Raypak P-R185B, RP2100, C-R185B, P-R185BL, C-R185BL User Manual

...

INSTALLATION AND OPERATING INSTRUCTIONS

RP2100

SWIMMING POOL and SPA HEATER

Atmospheric Models

P-R185B to P-R405B C-R185B to C-R405B

CATALOG NO. 6000.52-AK Effective: 05-01-04 Replaces: 03-15-04

Low NOx Models

P-R185BL to P-R405BL C-R185BL to C-R405BL

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of

this or any other appliance.

— 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.

Fig.# 9478

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

Part No. 240612

CONTENTS

4 PART ONE

OWNER'S OPERATING INSTRUCTIONS

4 SECTION 1

START-UP PROCEDURES

4 Before Start-Up 5 Lighting Instructions & Shut-Off Procedures-

Manually Lighted Pilots MV

6 Operating Instruction & Shut-Off Procedures-

Automatically Lighted Pilots IID

7 After Start-Up

7 SECTION 2

CAUTION

7 SECTION 3

MAINTENANCE & CARE PROCEDURES

8 Pool & Spa Water Chemistry 8 Cold Weather Operation 9 Winterizing the Pool & Spa Heater

10 PART TWO

INSTALLATION & SERVICE INSTRUCTIONS

10 SECTION 1

RECEIVING EQUIPMENT

10 SECTION 2

GENERAL SPECIFICATIONS

29 SECTION 4

SERVICING INSTRUCTIONS

29 General Location of Controls 29 Millivolt Controls 30 Digital Thermostat Controls 31 Digital Diagnostics and Codes 32 Remote Control and Operation Installation 34 Pressure Switch 34 Flame Roll-Out Safety Switch 34 High Limit 34 Pilot Safety 35 Burner Drawer Removal 35 Gas Valve Removal 35 Main Burner and Orifice Removal 35 Pilot Removal and Cleaning 35 Heat Exchanger Removal 36 Tube Cleaning Procedure 36 Desooting Procedure 36 Combustion Chamber Removal 36 Immersion Well Replacement 36 Unitherm Governor (U.G.) Replacement 37 Low NOx Pool Heaters

39 SECTION 5

TROUBLE SHOOTING GUIDE

39 Mechanical 40 Electrical MV Units 41 Electrical IID Units 42 Digital Control Logic

11 SECTION 3

INSTALLATION INSTRUCTIONS

11 Code Requirements 11 Clearances 12 Outdoor Heater Installation 12 Indoor Heater Installation 16 Specifications and Dimensions 16 Combustion Air 17 Vent Piping 17 Gas Supply Connections 19 Plumbing For Water Connections 23 Heat Exchanger Reversal Procedure 24 Electrical Wiring 25 Transformer Wiring 26 Wiring Diagram-Millivolt (Mechanical Therm.) 27 Wiring Diagram-IID (Atmospheric) 28 Wiring Diagram-IID (Low NOx)

43 SECTION 6

REPLACEMENT PARTS

44 Illustrated Parts List 46 Part Numbers

PART ONE OWNER'S OPERATING INSTRUCTIONS

FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

SECTION 1 - START-UP PROCEDURES

Your Raypak Pool/Spa heater has been designed for years of safe and reliable pool/spa water heating. It is available in millivolt or electronic control options. ASME certified units, typical used in commercial applications, are also available. This manual provides operation, installation, maintenance, and service information for these heaters.

OFF

Fig.# 9472

If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater contains the control center that allows you to turn the heater on or off 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). The heater is also equipped with a toggle switch to turn the heater on and off, see fig. # 9472 above for location. Section 4 of this manual contains more details about the use of the controls in the Controls Adjustments subsection (page 29).

BEFORE START-UP

BURNERS

Clean main burners, combustion fan and air louvers of dust, lint and debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not obstruct the flow of combustion and ventilating air.

WATER

Water must be flowing through the heater during operation. Insure that system is filled with water and have pump operating.

RP2100 DIGITAL IID POLYMER

Fig.# 9478

CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters.

LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES

MANUALLY LIGHTED PILOTS

MILLIVOLT SYSTEM

A. This appliance has a pilot that must be lit by

hand. When lighting the pilot, follow these

*If you cannot reach your gas supplier, call the fire department.

instructions exactly.

