Do not install on carpeting *** Clearance from top of heater

Table B. Minimum Clearances from Combustible Surfaces

F10647-2

Figure 2. Heater with Outdoor Stackless Top

Description Location

Back 9 (229)

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

masonry walls without ventilated air space

b. 1/2" (13 mm)insulation

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

c. 0.024 sheet metal over

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

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

masonry wall with ventilated air space

e. 0.024 sheet metal with

ventilated air space

f. 1/2" (13 mm) thick

insulation board with ventilated air space

g. 0.024 sheet metal with

ventilated air space over

0.024 sheet metal with ventilated air space.

h. 1" (25 mm) glass ber

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

Derived from National Fuel Gas Code, Table 10.2.3

Table C. Reduction of Clearances to Protected Surfaces

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

Distance

in. (mm)

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.

For U.S. installations, the point from where the ue products exit the heater must be a minimum of 4' (1.2 m) 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 Canadian installations, 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.

A minimum of 6' (1.8 m) is required from the heater to an inside corner wall for proper outdoor venting.

For installations in Florida and Texas, that must comply with the Florida or Texas Building Code, follow the directions shown in Figure 7 for the installation of hurricane tie-down brackets for all models.

4' (1.2 m) Minimum

3' (0.9 m) Minimum

10' (3 m) Minimum

Forced Air Inlet

Figure 3. Clearances

1' (0.3 m) Minimum

Pagoda Top Installation

1. Insert tabs into keyhole (4 places). See Figure 4, detail A.

2. Snap tabs into keyholes so as not to pull out. See Figure 4, detail B.

DETAIL A DETAIL B

OUTDOOR TOP

(SHIPPED LOOSE WITH HEATER)

Figure 4. Outdoor Top Installation

Indoor Heater Installation

The heater is also design-certied 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 specic 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 12 for details. Minimum allowable space is shown on the nameplate.

WARNING: Indoor heaters require a drafthood that

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.

Outdoor and Indoor Stacks

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.

Model

207A 009834 009838

266L/267A 009835 009839

337A 009836 009840

399L/407A 009837 009841

Table D. Outdoor and Indoor Stack Kit Number

Outdoor Stack Indoor Stack

Part No Part No.

or Canada CAN/CSA-B149) and any local codes that may have jurisdiction. The most common approach is the "2-opening" method, with combustion air opening no more than 12" from the oor and the ventilation opening no more than 12" from the ceiling. For opening sizes using this method, see below.

All Air from Inside the Building:

Each opening shall have a minimum net free area as noted:

Model Sq. in. (m2)

207A 200 (0.13)

266L/267A 266 (0.17)

337A 333 (0.21)

399L/407A 399 (0.26)

Table E. Opening Minimum Net Free Requirements -

Indoor Air

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. (m²)

Typical Screened

or Louvered

Opening

sq. in. (m²)

Typical Screened

and Louvered

Opening

sq. in. (m²)

NOTE: The outdoor drafthood kit does not require any additional vent pipe for proper operation. This drafthood functions as the vent termination.

Combustion and Ventilation Air

Indoor Units Only

The heater must have both combustion and ventilation air. The minimum requirements are listed in the latest edition of the National Fuel Gas Code (U.S. ANSI Z223.1

OUTDOOR STACK KIT

(1) Outdoor stack, painted

(1) Adapter plate

(3) Mounting brackets (clips)

(1) Top panel cover

(2) 1-foot sections of metal tape

(3) Screws

(1) Instructions

Clips

207A 50 (0.03) 75 (0.05) 100 (0.1)

266L/267A 67 (0.04) 101 (0.06) 134 (0.09)

337A 84 (0.05) 126 (0.08) 168 (0.11)

399L/407A 100 (0.06) 150 (0.1) 200 (0.13)

Table F. Opening Minimum Net Free Requirements -

Outdoor Air

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the heater. Such damage will not be covered by the warranty

INDOOR STACK KIT

(1) Drafthood, unpainted

(1) Adapter plate

(3) Mounting brackets (clips)

(3) Screws

(1) Instructions

Figure 5. Outdoor Stack Kit Components

Clips

Figure 6. Indoor Stack Kit Components

Min. Edge

Florida and Texas Building Code: Wind Speed = 150 mph 3 sec gust Exposure = C

Model

in. (mm)

207A 20 (508)

266L/267A 23 (584)

337A 26 (660)

399L/407A 29 (737)

2" x 6" x 1/8" Pallet Anchor Bracket (4 Total) (Kit# 011636)

31-13/16" (792 mm)

F10649

28"

(709 mm)

3" (76 mm)

Min. Conc.

Pad by others

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.

Distance

(152 mm)

Min. Edge

Distance

(152 mm)

(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)

(1)–1/4" x 1-3/4" S.S. Tapcon Bolt & Washer (Field-Supplied) Ea. Pallet Anchor Bracket

3" (76 mm) Min. Conc.

Pad by others

Use hole closest to unit (4 total)

Figure 7. Hurricane Tie-Down Bracket Installation

TOH

Specications and Dimensions

CONNECTION

(711 mm)

F10647-1

INDOOR

DRAFTHOOD

31-13/16" (792 mm)

7-3/4"

(197 mm)

Amp Draw

120 VAC, 1 Ph, 60 Hz 240 VAC, 1 Ph, 60 Hz

6 3

J*D

(521 mm)

20-1/2"

26-1/2"

(673 mm)

ELECTRICAL

CONNECTION

4-3/8"

(111 mm)

FLUE

10"

(254 mm)

8-7/8"

(225 mm)

(6-5/8" ASME)

(168 mm ASME)

34"

(867 mm)

STACKLESS

OUTDOOR

TOP

GAS

F10647

Figure 8. Front View

*Note: For outdoor stack, use J dimension in the table below for appropriate size plus 6" (152 mm).

(B)

Flue

Dia.

in.

(mm)

(C)

Indoor

Drafthood

in. (mm)

55-5/8 (1413)

(1422)

(1448)

(D)

in. (mm)

10.0

(254)

11.5

(292)

13.0

(330)

(J)*

in. (mm)

11-3/4

(298)

(279)

10-5/8

(270)

Gas

Conn.

in.

3/4 2

Water

Conn.

in.

Heater

Model

207A

266L

267A

337A

BTUH

Input (000)

(kw)

199.5

(58.4)

266.0

(77.9)

332.5 (97.4)

(A)

Cabinet

Width

in. (mm)

(508)6 (152)

(584)7 (178)

(660)8(203)

399L

407A

399

(116.9)

(737)9 (229)

58-1/2 (1486)

14.5

(368)

12-1/2

(318)

3/4 2

28"

Figure 9. Side View

Shipping Weights - lbs (kg)

Standard

Heater

w/Stackless

Top

174 (79)

197 (89)

219 (99)

237

(108)

ASME

Heater

Top

193 (88)

N/A

216 (98)

238

(108)

N/A

256

(116)

Indoor

Draft-

hood

(6.4)

(7.3)

(8.6)

(9.5)

Table G. Heater Specications and Dimensions

Vent Piping

WARNING: Indoor heaters require a drafthood that

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.

Flue materials must be certied to CATEGORY I or better. Type “B” double-wall or equivalent vent pipe is recommended. A draft of -0.01" to -0.08" WC must be maintained. However single-wall metal vent pipe may be used as specied in the latest edition of the National Flue Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149).

When properly installed outdoors, only the outdoor stackless top, provided, is required. If installed indoors, a drafthood is required, connected to a CATEGORY I (a heater that operates with a non-positive vent static pressure and a vent gas temperature that avoids excessive condensate production in the vent) vent per the National Fuel Gas Code and local requirements.

Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (3 m) (drafthood relief opening to vent terminal), the vent pipe size may be reduced by no more than one size as specied in 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 (20.8 mm per meter rise) and should be supported at not more than 5 ft (1.5 m) intervals.

Plumber's tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the ashing and extending above the roof more than 5 ft (1.5 m) should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the roof and walls.

