Raypak R106A Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Atmospheric
Above-Ground
Pool & Spa
Heater

(Chauffe-Piscine)

Models 106 & 156

English/French

WARNING: If the information in these

instructions are not followed exactly, a fire or
explosion may result causing property
damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use
gasoline or other flammable vapors and
liquids or other combustible materials in the
vicinity of this or any other appliance. To do
so may result in an explosion or fire.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

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

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

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

Installation and service must be performed by
a qualified installer, service agency or the gas

supplier

.

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

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

CE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAZ:

• Ne pas tenter d’allumer d’appareil.

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

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

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

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

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

CATALOG NO. 6100.62D Effective: 05-01-16 Replaces: 01-15-15 P/N 241519 Rev. 5

Rev. 5 reflects the following:
Changes to: “Unpacking” on page 7, “Gas Connections” on page 13, Fig. 7 on page 14.
Additions: None
Deletions: None

2

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

WATER CHEMISTRY 5

Automatic Chlorinators &
Chemical Feeders 5

SAFETY 6

Water Temperature Safety 6

INTRODUCTION 6

Ratings & Certifications 6
Model Identification 7
Specifications 7
Unpacking 7

INSTALLATION 8

Installation Codes 9
Installation Codes 10
Clearances 10
Base Installation 10
Outdoor Installation 10
Indoor Installation 12
Combustion & Ventilation Air 12
Gas Connections 13
Water Connections 15
Electrical Connections 17

OWNER’S OPERATING
INSTRUCTIONS 18

Control Adjustments—Analog 18
Control Adjustments—Digital 18

Thermostat Operation—Advanced Flame
Technology (AFT) Board 20
Status and Diagnostics 22
Remote Control Installation 23
Wiring Diagrams 25
Post Start-Up Inspection 26
Cold Weather Operation 26

MAINTENANCE 27
SERVICE 27

Water Pressure Switch 27
Flame Roll-Out Safety Switch 28
High Limits 28
Burner Tray Removal 29
Gas Valve Removal 29
Pilot Removal & Cleaning 30
Heat Exchanger Removal 31
Tube Cleaning Procedure 31
De-sooting Procedure 31
Replacement Parts 31

TROUBLESHOOTING 32

Mechanical 32
Electronic Control Logic Flowchart 33
Analog Control Logic Flowchart 34

ILLUSTRATED PARTS LIST 35

3

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

WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:

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

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

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.

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

WARNING: Both natural gas and propane have an
odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or
recognize this odorant. If you are unsure or
unfamiliar with the smell of natural gas or propane,
ask your local gas supplier. Other conditions, such
as "odorant fade," which causes the odorant to
diminish in intensity, can also hide, camouflage, or
otherwise make detecting a gas leak by smell more
difficult.

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 - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the

State of California to cause cancer, birth defects or
other reproductive harm.

WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the owner’s operating instructions provided
in this manual. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.

WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
Do not handle, use, or store gasoline or other
flammable or combustible materials in the vicinity of
a heater.

WARNING: 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.

4

WATER CHEMISTRY

OTE: Corrosive water voids all warranties.

N

Chemical imbalance can cause severe damage to

our heater and associated equipment. Maintain your

y
water chemistry according to Table A. If the mineral
content and dissolved solids in the water become too
high, scale forms inside the heat exchanger tubes,
reducing heater efficiency and damaging the heater. If
the pH drops below 7.2, this will cause corrosion of the
heat exchanger and severely damage the heater. Heat

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

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

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 chlo­inators are usually more efficient in heated water,

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

• Further advice should be obtained from your pool

r spa builder, accredited pool shop, or chemical

o
supplier for the correct levels for your water.

Automatic Chlorinators &
Chemical Feeders

All chemicals must be introduced and completely dilut­ed into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemi-

cals in the skimmer. High chemical concentrations
will result when the pump is not running (e.g.
overnight).

Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off. See
Fig. 1.

NOTE: 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

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)

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

3000 Maximum** 3000 Maximum** 3000 Maximum**

Table A: Water Chemistry

Other Pool and Spa

Types

5

Spa

Return to Spa

Fig. 1: Spa/Chlorinator Setup

SAFETY

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

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

Water Temperature Safety

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

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

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

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

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

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

INTRODUCTION

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

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

Ratings & Certifications

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

6

WARNING: Use of any parts not manufactured

P - R 106 A - E N - C

Plastic Header

R = Raypak
M = Rheem

D = Ruud

Model No.

Model Rev.

E = Electronic
A = Analog

N = Natural
P = Propane

C = Copper

nd/or approved by the manufacturer may cause

a
non-warrantable damage.