C. Use only your hand to push in or turn the gas

B. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

WHAT TO DO IF YOU SMELL GAS:

*Do not try to light any appliance. *Do not touch any electric switch; do not use any phone in your building. *Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

instructions.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat on the lowest setting.

3. Turn On/Off switch to the "Off" position.

4. Remove heater door panel.

5. Push in gas control knob slightly and turn clockwise to "Off".

NOTE: Knob cannot be turned from "Pilot" to Off"

unless knob is pushed in slightly. Do not force.

6. Wait 5 minutes to clear out any gas. If you then

smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to the next step.

7. Locate pilot mounted on the right side panel of the burner drawer. For burner drawer location, see location of control section, page 20.

GAS CONTROL KNOB SHOWN IN OFF POSITION

HONEYWELL PILOT

Fig. # 8083.0 Fig. # 8084.1

ROBERTSHAW PILOT

8. Turn knob on gas control counter-clockwise to "Pilot"

9. Place flame to end of pilot tube. Push in

control knob all the way and hold to light pilot. Continue to hold control knob in for about one minute after the pilot is lighted, release knob and it will pop back up. Pilot should remain

HONEYWELL GAS VALVE MILLIVOLT

lighted. If it goes out, repeat steps 5 through 9. *If knob does not pop up when released, stop and immediately call your service technician or gas supplier.

10. Stand to the side of the heater and turn the gas

control knob counter clockwise to "On".

11. Replace heater door panel.

12. Turn On/Off switch to the "On" position.

Fig. # 8081.0

ROBERTSHAW

GAS VALVE MILLIVOLT

Fig. # 8079.0

13. Set thermostat to the desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn On/Off switch to the "Off" position.

3. Remove heater door panel.

4. Push the gas control knob slightly and turn clockwise to "Off". Do not force.

5. Replace heater door panel.

CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters.

OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES

AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITIONS SYSTEMS

A. This appliance is equipped with an ignition

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

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

*Do not try to light any appliance. *Do not touch any electric switch; do not use any phone in your building *Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric 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. For Honeywell Valve: Turn gas control knob clockwise to "Off". For Robertshaw valve: Turn gas control knob clockwise to "Off".(Models 265-405) Push in and move gas control lever counter-clockwise to "Off" position. (Model 185)

7. Wait 5 minutes to clear out any gas. If you then smell gas STOP! Follow "B" in the safety information previously stated. If you don't smell gas, go to the next step.

8. Turn gas control knob counter-clockwise

to "On". (Honeywell VR 8300 and

Robertshaw 7000)

9. Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

2. Turn off all the electric power to the appliance if service is to be performed.

3. Remove heater door panel.

4. For Honeywell VR 8300 and Robertshaw

7000 gas valve.

Turn gas control knob clockwise

*If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it; call a qualified service technician. Force or attempted repair may result in fire or explosion.

D. Do not use this appliance if any part has been

underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater.

GAS CONTROL KNOB SHOWN IN "ON" POSITION

GAS INLET

ROBERTSHAW 7000 GAS VALVE IID MODEL 265-405

GAS CONTROL LEVER SHOWN IN "OFF" POSITION

GAS INLET

HONEYWELL VR 8300 GAS VALVE IID

ROBERTSHAW 7200 GAS VALVE IID MODEL 185

to "Off". Make sure knob rest against stop.

For Robertshaw 7200 gas valve.

Push in and move gas control lever counterclockwise to "Off" position.

5. Replace heater door panel.

Fig. # 8080.0

Fig. # 8934.1

AFTER START-UP

SECTION 2 - CAUTION

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 off, turn off the manual gas control to the appliance.

VISUAL INSPECTION

With the heater on, remove the door and make a visual check of the pilot and burner. The flame should be blue with a well-defined pattern.

4" MAX

Fig. # 8205.2

MAIN BURNER FLAME

Elevated water temperature can be hazardous, and the U. S. Consumer Product Safety Commission recommends the following guidelines:

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

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

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

4. Before entering the spa or hot tub, users should check the water temperature with an accurate thermometer; spa or hot tub thermostats may err in regulating water temperatures by as much as 4°F (2.2°C).