D-2 Power Vent Kit

Another option for an installation that requires horizontal runs is using the D-2 power vent kit option.

Model 120 VAC P/N 240 VAC P/N

207A 010744 009832

266L/267A 010744 009832

337A 010745 009833

399L/407A 010745 009833

Table H. Power Vent Kit Part Numbers

NOTE: The D-2 Power Vent operates with a positive 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, Catalog no 6000.57.1. CATEGORY I vent material such as B-vent must not be used under CATEGORY III conditions.

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 the 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.

Figure 10. D-2 Power Vent Option

The power vent system is a fan-assisted vent system designed for application used on models 207A-407A.

The power vent system, when installed as directed, is capable of operating in applications such as through-thewall venting with reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factorywired for 240 VAC, with capability of eld-rewiring for 120

VAC.

For more information consult the D-2 Power Vent manual, (Catalog No. 6000.57.1).

F10639-4

8' (2.4 m)

OR LESS

2' MIN

(0.6 m)

VENT PIPE

DRAFT HOOD

HEATER

VENT CAP

2' MIN

(0.6 m)

5' MIN

(1.5 m)

Figure 11. Venting Clearances

NOTE: With venting application of two or more heaters, contact the factory.

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

must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 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.

Supply Pressure

CAUTION: Do not use teon tape on gas line pipe

thread. Only sealant tape or a pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

A minimum of 5 in. WC and a maximum of 10.5 in. WC upstream pressure under load and no-load conditions must be provided for natural gas.

Gas Pressure Regulator

The gas pressure regulator is preset at 3.1 in. WC for natural gas. The pressure at the gas valve, taken with a manometer, should be about 3.1 in. WC natural gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise clockwise to decrease pressure.

to increase pressure or counter-

Gas Supply Connections

HEATER JACKET

GAS INLET

3" MIN

(76 mm)

Typical

Figure 12. Gas Supply Plumbing

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.

MANUAL SHUT-OFF VALV E (Field supplied)

FINISH FLANGE

UNION

(Field supplied)

SEDIMENT TRAP (Field supplied)

GAS VALVE

MANUAL

SHUT-OFF

VALV E

UNION

Figure 13. Manual Shut-O󰀨 Valve Installation

Gas Pressure Adjustment Locations

F10638-1

Gas Pressure Adjustment

Figure 14. Honeywell VR8340

Pipe Sizing for Gas Connection

The capacities shown below are based on using SCH 40 black iron pipe. For capacities using other materials, consult local codes.

Maximum Equivalent Pipe Length (ft) (m)

Natural Gas 1000 BTU/FT

WC Pressure Drop

Model 3/4" 1" 1-1/4" 1-1/2"

207A 25 (7.6) 90 (27.4) 360 (109.7) n/a

266L/267A 15 (4.6) 50 (15.2) 210 (64.0) 445 (135.6)

337A 10 (3.0) 30 (9.1) 140 (42.7) 290 (88.4)

0.60 Specic Gravity @ 0.5 in.

Figure 15. Polymer Headers Water Flow

F10637-1

Figure 16. Brass Headers (ASME) Water Flow

399L/407A * 20 (6.1) 95 (29.0) 215 (65.5)

* 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.

Table I. Gas Pipe Sizing

Flow Rates

Model Pipe Size Min. GPM (lpm) Max. GPM (lpm)

207A 1-1/4"–1-1/2"–2" 20 (75) 125 (473)

266L/267A 1-1/4"–1-1/2"–2" 25 (95) 125 (473)

337A 1-1/4"–1-1/2"–2" 35 (132) 125 (473)

399L/407A 1-1/4"–1-1/2"–2" 40 (151) 125 (473)

* When ow rates exceed maximum GPM an external auxiliary bypass valve is required. See external bypass valve section for details.

Table J. Min/Max Flow Rates

Pressure Drop

Flow GPM

(lpm)

207A 266L/267A 337A 399L/407A

Ft. of Head (m of Head)

20 (75) 4.0 (1.2)

25 (95) 4.0 (1.2) 4.6 (1.4)

30 (113) 4.0 (1.2) 5.2 (1.6)

35(132) 4.0 (1.2) 5.8 (1.8) 5.2 (1.6)

40 (151) 4.6 (1.4) 5.8 (1.8) 5.2 (1.6) 5.2 (1.6)

50 (189) 4.6 (1.4) 6.3 (1.9) 6.9 (2.1) 6.9 (2.1)

60 (227) 4.6 (1.4) 6.9 (2.1) 6.9 (2.1) 6.9 (2.1)

70 (265) 4.6 (1.4) 8.1 (2.5) 9.2 (2.8) 9.2 (2.8)

80 (303) 4.6 (1.4) 9.2 (2.8) 9.8 (3.0) 9.8 (3.0)

90 (340) 6.9 (2.1) 10.4 (3.2) 10.4 (3.2) 10.4 (3.2)

100 (378) 8.1 (2.5) 11.0 (3.4) 12.1 (3.7) 12.1 (3.7)

110 (416) 10.4 (3.2) 11.5 (3.5) 13.3 (4.0) 13.3 (4.0)

120 (454) 11.0 (3.4) 12.7 (3.9) 17.9 (5.4) 17.9 (5.4)

125 (473) 11.5 (3.5) 13.8 (4.2) 20.2 (6.2) 20.2 (6.2)

Table K. Polymer Heat Exchanger Pressure Drop -

Residential Models - UG Fully Open

Pressure Drop

F10664

O-RING

Flow GPM

Ft. of Head (m of Head)

(lpm)

207A 267A 337A 407A

20 (75) TBD

30 (113) TBD TBD

40 (151) TBD TBD TBD TBD

50 (189) TBD TBD TBD TBD

Brass Headers (ASME Models)

Heater must be located so that any water leaks will not damage the structure of adjacent area. Before attaching the ProTek Shield Adapter to the inlet connection and the 2-inch unions, make sure the O-rings are properly seated in the grooves. Use Aqualube or equivalent non-petroleumbased lubricant on the O-ring. Hand tighten the unions. Glue PVC piping directly to the unions.

60 (227) TBD TBD TBD TBD

70 (265) TBD TBD TBD TBD

80 (303) TBD TBD TBD TBD

90 (340) TBD TBD TBD TBD

100 (378) TBD TBD TBD TBD

Table L. Brass Heat Exchanger Pressure Drop - ASME

Models - UG Fully Open

NOTE: Table capacity is based on Schedule 40 black iron pipe. For capacity using other material, consult local codes.

Polymer Headers (Residential Models)

Before attaching the 2-inch unions to the inlet/outlet header, make sure the O-rings are properly seated in the grooves. Use Aqualube or equivalent non-petroleumbased lubricant on the O-ring. Hand tighten the unions. Glue PVC piping directly to the unions.

O-RING

HEADER FLANGE (CPVC)

PLUMBING

PROTEK SHIELD ASSY

HEADER FLANGE NUT (CPVC)

F10641

HEADER FLANGE (CPVC)

HEADER FLANGE NUT

(CPVC)

HEADER

PROTEK SHIELD ASSEMBLY

PLUMBING

Figure 18. Inlet/Outlet Header – Brass

NOTE: Some jurisdictions require the addition of a ow switch on ASME installations. Kit # TBD can be ordered that will allow a standard ASME unit to comply with the code requirements.

ProTek Shield Assembly

This heater is equipped with a ProTek Shield Assembly (located under the inlet connection on polymer headers and in the ProTek Shield Adapter assembly shipped loose in the accessory carton for eld installation on brass ASME headers).

This component provides protection to the heat exchanger against galvanic corrosion, when properly bonded to the heat exchanger. It should be replaced when the weight of the ProTek Shield is reduced to about 40% of the original weight (1.46 #).

Figure 17. Inlet/Outlet Header – Polymer

High temperature CPVC header anges and header ange nuts are provided. If there is any possibility of backsiphoning when the pump stops, it is suggested that a check valve (or valves) also be installed in the system.