Ambient Temperature Rating of
Components

• Analog heater -40°F to +175°F (-40°C to 79.4°C)

• Electronic heater -32°F to +175°F (-35.5°C to

79.4°C)

Model Identification

The model identification number and heater serial
number are found on the heater rating plate.

Specifications

Shipping Weight

Model

No.

106

156

Input*

105,000

BTU/hr.

(30.75

KW)

150,000

BTU/hr.

(43.93

KW)

Gas
Conn.
(NPT)

1/2 in.

(1.27

cm)

Table B: Specifications

Water
Conn.
(NPT)

1-1/2 in.

or 2 in.
(3.8cm

or 5
cm)

Std.
Heater w/
Stackless

Top

85 lbs.

(38.6 kg)

100 lbs.

(45.4 kg)

Drafthood
Assembly

14 lbs.

(6.35 kg)

Unpacking

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

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

1. 2” CPVC union with “O” rings (2)

2. Plastic pipe finish flange for gas line

3. Bonding lug with mounting screw

4. IOI Manual

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

Fig. 2: Location of Heater Rating Plate

The model identification number will be similar to the
example shown below:

on the Bill of Lading.

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

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

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

7

INSTALLATION

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

o cause cancer, birth defects or other reproductive harm.

t

ARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as

W

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

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

IMPORTANT NOTICE
These instructions are intended only for the use by qualified personnel, 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 equip-

ment, create a hazard resulting in asphyxiation, explosion or fire, and will void the warranty.

8

9

Installation Codes

Installations must be in accordance with local, state,

rovincial, and national codes, laws, regulations and

p
ordinances. In the absence of local codes, installations
must be in accordance with the latest editions of the:

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

• National Electrical Code, ANSI/NFPA 70

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

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

owever for ease of servicing, we recommend a

H
clearance of at least 18" (45.7cm) on the rear. This

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

eater.

h

Minimum clearance from drafthood to combustible
construction 6 inches from the vent.

Degagement minimal de 6 po requis entre le coupe­tirage et une construction combustible. 2 po du conduit
de raccordement.

AVERTISSEMENT: Cet appareil doit être installé
conformément au National Fuel gas Code ANSI
Z223.1, et aux exigences de l’autorité competente.

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

Clearances

The required minimum clearances from combustible
surfaces are shown in Table C below.

Heater Side

Top* Unobstructed 30 in. (76.2 cm)

Front 24 in. (61 cm) Alcove

Vent N/A 6 in. (15.2 cm)

Back 12 in. (30.5 cm) 12 in. (30.5 cm)

Right Side 6 in. (15.2 cm) 6 in. (15.2 cm)

Outdoor

Installations

Indoor

Installations

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

FLOORING: This heater can be installed on com­bustible flooring.

Base Installation

Heater must be mounted on a level base, such as
cementable slab or cement blocks. Heaters may not
be installed on carpeting.

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

Ce chauffe-piscine doit êntre installè à au moins 5
peds (1.52m) de la paroi interne de la piscine à moins
d’êntre isolé de la piscine par un clôture, un mur ou
autre barrière permanente.

Outdoor Installation

Left Side 6 in. (15.2 cm) 6 in. (15.2 cm)

*Clearance from top of vent terminal.

Table C: Required Minimum Clearances from

Combustible Surfaces.

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

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

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

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

10

Fig. 3: Overall Dimensions

OUTDOOR
STACK

Amp Draw

20 Volt240 Volt

1

4 2

NOTE: This heater is design-certified for outdoor
installation when equipped with the approved top(s)
for outdoor use.

Heater with Outdoor Stackless Top

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

Ne pas installer ce chauffe-piscine sous une saillie
mesurant moins de 3 pi de hauteur. La partie sous Ia
saillie doit etre ouverte sur 3 côtes.

• For U.S. installations, the point from where the flue
products exit the heater must be a minimum of 4 ft
(1.2m) below, 4 ft (1.2m) horizontally from, or 1 ft
(0.3m) above any door, window or gravity inlet into
any building. The top surface of the heater shall be at
least 3 ft (0.9m) above any forced air inlet, or intake
ducts located within 10 ft (3m) horizontally. See
Fig. 5.

Outdoor Stack

NOTE: The outdoor stack is optional equipment and

does not come standard with the heater. Use part
number 014718 for the 106 and 014719 for the 156.

High Wind Conditions
(Outdoor Units Only)

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

In areas of daily high winds, it may be necessary to
replace the outdoor stackless top with a stack adapter
in combination with a wind-resistant/weather-proof
outdoor stack. See Fig. 4.