Fig. # 8964.1

PILOT BURNER FLAME

A yellow or "floating" flame indicates restricted air openings or incorrect orifice size. Should this occur, shut the heater off and contact your installer or gas supplier.

WATER PRESSURE SWITCH

A water pressure switch is provided in the heater to shut off the burners in the event that water supply to the heater is interrupted. It is very important to verify that the switch electrically opens and shuts off the gas valve when water flow 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 qualified service person at the time of installation and periodically checked thereafter. Refer to Pressure Switch Adjustment on pg. 34 of this manual).

WARNING: Operation of the heater without water circulation will cause rapid and severe damage to the heater.

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 anticoagulant, should not use spas or hot tubs.

SECTION 3 - MAINTENANCE AND CARE PROCEDURES

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 passage ways. 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. Clean main burners and pilot burner of dust and lint.

3. Inspect and operate all controls, gas valve and pressure relief valve.

4. Make visual check of the burner and pilot flame. Flame pattern on the main burner and pilot is indicated in the previous illustration. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supplier or qualified service agency.

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 chlorine tablets or bromine sticks in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight).

5. On indoor heaters, clean room intake openings to assure 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.

BASIC TIPS IF HEATER WILL NOT FIRE:

If you have no electrical power; it may be your "circuit breaker" has tripped. Try re-setting it.

If you have electrical power but the heater will not fire

check the following:

1. The time clock must be moved to the "ON" position.

2. Your pump strainer basket may be full. If so remove debris.

3. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, look to see if the filter pressure will be higher than usual).

4. The pump may have lost it's prime. It may 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 it's normal flow rate.

POOL & SPA WATER CHEMISTRY

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 off.

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

COLD WEATHER OPERATION

IMPORTANT FREEZE INFORMATION

MODERATE CLIMATE: Heater operation can con-

tinue during short term cold spells. When temperatures are below freezing, flow (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 is not recommended. When starting the heater with pool temperatures below 50°F operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F can seriously damage the heater, and is not covered by the warranty.

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

Chemical imbalance can cause severe damage to your heater and associated equipment. Maintain your water pH between 7.4 and 7.8 and total alkalinity between 100 and 150 p.p.m. If the mineral content and dissolved solids in the water become too high, scale forms inside the heat exchanger tubes, reducing heater efficiency and also damaging the heater. If the pH drops below 7.2, the heater will be severely damaged. This will result in corrosion of the heat exchanger. Heat exchanger

damage resulting from chemical imbalance is not covered by the warranty.

WINTERIZING THE POOL & SPA HEATER

Heaters installed outdoors in freezing climate areas are subject to be shut down for the winter. Observe the following procedure for winterizing the heater:

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

2. Open drain plug located on the 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.

Return Header

Drain Plug

3. For ASME Heaters only:

Disconnect compression fittings from the pressure switch and return header that connects to the 1/4" copper tube and allow the tube to drain. For ASME Heaters only.

PART TWO INSTALLATION AND SERVICE INSTRUCTIONS

SECTION 1 - RECEIVING EQUIPMENT

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 equipment. Remove the heater from the carton and if it is damaged, report the damage to the carrier immediately. Save the carton.

These items are shipped loose inside the carton with the heater:

STANDARD UNIT (POLYMER HEADERS) ASME UNIT (CAST IRON HEADERS)

1. "Pagoda" Top 1. "Pagoda" Top

2. 2" CPVC Union with "O" rings (2) 2. In/Out Flanges (2)

3. Plastic pipe finish flange for gas line 3. 1-1/2" Flange Gaskets (2)

4. Bonding lug with mounting screw 4. 2" Flange Gaskets (2) (IID units only) 5. Flange Bolts (4)

6. Pressure Relief Valve

7. 2" CPVC Adapters (2)

8. Plastic pipe finish flange for gas line.

9. Bonding lug with mounting screw. (IID units only).

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

When ordering parts, you must specify model and serial number of heater. When ordering under warranty conditions, you must also specify date of installation. (Raypak recommends that this manual be reviewed thoroughly before installing your Raypak pool/spa heater. If there are any questions that this manual does not answer, please contact the factory or your local Raypak representative.)