F10715

Figure 19. ProTek Shield Assy

CAUTION: STOP the pool pump before attempting

F10642-2

F10642-1

BYPASS DISC

to remove ProTek Shield Assembly. Failure to do so may result in damage to ProTek Shield Assy, loss of pool water, or personal injury.

CAUTION: Do not use tools to remove (twist) the ProTek Shield Assy or the wing nut on the stud of the ProTek Shield Assy. Non-warrantable damage may occur.

Follow the steps below to replace the ProTek Shield Assy:

1. Shut off the pool pump and bleed pressure from the system.

2. Close isolation valves to minimize pool/spa water loss.

3. Remove wing nut from bottom stud on ProTek Shield Assy.

4. Remove bonding wire ring terminal from stud.

5. Rotate ProTek Shield Assy clockwise (by hand) to

unscrew it from the assembly.

6. Inspect/replace as necessary and reverse above procedure to reinstall. Hand tighten only! Do not use tools.

UG/BYPASS ASSY

UNITHERM GOVERNOR

Figure 21. Unitherm Governor – Brass

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.

UG/BYPASS ASSY

NOTE: Make sure the O-ring is properly seated in the O-ring groove before installation.

Unitherm Governor Operation

a thermostatic mixing valve specically designed to maintain constant heater internal temperature between 105°F (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. Unitherm Governor – Polymer

CAUTION: The patented Unitherm Governor is

UG PLUG

UNITHERM GOVERNOR

GASKET

F10725

SPRING "RED" - 206/266 "SILVER" - 336/406

Figure 22. Internal Automatic Bypass Valve ASME

NOTE: The Unitherm Governor and Bypass Valve Assy are not individually replaced components on ASME units. If either needs to be replaced, the entire UG/ Bypass assy must be replaced. The "red" spring is used on models 207A, 266L, and 267A. The "silver" spring is used on models 337A, 399L, and 407A.

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

VALV E

TO POOL/SPA

BYPASS VALVE

Do not use gate valve.

Figure 23. Auxiliary Bypass Valve

FROM POOL/SPA

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.

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 BTU output of the model to be installed, is recommended for this heater. The maximum acceptable pressure relief valve setting is 125 psi (862 kPa).

A 3/4" NPT connection is provided in the Polymer header for installation of a pressure relief valve. The valve shall be installed in a vertical position. Do not over-tighten. Install pressure relief valve hand tight plus 1/2 turn.

PRESSURE RELIEF VALVE

PRV DISCHARGE CONNECTION

F10663

Figure 25. Pressure Relief Valve Brass Header

(ASME Models)

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.

PRESSURE RELIEF VALVE

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. See. Figure 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).

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

IN/OUT HEADER

F10662

Figure 24. Field-Supplied Pressure Relief Valve Polymer

Header (Residential Units)

A 3/4" NPT connection is provided in the header for installation of a 75 PSI (517 kPa) pressure relief valve. The PRV is shipped loose in the accessory carton with the pagoda top. The valve pressure relief shall be installed in a vertical position.

CAUTION: An additional source of heated water,

e.g. a 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 setpoint, 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. PVC pipe may be glued directly into the headers unions.

Plumbing Diagram

TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER

Water Connection

ISOLATION VALVE

THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED

TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER

Figure 29. Single Pool Heater Installation

BALL VALVE

PRESSURE RELIEF VALVE

PUMP

UNION

CHECK VALVE

THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED

Figure 30. Multiple Pool Heater Installation

Heat Exchanger Reversal

Procedure for Residential Models

1. Remove right and left side access panels. See

Figure 26.

F10652

Figure 26. Access Panels

2. Disconnect wires at high limit, AGS (automatic gas shut-off), water pressure switch on the in/out header, and ProTek Shield bonding wire. See Figure 27.

Re-attach the headers to the opposite sides, making sure they are installed in an upright position. Do not over-tighten. Torque should not exceed 7 ft/lb. See

Figure 27.

5. Reconnect high limit, AGS, water pressure switch

wires, and ProTek Shield bonding wire.

6. Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting. Tighten 1/2 turn past hand tight.

7. Allow for water flow through the heater and check for leaks.

8. Re-attach access panels to the opposite sides.

For instructions on reversing the heat exchanger connections on ASME models, call your factory representative.

5. 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.

F10653

Figure 27. Component Wiring Locations – In/Out Header

3. Remove the thermostat temperature sensor by loosening the compression fitting nut. Re-route the sensor to left side of the heater. See Figure 28.

F10654

Figure 28. Thermostat Temperature Sensor Location

4. Remove (12) nuts holding the inlet/outlet and return headers to the tube sheets. Clean off tube sheet area where the gasket seats. Also clean off the header and the gasket. Apply a non-petroleumbased lubricant to the gasket such as Aqualube.

WARNING: Digital heaters are factory-wired for

240 VAC, 1Ph, 60Hz 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.

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.

Electrical Power Draw

F10651

RED

WHITE

CAUTION: Heater must be electrically grounded and

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 a󰀨ect the heater’s electronics.

NOTE: See "Time Clock/Fireman’s Switch" on page 28 for further instructions if using a time clock/ reman’s switch.

BLACK

WHITE

SUPPLY

RETURN

NEUTRAL

HOT

BLACK BLACK

WHITE WHITE

SIDE

GROUND

GREEN GREEN

RED

Figure 32. 120 VAC Wire Connection Models

HEATER 7 WIRES

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.

When operating on 120VAC power, units draw 6 amps. When operating on 240VAC units draw 3 amps.

OPTION LOCATION LEFT SIDE FIELD WIRING

BONDING LUG (OPTIONAL LOCATION)

CONTROL BOX (FACTORY MOUNTED LOCATION)

SWAY BRACE

BONDING LUG (STANDARD LOCATION)

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.

There should be no connection to the white wires for 240 VAC operation. Attach a wire nut to each white wire

independently.

WARNING: DO NOT attempt to operate the heater

at 208 VAC.

240V LOW NOx HEATER

HOT

BLACK

SUPPLY

SIDE

GROUND

HOT

RED

GREEN GREEN

Figure 33. 240 VAC Wire Connection

BLACK

RED

WHITE

HEATER

7 WIRES

Figure 31. Heater Wiring Locations

Transformer Wiring

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.

There should be no connection to the red wires for 120 VAC operation. Attach a wire nut to each red wire

independently.

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

CAUTION: 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.

NOTE: 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󰀨.

6. WIRING DIAGRAM

7. CONTROLS

PRESSURE SWITCH TEMP SENSOR HL1 - HIGH LIMIT HL2 - HIGH LIMIT

PROTEK SHIELD ASSY

GAS VALV E

CONTROL BEZEL

PILOT

AIR PRESSURE SWITCH

MANUAL RESET ROLL-OUT SWITCH

Figure 34. Location of Controls (View One)

UNITHERM GOVERNOR

F10639-3

NOTE: Caution must be used to not damage controls or wiring.

KNURLED SCREW

F10647-3

Figure 36. Knurled Screw Location

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. See Figure 37.

BLOWER DRAIN PLUG IN REAR HEADER

F10639-2

Figure 35. Location of Controls (View Two)

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.

TEMP ADJUST BUTTONS

TEMP

LCD DISPLAY

Figure 37. Control Adjustments

MODE BUTTON

MODE

OFF

Mode Button

Program Mode Button (SW1)

The Mode 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.

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.

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.

By default, the setpoint range is 50-104°F (10-40°C). See

page 24 to increase the MAX setting, if necessary.

Service Menu and Fault History

To access the Service Menu and fault history, press the MODE 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 40. Flame Strength Indicator

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

Figure 38. Alternating Display During Heating

Figure 39. Thermostat Program Button (SW1)

Figure 41. Supply Voltage Indicator

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

Figure 42. Run Time/Cycles

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

Figure 43. Fault History Indicator

Program Button

1. Remove the four 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 39. Press and hold the button for 5-7 seconds until SET FACTORY DEFAULTS appears on the display. Release the program button.

2. Press the MODE 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 44 below.

Resets board to factory default settings.

Resets faults in the History File.

Change from Fahrenheit to Celsius.

SPA setpoint maximum adjustment.

POOL setpoint maximum adjustment.

Figure 44. Programmable Events

Set Factory Defaults

Refer to step one above to access the program screen. SET FACTORY DEFAULTS should appear on the screen. If it does not, press the MODE 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 MODE 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 MODE button until FAHRENHEIT or CELSIUS appears on the digital display. The UP or DOWN buttons will select FAHRENHEIT or CELSIUS on the temperature display. Choose the desired temperature scale.

Spa Max Temp – Spa Setpoint Maximum Adjustment

Refer to step one above to access the program screen. Press the MODE 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 Setpoint Maximum Adjustment

Refer to step one above access into the program screen. Press the MODE 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).

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 MODE button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the MODE button to lock in selections. Conrm your selection and record your PIN.

To unlock the controls, press any button to bring up the ENTER PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Successfully unlocking the control will display LOCKOUT CLEARED. Failure to enter the correct PIN will display INVALID PIN.

In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to SET FACTORY DEFAULTS. This will clear the PIN and allow normal operation and selection of a new PIN if desired. See the "Program Button" on page 24 for details.

NOTE: Both the POOL and SPA setpoints will revert back to 65°F (18°C) and the POOL and SPA maximum temperature settings will be 104°F (40°C). These setpoints will need to be readjusted to desired settings.

NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water temperature at the inlet to the heater may di󰀨er from that observed at a given location in the pool or spa.

Status and Diagnostics

The digital 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.

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

Display Condition

Water Sw Open Water pressure switch open.

Vent/Field Sw #1

Hi Limit 1 Fault High limit 1 open.

Vent spill switch/eld switch #1 open.

Display Condition

Heating Call for heat established, ame present.

Spark Spark operating.

No Demand Heat demand is satised.

Table M. Heater Status Messages - No Active Faults

The following conditions are displayed in Pool, Spa and Remote modes when there are active fault conditions.

Display Condition

Sensor Failure

Sensor Open

Sensor Short

Flame w/o CFH

MV Output Fault

Lo NOx Tab Fault

Internal Fault Board fault, replace board.

EEPROM Fault

Clock/Fireman Sw

Low Temp Lockout

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

Thermistor sensor failed open. Below

-20°F (-29°C).

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

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

Main gas valve output is not in commanded state.

Voltage is sensed at the Lo NOx terminal on a non-Lo NOx Heater (Lo NOx tab is intact)

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).

Hi Limit 2 Fault High limit 2 open.

Rollout Sw Open Rollout switch open.

Flow/Field SW #2

Fan Lockout

Fan 5 Min Delay

Ignition Lockout (Propane Tab Broken)

Ignition Failure (Propane Tab Not Broken)

Ign 6min Delay (Propane Tab Not Broken)

Table O. Heater Status Messages - Demand for Heat

Field-supplied ow switch/eld switch #2 open.

3 fan switch faults within same heat demand cycle, power must be cycled to clear the fault

Heater shut down for 5 minutes because LoNOx fan switch didn't close

Alternating with “No pilot sensed”

- Pilot ame not established within the required time (15 sec or 90 sec).

Alternating with “Main Ign Failure”

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

Alternating with “No pilot sensed”

- Pilot ame not established within 90 seconds.

Alternating with “Main Ign Failure”

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

Table N. Heater Status Messages - Active Faults

Remote Control Installation

and Operation

CAUTION: Before installing remote controls

to the 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 45. 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.

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 28.

OFF Mode

Activating the Remote

To activate or deactivate the remote function:

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

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

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

Figure 46. Remote Control Menu - Activation

Remote Control Wiring

ATTENTION

OBSERVE PRECAUTIONS

ELECTROSTATIC

SENSITIVE DEVICES

CAUTION: Electrostatic Discharge (ESD) damage

can be caused by direct or indirect contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact of a nger allows the body to discharge, possibly causing device damage. This damage can be limited if the service person discharges himself, following ESD preventive/removal practices, and holds on to the heater enclosure for 5 seconds before proceeding.

Heating in the POOL Mode

Heating in the SPA Mode

Remote Mode

Figure 45. Remote Control Menu - Remote Operation

Important Installation Notes for Remote or External Wiring Conguration:

• Remote wiring must be run in a separate conduit.

• Remote wiring must not be run parallel to high voltage

lines.

• For runs of under 30' (9 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 m), the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5" to 2.5" (3.8 to 6.4 cm) lay that is shielded and jacketed.

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

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

provided 7-pin wiring connector must be utilized.

NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board.

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 MODE 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 MODE 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 MODE 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 47.

BLU - 24VAC

ORN/BLK - To Spa (COMM)

Wire Nut BLK/ORN - To Pool (COMM)

Figure 48. 2-Wire Remote Harness Installation on the P8

Connector of the Board

Pool Common (BLK/ORN)

Spa Common (ORN/BLK)

24VAC HOT (BLU)

Figure 47. 7-Pin Remote Interface Harness

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

7. Install the “7-Pin Remote Interface Harness” to the P8 connector and turn power "ON" to the heater. See Figure 48.

For activation of the remote control, see section on page

26.

3-Wire Remote Control Using ThreePosition Switch (Pool-O󰀨-Spa, or Low-O󰀨High)

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

1. Turn on power to the heater.

2. Push the MODE 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 MODE button to OFF and remove power from the heater.

BLU - 24VAC

ORN/BLK - To Spa (COMM)

BLK/ORN - To Pool (COMM)

Figure 49. 3-Wire Remote Harness Installation on the P8

Connector of the 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 47.

5. Install the “Remote Interface Harness” to the P8 connector and turn power ON to the heater. See Figure 49.

For activation of the remote control, see section on page

26.

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 15 to 20 minutes prior to shutting down the pool pump.

The reman’s switch connection is located on the 14pin 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 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 m) of total wiring using 18 AWG stranded copper wire rated for 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.

Water Pressure Switch

The water pressure switch ensures that the heater operates only when the lter pump is in operation. It is located on the In/Out header. It is factory-set at 1.75 PSI for deck level installation.

Water Pressure Switch Adjustment

When the heater is located below the level of the spa or pool, it may be necessary to adjust the pressure switch to compensate for the no-ow static head, If it is necessary to adjust the water pressure switch, do the following:

1. Make sure the pool filter is clean before adjusting the switch.

2. Set the heater control to the OFF mode.

3. Turn the filter pump ON and confirm that the pressure switch is closed (use a multimeter to check). If the pressure switch fails to close, either the switch setting is too high or not enough pressure is being supplied by the filter pump.

4. Turn the heater ON.

5. Manually turn the pressure adjustment knob clockwise

until the heater shuts off. (A flat screwdriver may be necessary if knob is too tight.)

6. Slowly turn the adjustment knob counter-clockwise until the heater calls for heat again.

7. Turn an additional 1/2 turn counter-clockwise.

8. While the heater is running, check the adjustment by turning the pump off and on several times. The burners should shut off immediately when the pump is turned off. If it does not, repeat the above steps until proper operation is observed.

F10671

Figure 50. Water Pressure Switch Assembly

NOTE: The sheet metal access panels should be in place at all times to protect the water pressure switch from rain and other environmental factors.

MAY REQUIRE ADJUSTMENT

FOR LOWER PRESSURE

MAY REQUIRE ADJUSTMENT FOR HIGHER PRESSURE

5 ft. (1.52 m) MAX

POOL OR SPA

Figure 51. Pressure Switch Adjustment Requirements

NOTE: If heater is installed outside of the limits shown, a higher pressure rated (11 psi / 76 kPa) switch may be used. A ow switch, mounted and wired adjacent to the heater, may be used in place of the factory-mounted pressure switch. See "ILLUSTRATED PARTS LIST" on page 39 for 11 psi / 76 kPa water pressure switch.

Two Speed Pumps

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

CAUTION: Do not operate the heater without the

function of a properly adjusted water pressure switch or ow switch.