SECTION 2 - GENERAL SPECIFICATIONS

These heaters are design certified and tested under the requirements of ANSI Z21.56 / CSA 4.7 American National Standard / CSA Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. The appropriate top designated for that type of use is required. If desired, the top can be changed at a later date to change from outdoor to indoor or vice versa. Millivolt heater contains a self-generating electrical system operating between .25 and .75 volts.

Ambient Temperature Rating of Heater Components

Millivolt Heater with Honeywell Gas Valve +32°F to +175°F

Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F

Electronic Ignition Heaters* -32°F to + 175°F

*Requires 120V or 240V Power Supply

Atmospheric heaters:

Rated inputs suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000 feet above sea level, as high elevation reduces combustion performance.

Low NOx heaters:

Rated inputs suitable for up to 5000 feet elevation. For elevations above 5000 feet, consult the factory.

SECTION 3 - INSTALLATION INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm.

IMPORTANT NOTICE

These instructions are intended for the use of qualified personnel only, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. If your state is such, be sure your contractor bears the appropriate license. Persons not qualified shall not attempt to fix this 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 fire, and will void the warranty.

CODE REQUIREMENTS NOTE: The heater should not be located in an area

where possible water leakage will result in damage to the area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

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 and National Electrical Code, ANSI/NFPA 70, and for Canada, the latest edition of CAN/CGA-B149.1 and B149.2, and Canadian Electrical Code, CSA C22.1 Part 1 and Part

BASE INSTALLATION

Heater must be mounted on a level base, such as cement slab, cement blocks or other non-combustible surface. An optional non-combustible base is available for all models.

An alternative method for providing a base for combustible floors is illustrated below. Heaters must

not be installed

on carpeting.

12"

inimum

Minimum

HEATER

Sheet Metal

24 Gauge

Minimu

Fig. # 8148.1

Utilize hollow concrete cinder blocks, align holes and leave ends open.

CLEARANCES

ALL HEATERS For clearances from combustible surfaces, see the chart below.

CLEARANCE FROM COMBUSTIBLE CONSTRUCTION

INDOOR INSTALLATIONS:

Top*- 30"(Drafthood) Back - 6" Front - Alcove Right Side - 12" (Water Side) Vent - 6" Left Side - 6"

(Opposite Water side)

OUTDOOR INSTALLATION:

Top* - Unobstructed (Stackless top or outdoor stack) Back - 6" Side - 6" *Clearance from top of vent terminal

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

However for ease of servicing, we recommend a clearance of at least 24" in the front, and at least 18" on the 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 (6" minimum), may require removal of the heater to service either the heat exchanger or the burner tray. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

OUTDOOR HEATER INSTALLATION

These heaters are design certified for outdoor installation, when equipped with the approved tops designated for outdoor use.

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 some electrical components, and this would void the warranty.

WARNING: Do not install within 3 feet of a heat pump or an outdoor condensing unit. Strong air intake from these equipment can disturb the combustion process and cause damage or personal injury.

HEATER WITH OUTDOOR STACKLESS TOP

VENT TERMINAL (Outdoor) Stackless Top Installation

1. Insert tabs into keyhole (4 places).

Pagoda Top (Shipped Loose with Heater)

2. Snap tabs into keyholes so as not to pull out.

Fig. # 8278.2

Fig. #RP8280.1

Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three (3) 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 flue products exit the heater must be a minimum of four (4) feet below, four (4) feet horizontally from, or one (1) foot above any door, window or gravity inlet into any building. The top surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally.

For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 feet below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CGA-B149.1 and

U.S. Installations only

Fig# 8245.1

B149.2.

INDOOR HEATER INSTALLATION

The design is also certified for indoor installation when equipped with the approved draft hood.

For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with occupied area. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific requirements.

Locate heater as close as practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent Piping section (pg. 17) for venting details. Minimum allowable space is shown on the nameplate.

WARNING: Indoor boilers require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.

OUTDOOR STACK / INDOOR STACK INSTALLATION

NOTE: The outdoor and indoor stack are optional equipment and do not come standard with the heater.