Flame Roll-Out Safety Switch

Heaters are equipped with a thermal cuto󰀨 device to prevent ame roll-out in the event the heat exchanger becomes blocked. It is a “manual reset” type roll-out switch that must be reset by a service technician after any over-temperature conditions have been xed. Excessive restriction in the heat exchanger ue passage may cause

the switch to disable the heater.

Figure 52. Flame Roll-out Switch – Manual Reset

High Limits

The heater is equipped with two high limits.

On units with polymer headers, both are automatic and are located in the inlet/outlet header. Both are set at 135°F (57°C).

On units with brass header, both are located on the inlet/ outlet headers. HL1 is manual reset and set to open at 160°F (71°C). HL2 is automatic and set to open at 135°F (57°C).

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.

Burner Tray Removal

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to the

base of the unit, (2) screws that mount the blower box to the burner tray, and (1) screw that secures the anti-rotation bracket to the heater.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the pilot assembly.

9. Disconnect wire connector from the combustion blower.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

NOTE: An erratic high limit is often characteristic of an internal heat exchanger problem, e.g. scale build-up, defective bypass. Refer to "TROUBLESHOOTING" on page 35.

AUTO RESET

Figure 53. High Limit Switches

MANUAL RESET (ASME ONLY)

F10669-1

High Limit Removal

1. Shut off main electrical power switch to heater.

2. Remove inlet/outlet sheet metal access panel.

3. Remove defective high limit and replace with the correct, new high limit.

4. Replace access panel.

Figure 54. Burner Tray Assembly

Gas Valve Removal

1. Shut off gas supply to the heater. Remove gas piping to gas valve inlet.

2. Remove burner tray, following above procedure.

3. Disconnect, pilot tubing from gas valve.

4. Remove (2) screws that mount anti-rotation bracket to the burner tray.

5. Turn vertical gas pipe from manifold slightly and unscrew gas valve.

6. Reverse above procedure to reinstall.

Main Burner And Orice Removal

1. Remove burner tray, following above procedure.

2. Remove pilot. See pilot removal procedure.

3. Remove (8) total screws from the burner hold-down brackets, front and rear of tray.

4. Remove (8) total screws from the left and right sides of the manifold assembly. Detach the air/gas manifold assembly from the burner tray assembly.

5. Remove burners by raising them straight up off the rear end slots.

6. Use a long 9/16” socket wrench to remove orifice from the gas manifold.

7. Reverse above procedure to reinstall.

Pilot Removal

1. Disconnect pilot tubing from gas valve.

2. Remove the pilot wire from the pilot assembly.

3. Remove (2) screws that mount the pilot assembly to the burner tray.

4. Pull the pilot assembly downwards and outwards.

5. Reverse above procedure to reinstall.

Electrode Alignment Detail

.18± .04 inch (4.57±1 mm)

Figure 55. Lo NOx Pilot

Combustion Blower Removal

1. Remove the (2) screws that secure the blower box to the burner tray.

2. Remove (2) screws that mount the blower box to the base of the heater.

3. Disconnect wire connector from the combustion blower.

4. Carefully remove blower box with combustion blower.

5. Remove (2) screws that secure combustion blower

to blower box.

6. 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 access 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, remove ProTek Shield Assy bonding wire from heat exchanger stud, 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.

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.

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 descale solvent for severe scale build-up.

Extension

F10724

F10642-2

Pieces (2)

Figure 56. Tube Cleaning Kit

Auger

with Carbide Tip

Wire Brush

Desooting Procedure

WARNING: Soot Is Combustible. Exercise Extreme

Care.

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. See page 29.

4. Remove ProTek Shield Assy bonding wire from heat exchanger stud.

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

6. 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.

Combustion Chamber Removal

To remove combustion chamber, you must rst have removed the heat exchanger.

Unitherm Governor (U.G.) 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 on polymer header models.

4. Unsnap old U.G. to remove from retainer plug. Snap in new U.G.

5. Reinstall retainer plug, taking care to lubricate gasket with a non-petroleum based grease such as AquaLube.

UG PLUG

UNITHERM GOVERNOR

GASKET

F10725

Figure 58. Unitherm Governor – Polymer

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.

UG/BYPASS ASSY

Figure 57. Refractory Panels

WARNING: When removing the burners or heat

exchangers, take precautions to avoid creating airborne dust and avoid inhaling airborne bers. When cleaning spills, use wet sweeping or High E󰀩ciency Particulate Air (HEPA) ltered vacuum to minimize airborne dust. Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust. Wear appropriate personal protective equipment including gloves, safety glasses with side shields, and appropriate NIOSH certied respiratory protection, to avoid inhalation of airborne dust and airborne ber particles.

UNITHERM GOVERNOR

Figure 59. Unitherm Governor/Bypass Valve Assy – ASME

NOTE: The U.G. on ASME models (brass headers) can only be replaced by replacing the entire Unitherm Governor/Bypass Valve Assembly.

8. OPERATING

OFF

INSTRUCTIONS

Before Start-Up

Visual Inspection

Flames can be observed through the opening below the plenum. Flame color is blue and evenly spread on the top surface of the burner. At least every three months a visual inspection should be made of the burners.

Burners

Keep heater area clear and free from combustibles, ammable liquids and chemicals. Do not obstruct the ow of combustion and ventilation air.

Water

Water must be owing through the heater during operation. Ensure that the system is lled with water and that the pump is operating.

Start-Up Procedures

Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with only electronic ignition. ASME-certied units typically used in commercial applications, are also available. This manual provides installation, operation, maintenance, and service information for these heaters.

TEMP ADJUST BUTTONS

MODE BUTTON

Water Pressure Switch

A water pressure switch is provided in the heater to shut o󰀨 the burners in the event that water supply is interrupted. It is very important to verify that the switch electrically opens and shuts o󰀨 the gas valve when water ow to the heater is interrupted. Otherwise rapid and severe damage will likely occur to the heater.

The water pressure switch should be checked and adjusted for proper operation by a qualied service person at the time of installation and periodically checked thereafter. Refer to "Water Pressure Switch Adjustment" on page

28.

TEMP

LCD DISPLAY

Figure 60. Heater Control Toggle Switch

MODE

If your digital 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 60 for location of toggle switch to turn the heater On and O󰀨.

See Section 7 for additional details about the use of the controls in the Control Adjustments subsection.

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

supply fail to shut o󰀨, turn o󰀨 the manual gas control to the appliance.

F10671

Figure 61. Water Pressure Switch

WARNING: Operation of the heater without water

circulation will cause rapid and severe damage to the heater, and will void the warranty.

Blower Adjustment

This heater is equipped with a combustion air plate (ba󰀪e) mounted on the air intake to the combustion air blower. The ba󰀪e has a hole that is utilized to control the air inlet to the blower.

When the combustion air setting is proper, there will be some lifting of the ames on some areas of the burner deck under cold-start conditions. After about ve minutes of operation, the ames should settle down and blue tips should become visible. Lifting of ames beyond ve minutes would indicate too much combustion air.

OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES

ELECTRONIC IGNITION DIGITAL MODELS

(AUTOMATICALLY–LIGHTED PILOT)

FOR YOUR SAFETY READ BEFORE LIGHTING

A. This appliance is equipped with an ignition de-

vice which automatically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING, smell all around the ap-

pliance 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 neigh-

bor’s phone. Follow the gas supplier’s instructions.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn o󰀨 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".

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.

*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 qualied 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 qualied service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn O󰀨 Gas To Appliance” and call your service technician or gas supplier.

HONEYWELL VR8340 GAS VALVE IID

GAS

INLET

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

2. Turn o󰀨 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". Make sure knob rests against stop.

5. Replace heater door panel.

9. MAINTENANCE AND CARE

F10673

Cold Weather Operation

WARNING: Check the heater for possible rodent

nests 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

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

2. The Low NOx burners and orifice areas should be inspected annually. Dirt and debris can affect the operation of the heater and could damage the burners or prevent the heater from firing. DO NOT clean the burners with a wire brush.

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 color is blue and evenly spread on the top surface of the burner.

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

CAUTION: Combustion air must not be contaminated

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.

Important Freeze Information

MODERATE CLIMATE: Heater operation can continue

during short-term cold spells. When temperatures are between 0°F (-18°C) and 32°F (0°C), ow (continuous pump operation) must be maintained.

CAUTION: Do not use the heater to maintain

water temperatures just above freezing or for freeze protection. When heater is used during freezing weather, care must be taken to avoid freeze-ups. Continuous pump operation is a must. Additional protection may be required. The heater is not warranted against freeze-ups.

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 below.

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. Remove the ProTek Shield Assy located in 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. See

Figure 62 and Figure 63.

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" on page 35:

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 is 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.

DRAIN PLUG

Figure 62. Return Header Drain Plug, Polymer

("P" Prex Model)

DRAIN PLUG

Figure 63. Return Header Drain Valve, Brass

("B" Prex Models)

O RING

F10672

10. TROUBLESHOOTING

IMPORTANT NOTICE: These instructions are intended for the use of qualied personnel who are specically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualied shall not attempt to install this equipment nor attempt repairs according to these instructions.

Problem Possible Cause Corrective Action

Harmonics, or whining noise Unitherm 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

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

Pilot outage or “Weak Flame” signal

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

Outer jacket very hot (paint blistered)

Takes too long to heat pool or spa

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

Gasket brittle and leaking (overheated)

Combustion fan not running "Fan 5 min Delay" signal or "Fan Lockout" signal

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

Dirty lter ................................................ Clean or replace lter

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

External bypass setting out of

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

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

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

Bypassing too much water ..................... Inspect bypass for movement, if no movement, replace

Unitherm governor not functioning ......... Replace if no movement when heated

Unitherm governor inoperative ............... Check movement by putting in hot water (110°F [43°C] or

*Air starvation ......................................... Refer to installation instructions

*Improper venting ................................... Follow recommended installation instructions

*Insects or debris clogging burner intake

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

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

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

*Insects or debris clogging burner intake

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

*Broken refractory caused by shipping

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

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

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

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

Dirty lter ................................................ Clean lter

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

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

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

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

Fan relay................................................. Replace fan relay

Fan ......................................................... Loose connection or failed motor

Burned motor .......................................... Incorrect wiring, replace blower

Air pressure switch ................................. Replace air switch

higher)

check pool pH and total alkalinity

Adjust manual bypass valve until heater outlet water temp is between 105°F and 110°F (40°C and 43°C)

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

Digital - Flow Chart

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO PC BOARD?

(24 V NOMINAL)

YES

SPARK ACROSS

IGNITER/SENSOR GAP?

YES

WARNING: HIGH VOLTAGE

For qualied technicians ONLY

NOTE: Some heaters may be equipped with an ignition module that shuts o󰀨 pilot gas if pilot fails to light. To reset, interrupt power to heater.

NOTE: Before troubleshooting, familiarize yourself with the start-up and check-out procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat

(controller) and wiring. Make sure that the line voltage is NOT 208 VAC.

Pull ignition lead and check spark at PC board. Spark Okay?

YES NO

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from excessive temperatures.

Replace the PC board.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

• Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orice is not blocked.

• Check electrical connections between PC board and pilot operator on gas control.

• Check for 24 VAC across PV-MV/PV terminals on PC board. If voltage is okay, replace gas control; if not, replace PC board.

NOTE: If PC board goes into lockout, reset system. Lockout is used on L.P.G. models.

• Check for 24 VAC across MV-MV/PV terminals. If no voltage, replace module.

• Check electrical connections between PC board and gas control. If okay, replace gas valve or gas control operator, i.e. pilot gas valve, etc.

NOTE: IF PC board goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the time of checkout.

• Check that pilot ame covers ame rod and is steady and blue.

• If checks are okay, replace PC board.

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve.

TROUBLESHOOTING

ENDS

Control Logic - Flow Chart

Power On

Is the water

temperature displayed?

YES

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

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

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

Push MODE

switch to select

"Pool" or "Spa"

Push Temp

arrow to scroll to

desired temperature

Water temperature

and set

temperature

displayed?

YES

“Heating” will display briefly

“Spark”

Flame icon displayed

and flashing?

Water temp displayed?

(pilot lit and rectified)

YES

“Remote” and Water Temperature displayed

(a remote control is controlling the heater)

Note: Disconnect the remote by turning the

remote function off. See page 28 for instructions.

Is a fault code displayed and flashing?

YES

Diagnostic Readouts

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

Temperature sensor out of range (replace sensor)

Sensor Failure

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

Sensor resistance at various temperatures

Temp Degrees F 40 50 60 70 80 90 100 106 Temp Degrees C 4 10 15 21 27 32 38 41 Resistance (k) 261.1 199.0 153.1 118.8 93.0 73.3 58.3 51.0

If okay, replace Circuit Board

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

“Hi Limit 1 Fault” High limit switch. Verify water flow. Inspect internal “Hi Limit 2 Fault” Thermostat (Unitherm Governor) and bypass valve. Press manual button on HL1 fault on brass (ASME) models.

“Rollout Sw Open” Rollout Sensor - Check for blocked heat exchanger and soot. Press manual reset button.

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

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

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

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

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

Heater Fired?

YES

END

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

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

11. 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

12. ILLUSTRATED PARTS LIST

9-M

3-V

I-S

I3-S

8-S

2-J

8-C

6-M

1-V

5-C

4-C

11-S

17-HM

3-J

4-V

2-V

I5-HP

3-HP

4-S

9-M

6-HP

6-S

3-R

4-HP

2-S

5-HP

7-HP

6-HP

I2-S

20-HP

7-S

2-R

3-S

14-S

8-M

7-M

1-G

4-B

15-M

3-B

10-S

2-M

2-B

1-B

8-B

25 -M

5-B

7-C

6-B

13-M

10-M

12-M

5-S

4-S

1-R

12-M

1-J

1-M

3-HM

7-HM

5-HM

2-S

16-M (OPTIONAL)

6-C

6-HM

4-HM

1-M

17-M

2-HM

4-S

8-HP

18-M

FOR UNITS WITH ASME BRASS HEADERS FROM 12/2019

2-S

6-HM

6-C

14-HM

13-HM

19-HM

2-HM

9-S

21-HM

17-HP

15-HM

26-HM

20-HP

16-HM

27-HM

18-HP

1-C

9-C

28-HM

(OPTIONAL)

11-HM

6-M

2-C

17-HM

7-HM

3-HM

3-C

4-HM

4-S

19-HM

20-HM

18-HM

FOR UNITS WITH ASME CAST IRON HEADERS PRIOR TO 12/2019

12-HM

10-HM

8-HM

9-HM

3-M

(OPTIONAL)

1-M

6-C

8-HP

1-C

11-HP

19-HP

6-M

(OPTIONAL)

6-C

1-M

19-HP

11-HP

1-C

18-HP

16-HP

12-HP

2-HP

13-HP

17-HP

20-HP

FOR UNITS WITH POLYMER HEADERS FROM 10/2019

6-P

14-HP

1-P

2-P

8-HP

18-HP

FOR UNITS WITH POLYMER HEADERS PRIOR TO 10/2019

15-HP

13-HP

14-HP

17-HP

19-M

20-M

12-HP

2-HP

16-HP

10-HP

4-P

IID LOW NOx PILOT

22-M

21-M

24-M

23-M

22-M

TEXAS CODE OPTION PRIOR TO 12/2019

CALL OUT DESCRIPTION 207A 266L/267A 337A 399L/407A

BB BURNER TRAY***

1-B Burner Tray w/Burners (0-5000) 010343F 010344F 010345F 010346F

Burner Tray w/o Burner (0-5000) 010084F 010085F 010086F 010087F 2-B Burner Hold Down Kit 010254F 010255F 010256F 010257F 3-B Burner 017045F/3 017045F/4 017045F/5 017045F/6 4-B Burner Orifice Nat. #26 (0-5000)* 351632/3 351632/4 351632/5 351632/6