OUTDOOR KIT INCLUDES:

1- Draft hood, painted 1- Adapter plate 3- Mounting brackets (clips) 1- Top panel cover 2- 1 foot sections of metal tape 3- Screws 1- Instructions

OUTDOOR STACK INDOOR STACK Model Part No. Part No. 185 006751 006696 265 006752 006697 335 006753 006698 405 006754 006699

Clips

ASSEMBLY PROCEDURE

INDOOR KIT INCLUDES:

1- Draft hood, unpainted 1- Adapter plate 3- Mounting brackets (clips) 3- Screws 1- Instructions

Clips

1. Make sure that the gas and electricity to the unit has been turned off.

2. Remove the "pagoda" top from the louvered top and discard. See Fig. 3.

3. Remove the louvered top and set aside, saving the four phillips screws for reassembly. See Fig. 3.

4. Remove and discard the rain shield. See Fig. 4.

5 Install adapter plate on top of heater flue collector.

See Fig. 5.

6. Reinstall louvered top on heater and fasten with Phillips screws set aside in step 3.

SECURING THE TOP PANEL COVER INDOOR KIT ONLY

7. Reinstall the louvered top.

8. Mount the draft hood onto the adapter plate lip inside the heater. See Fig. 6.

9. Proceed to installing the clips, step 14.

SECURING THE TOP PANEL COVER OUTDOOR KIT ONLY

10. After removing the drafthood from the box, slide the top panel cover over the draft hood.

11. Holding both pieces together, mount the draft hood on the adapter plate lip inside the heater. See Fig. 6.

12. Take the two pieces of tape and attach to each side of the drafthood leaving 6" hanging down.

13. Slide the top panel cover up and attach the tape to the underneath side. This is to temporarily keep the top panel cover out of the way while you are attaching the clips as shown in the next steps. See Fig. 7.

INSTALLING THE CLIPS INDOOR & OUTDOOR KITS

14. Notice that there are three pilot holes above the base of the drafthood as shown in Fig.8. These are the locations where the three clips are to be attached.

15. Insert the long edge of one clip between the top panel cover and the drafthood, see Fig. 9.

16. With a twisting motion, rotate the clip up, see Fig. 10.

17. Pull up on clip, see Fig. 11.

18. Hold the clip up and align the clip hole to the pilot hole, see Fig. 12.

19. Insert screw into hole and secure using a 5/16" nut driver.

20. Repeat steps 15-19 using remaining two clips.

21. This completes the indoor drafthood installation. If installing an outdoor drafthood, proceed to step 22.

INSTALLING THE TOP COVER OUTDOOR KIT ONLY

22. Remove the two pieces of metal tape holding the top panel cover up and discard.

23. Insert the rear two tabs into the slots on the heater top and slide the top panel cover backwards. See Fig.13.

24. Lower the top panel cover and using your thumbs, push tabs in and insert the two front tabs into the slots on the top of the heater. See Fig.14.

25. Lower the top panel cover flush to the top and release the tabs. They will spring into place as shown in Fig.15.

26. Turn the gas and electricity to the heater on.

SPECIFICATIONS AND DIMENSIONS

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*Designation for Propane is "EP", Natural gas is "EN". Prefix "C" is for Cast Iron (ASME) Headers; "P" is for Plastic (Polymer) Headers. Atmospheric heaters: reduce input 4% for each 1000 ft. above sea level when installed above 2000 ft. elevation. Low NOx heaters: for elevations above 5,000 feet consult factory. For Canada, no de-rating is required for elevations up to 4500 feet. Manufactured under Patent No. 3,623,458. Note: Plastic (Polymer) headers cannot be used for ASME installations.

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COMBUSTION AND VENTILATION AIR (Indoor Units Only)

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings, one opening that is 12 inches from the ceiling for ventilation and one opening that is 12 inches from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code, ANSI Z2231(Canada-CAN/ CGA-B149.1 and B149.2) and any local codes that may have jurisdiction.

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty.

Fig # 9037.2

*Electrical Connection On Left Side is 19-1/8".

a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted:

Model Square Inches Model Square Inches 185 181 335 333 265 264 405 399

b. All Air From Outdoors: When air is supplied directly from outside of building, each opening shall have a minimum net free square inches as noted:

Model Square Inches 185 46 265 66 335 84 405 100

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