Burner Orifice Nat. #31 (above 5000 ft.)* 351523/3 351523/4 351523/5 351523/6 8-B Combustion Air Seal Gasket 016361F 016361F 016361F 016361F 5-B Blower 010042F 010042F 010042F 010042F 7-B Cooling Fan 010871F 010871F 010871F 010871F 6-B Combustion Air Orifice Plate 010338F 010339F 010340F 010341F

C CONTROLS

1-C Thermostat Auto Reset 135 Deg Surface Mount 006725F 006725F 006725F 006725F 2-C 3-C

AGS 135° (Auto Gas Shut-Off) - Red Epoxy - prior to 12/2019

High Limit 140° - Black Epoxy - prior to 12/2019

600892B 600892B 600892B 600892B

600893B 600893B 600893B 600893B 4-C P. C. Board/Control 013464F 013464F 013464F 013464F 5-C LCD Display

Units manufactured from 5/2011 013640F 013640F 013640F 013640F 8-C Fuse 5 AMP 013733F 013733F 013733F 013733F 6-C Temperature Sensor 009577F 009577F 009577F 009577F 7-C Blower Pressure Switch 008062F 008135F 010354F 010355F 9-C Thermostat Manual Reset 160 Deg Surface Mount (ASME Only) 016213F 016213F 016213F 016213F

G GAS VALVE

1-G Combination Valve - Gas On/Off -Nat 010329F 010329F 010329F 010329F

HP HEAT EXCHANGER - POLYMER

1-HP Heat Exchanger Assy Copper

Units manufactured from 10/2019 017994F 017995F 017996F 017997F

Units manufactured prior to 10/2019 010043F 010044F 010045F 010046F

Heat Exchanger Assy Cupronickel ***

Units manufactured from 10/2019 017998F 017999F 018000F 018001F

Units manufactured from 7/2013 thru 9/2019 014926F 014927F 014928F 014929F

Units manufactured prior to 7/2013 010356F 010357F 010358F 010359F 2-HP

Inlet/Outlet Header Complete

Units manufactured from 10/2019 017959F 017959F 017959F 017959F

Units manufactured from 7/2013 thru 9/2019 006827F 006827F 006827F 006827F

Inlet/Outlet Header (Includes 6-HP)

Units manufactured from 10/2019 017965F 017965F 017965F 017965F

Units manufactured from 7/2013 thru 9/2019 014648F 014648F 014648F 014648F 3-HP Return Header (Includes 6-HP) 015095F 015095F 015095F 015095F 4-HP Tube Bundle Copper ** 010059F 010060F 010061F 010062F

Tube Bundle Cupronickel **

Units manufactured from 7/2013 014930F 014931F 014932F 014933F

Units manufactured prior to 7/2013 010364F 010365F 010366F 010367F 5-HP Baffle (Copper Heat Exchanger) 010038F 005261F 010040F 010041F

Baffle (Cupronickel Heat Exchanger)

Units manufactured from 6/2013 014934F 014935F 014936F 014937F

Units manufactured prior to 6/2013 010038F 005261F 010040F 010041F 6-HP Flange Nut Kit 008259F 008259F 008259F 008259F 7-HP O Ring Gasket (2) 006713F 006713F 006713F 006713F 8-HP Sensor Adapter Digital Electronic 006714F 006714F 006714F 006714F 9-HP Bypass Kit 006715F 006715F 006715F 006715F 10-HP Bypass Valve 006716F 006716F 006716F 006716F 11-HP Bypass Dam / Shaft 006717F 006717F 006717F 006717F 12-HP Bypass Spring (All Sizes Included) 006718F 006718F 006718F 006718F 13-HP Unitherm Governor 006719F 006719F 006719F 006719F 14-HP Unitherm Governor Plug 006720F 006720F 006720F 006720F 15-HP Drain Plug 006721F 006721F 006721F 006721F 16-HP Inlet/Outlet Header Dam

N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP

17-HP 2" CPVC Connector & Nut (2) 006723F 006723F 006723F 006723F 18-HP O Ring (2) 006724F 006724F 006724F 006724F 19-HP Inlet/Outlet Header Baffle w/Header Dam 006826F 006826F 006826F 006826F

20-HP

ProTek Shield

Assy

017960F 017960F 017960F 017960F

*FOR INSTALLATIONS AT OVER 5,000 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 and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.

***Replacement burner trays are built for sea level, natural gas applications unless otherwise specified at the time the order is placed.

CALL OUT DESCRIPTION 207A 267A 337A 407A

failure of this replacement part.

HM HEAT EXCHANGER - METAL

1-HM Heat Exchanger Assy.Copper ASME

2-HM Inlet/Outlet Header ASME Complete

15-HM Inlet & Outlet Flange (Complete) - prior to 12/2019 003766F 003766F 003766F 003766F 20-HM Inlet & Outlet Flange - prior to 12/2019 016166F 016166F 016166F 016166F 21-HM Flange Bolts - prior to 12/2019 016167F 016167F 016167F 016167F 16-HM Flange Gasket 1 1/2" Connections - prior to 12/2019 062236B 062236B 062236B 062236B

3-HM Return Header ASME

4-HM Tube Bundle Copper ASME **

5-HM Baffle 010038F 005261F 010040F 010041F 6-HM

7-HM Header Gasket (9) 800014B 800014B 800014B 800014B 8-HM Unitherm Governor 062234B 062234B 062234B 062234B 9-HM U.G. Retainer Spring 013792F 013792F 013792F 013792F 18-HM U.G. Plug 013738F 013738F 013738F 013738F 10-HM Bypass Valve 016194F 016194F 016194F 016194F 11-HM Bypass Spring

12-HM Drain Valve 013793F 013793F 013793F 013793F 13-HM Sensor Well 003765F 003765F 003765F 003765F 14-HM Well Retaining Clip 300203 300203 300203 300203 17-HM Rear Drain Plug & Cover 005264F 005264F 005264F 005264F 19-HM Adapter CPVC 2" 005393F 005393F 005393F 005393F 26-HM Adapter - ProTek Shield (Includes 27-HM) 018006F 018006F 018006F 018006F 27-HM Nut - ProTek Shield Adapter - 2-Pc 018007F 018007F 018007F 018007F 28-HM U.G./Bypass Assembly 017958F 017958F 017962F 017962F **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 inspect the bypass assembly. Failure to do so could cause premature

Units manufactured from 12/2019 (Brass) 017983F 017984F 017985F 017986F Units manufactured prior to 12/2019 (Cast Iron) 010051F 016193F 010053F 010054F Heat Exchanger Assy.Cupronickel ASME Units manufactured from 12/2019 (Brass) 017987F 017988F 017989F 017990F Units manufactured prior to 12/2019 (Cast Iron) 010360F 010361F 010362F 010363F

Units manufactured from 12/2019 (Brass) 017961F 017961F 017992F 017992F Units manufactured prior to 12/2019 (Cast Iron) 006730F 006730F 006730F 006730F Inlet/Outlet Header ASME Units manufactured from 12/2019 (Brass) 017966F 017966F 017966F 017966F Units manufactured prior to 12/2019 (Cast Iron) 012319F 012319F 012319F 012319F

Flange Gasket 2" Connections - prior to 12/2019 800080B 800080B 800080B 800080B

Units manufactured from 12/2019 (Brass) 017973F 017973F 017973F 017973F Units manufactured prior to 12/2019 (Cast Iron) 006731F 006731F 006731F 006731F

Units manufactured from 12/2019 017974F 017975F 017976F 017977F Units manufactured prior to 12/2019 010055F 006733F 010057F 010058F Tube Bundle Cupronickel ASME ** Units manufactured from 12/2019 017978F 017979F 017980F 017981F Units manufactured prior to 12/2019 010368F 010369F 010370F 010371F

Stud Bolt Kit Units manufactured from 12/2019 017982F 017982F 017982F 017982F

Units manufactured prior to 12/2019 007870F 007870F 007870F 007870F

Units with Plastic Bypass Valve Units with Brass Bypass Valve (Units manufactured to 3/5/17) 013794F 013794F 013794F 013794F

(Units manufactured from 3/5/17)

016196F 016196F 016196F 016196F

CALL OUT DESCRIPTION 207A 266L/267A 337A 399L/407A

J CONTROL BOX

1-J Transformer 120/240/24V 006736F 006736F 006736F 006736F 2-J Rocker Switch 009493F 009493F 009493F 009493F 3-J Relay Low Nox 008784F 008784F 008784F 008784F

M MISCELLANEOUS COMPONENTS

1-M Pressure Switch 1.75 PSI 006737F 006737F 006737F 006737F

2-M Roll-Out Switch 300ºF 006035F 006035F 006035F 006035F 3-M PRV

4-M Deliming Kit 052871F 052871F 052871F 052871F 5-M Wire/Harness 010347F 010347F 010347F 010347F 6-M Control Bezel (Includes Switch Decal)

7-M Switch/Decal-Membrane

8-M Control Bezel Cover 009487F 009487F 009487F 009487F 9-M Gasket Insulation (Swaybrace & Jacket Top) 010350F 010350F 010350F 010350F 10-M Blower / Air Pressure Switch Sample Tube 010348F 010348F 010348F 010348F 11-M Touch-up Paint

12-M Tie Down Bracket (Optional) 011636 011636 011636 011636 13-M Roll-Out Switch 250ºF (Optional) 011745F 011745F 011745F 011745F

14-M Texas Code Option (ASME Only) - Units manufactured prior to 12/2019

16-M Flow Switch 007142F 007142F 007142F 007142F

17-M Flow Switch Paddle 010026F 010026F 010026F 010026F 18-M T & P Gauge 014647F 014647F 014647F 014647F 19-M 2" CPVC Connector (Outlet Plumbing)

20-M 2" CPVC Connector & Nut (2) 006723F 006723F 006723F 006723F

21-M O Ring (2) 006724F 006724F 006724F 006724F 15-M PC Board Shield (Optional) 015557F 015557F 015557F 015557F 25-M Gas Line Finish Flange 016160F 016160F 016160F 016160F

1-P Pilot Nat. IID Low Nox 010232F 010232F 010232F 010232F

2-P Pilot Electrode N/A N/A N/A N/A 3-P Pilot Mounting Bracket 010233F 010234F 010235F 010236F 4-P Pilot Tube 011926F 011926F 011926F 011926F 5-P Hi Tension Wire IID 010349F 010349F 010349F 010349F 6-P Adapter Nut (Metric) 011927F 011927F 011927F 011927F

Pressure Switch 11 PSI Special-See Water Pressure Switch Adj

PRV - 75 PSI ASME (Brass) Units manufactured from 12/2019 017957F 017957F 017957F 017957F PRV - 125 PSI (Optional) 008091F 007224F 007224F 007224F

Units manufactured from 5/2011 013491F 013491F 013491F 013491F Units manufactured prior to 5/2011 009491F 009491F 009491F 009491F

Units manufactured from 5/2011 013492F 013492F 013492F 013492F Units manufactured prior to 5/2011 009492F 009492F 009492F 009492F

Green 750125 750125 750125 750125 Dark Gray 750126 750126 750126 750126 Cool Dark Gray 750256 750256 750256 750256 Warm Dark Gray 750258 750258 750258 750258

Roll-Out Switch 250ºF (Upgrade) 011733F 011733F 011733F 011733F

Flanged Connection (Not Shown) 015889F 015889F 015889F 015889F NPT Connection (Shown) 015890F 015890F 015890F 015890F

NPT Connection 013795F 013795F 013795F 013795F Flanged Connection 015883F 015883F 015883F 015883F

P PILOT

009133F 009133F 009133F 009133F

CALL OUT DESCRIPTION 207A 266L/267A 337A 399L/407A

R REFRACTORY

1-R Refractory Common (Left & Right) 010079F 010079F 010079F 010079F 2-R Refractory Uncommon (Front and Rear) 010080F 010081F 010082F 010083F 3-R Refractory Retainer Kit 010262F 010263F 010264F 010265F

S SHEETMETAL

1-S Jacket Top (Louvered) 010047F 010048F 010049F 010050F 2-S Flue Collector (Units with Polymer Header) 010063F 010064F 010065F 010066F

Flue Collector (Units with Metal Header) 010067F 010068F 010069F 010070F

3-S Door Assy.

Raypak Cool Dark & Warm Dark Gray 013871F 013872F 013873F 013874F Green 010267F 010268F 010269F 010270F Rheem Cool Dark & Warm Dark Gray 013875F 013876F 013877F 013878F Green 010271F 010272F 010273F 010274F Ruud Cool Dark & Warm Dark Gray (Units mfd after to 9/2012) 013871F 013872F 013873F 013874F Warm Dark Gray (Units manufactured prior to 9/2012) 013879F 013880F 013881F 013882F Green 010271F 010272F 010273F 010274F Jacuzzi N/A 016700F N/A 016701F

14-S Screw & Retainer 006744F 006744F 006744F 006744F

4-S Access Panel Set (3 Pcs. Units with Polymer Header) 010311F 010311F 010311F 010311F

Access Panel Set -ASME Access Panel Set (3 Pcs. for BR Header) 017967F 017967F 017967F 017967F

Access Panel Set (3 Pcs. for CI Header) - prior to 12/2019 010312F 010312F 010312F 010312F 5-S Jacket Side Panel Right 010313F 010313F 010313F 010313F 6-S Jacket Side Panel Left 010314F 010314F 010314F 010314F 7-S Jacket Rear Panel (2 Pcs.) 010315F 010316F 010317F 010318F 8-S Poolstat Cover/Lock 009505 009505 009505 009505 9-S High Limit Cover 010319F 010319F 010319F 010319F 10-S Base Heat Shield - prior to 10/2019 010320F 010320F 010320F 010320F 11-S Up Front Control Panel

Green 010321F 010322F 010323F 010324F

Cool Dark Gray 013887F 013888F 013889F 013890F

Warm Dark Gray 013891F 013892F 013893F 013894F 12-S High Limit Shield 010342F 010342F 010342F 010342F 13-S Weather Shield 010325F 010326F 010327F 010328F

V VENTING

1-V Indoor Stack Kit (Includes inner adapter panel) 009838 009839 009840 009841

Outdoor Stack Kit (Includes inner adapter panel) 009834 009835 009836 009837 2-V Stack Adapter 010330F 010331F 010332F 010333F 4-V Outer Stack Adapter 011461F 011462F 011463F 011464F 3-V "Pagoda" Top

Cool Dark Gray 013883F 013884F 013885F 013886F

Green 010334 010335 010336 010337

Raypak Low NOx Series, Low NOx 267A, Low NOx 337A, Low NOx 207A, Low NOx 266L Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. WARNINGS

Pay Attention to These Terms

2. WATER CHEMISTRY

Automatic Chlorinators and Chemical Feeders

3. BEFORE INSTALLATION

Receiving equipment

Elevation

Ambient Temperature Rating

4. INSTALLATION

Installation Codes

Clearances

Outdoor Heater Installation

Combustion and Ventilation Air

Vent Piping

D-2 Power Vent Kit

Gas Supply Connections

Flow Rates

PROTEK SHIELD ASSEMBLY

Internal Automatic Bypass Valve

Unitherm Governor Operation

External Auxiliary Bypass Valve

Auxiliary Bypass Valve Adjustment

Pressure Relief Valve Installation

Plumbing Diagram

Heat Exchanger Reversal

5. ELECTRICAL WIRING

Electrical Power Draw

Transformer Wiring

6. WIRING DIAGRAM

7. CONTROLS

Control Adjustments

Control Panel Removal

Operation

Status and Diagnostics

Remote Control Wiring

Before Start-Up

Start-Up Procedures

9. MAINTENANCE AND CARE

Cold Weather Operation

10. TROUBLESHOOTING

Digital - Flow Chart

Control Logic - Flow Chart

11. REPLACEMENT PARTS

12. ILLUSTRATED PARTS LIST