• For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10 ft
(3m) below, or to either side, of any opening into the
building. Refer to the latest revisions of CAN/CSA­B149. The heater must be raised 7 in (0.2m) above
the surface which could support snow, ice or debris.
Refer to the latest revisions of CAN1-2.21-M85.

Fig. 4: Outdoor Stack

11

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

AUTION: Combustion air must not be

C

contaminated by corrosive chemical fumes which

an damage the heater and void the warranty. Do

c
not store chlorine, bromine, baquasil or acid in the
same room as the heater.

Indoor Installation

The heater is design-certified for indoor installation
when equipped with the approved drafthood.

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

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

Locate heater as close as is practical to a chimney or
gas vent. Heater must always be vented to the out­side. See Vent Piping section for details. Minimum
allowable space is shown on the rating plate. Follow
the installation instructions provided with the Indoor
Drafthood Kit for installation.

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

Model Area

106 105 in² (677 cm²)

156 150 in² (968 cm²)

Table E: Minimum Air Area

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

Vent Piping

Vent piping the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least 10 ft (3m) (drafthood relief opening to vent ter­minal), the vent pipe size may be reduced as specified
in the National Fuel Gas Code, ANSI Z223.1 (Canada

- CAN/CSA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows.

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

Ce coupe-tirage doit être installé sans modification.
Voir Ia plaque signalétique.

Combustion & Ventilation Air

(Indoor Units Only)

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

Model

106 27 in² (174 cm²) 41 in² (265 cm²) 54 in² (348 cm²)

156 38 in² (245 cm²) 57 in² (368 cm²) 76 in² (490 cm²)

Unrestricted

opening

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

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

Typical screened

or louvered opening

Typical screened

and louvered opening

Table D: Minimum Air Net Area

12

4 ft (1.2m)

4 ft (1.2m)

1 ft (0.3m)

1

0 ft (3m)

4 ft (1.2m)

3 ft (0.9m)

Fig. 5: Outdoor Installation Clearances

2’ (0.6m)

MIN

10’ (3m)

OR LESS

2’ (0.6m)

MIN

5’ (1.5m)

MIN

The discharge opening must be a minimum of 2 ft
(0.6m) vertically from the roof surface and at least 2 ft
(0.6m) higher than any part of the building within 10 ft.
(3m) vent stack shall be at least 5 ft (1.5m) in vertical
height above the drafthood outlet. The vent cap loca­tion shall have a minimum clearance of 4 ft (1.2m)
horizontally from, and in no case below, unless a 4 ft
(1.2m) horizontal distance is maintained, from electric
meters, gas meters, regulators and relief equipment.

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

Type "B" double-wall or equivalent vent pipe is recom­mended. However single-wall metal vent pipe may be
used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1 (Canada - CAN/CSA­B149).

Gas Connections

Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve locat­ed outside the heater jacket. Use the pipe finish flange
to seal between the gas line and the heater jacket (see
Fig. 7). All gas piping should be tested after installa­tion in accordance with local codes.

CAUTION: Do not use 5, 10 or 20 gallon (19.38 or
76 Liter) propane tanks, like those used with con­sumer barbecues, to supply gas to this heater.

Fig. 6: Vent Piping Requirements

CAUTION: The heater and its manual shut-off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa). The heater
and its gas connections shall be leak tested before
placing the appliance in operation. Use soapy water
for leak test. do not use open flame.

13

Fig. 7: Gas Line Sediment Trap

Gas Pressure Adjustment Locations

Fig. 8: Honeywell Gas Valve

Electronic Ignition Gas Valves

NOTE: Do not use Teflon tape on gas line pipe

thread. A flexible pipe sealant suitable for LP gases
is recommended.

Gas Pressure Regulator

The gas pressure regulator is preset at 4.0 in W.C.
(1.0kPa) for natural gas and 10.0 in W.C. (2.5kPa) for
propane gas.

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

Gas Pressure* Natural Gas Propane Gas

Max. Inlet

(static)

Min. Inlet

(dynamic)

Manifold Gas

(dynamic)

10.5 in. WC
(2.6 kPa)

5 in. WC

(1.2 kPa)

4 in. WC

(1.0 kPa)

13 in. WC

(3.2 kPa)

11 in. WC

(2.7 kPa)

10 in. WC

(2.5 kPa)

Fig. 9: Location of Gas Pressure Adjustment

*Static means without heater operating, dynamic refers to heater
operating.

Table F: Gas Pressure

14

Pipe Sizing for Gas Connections

In/Out Header

O-Ring

Tail Piece

Nut

2” Pipe
(5cm)

Drain Plug

In/Out Header

Hose Connector

Hose

NAT LPG NAT LPG NAT LPG

105,000 BTU/hr 26 ft 65 ft 99 ft 252 ft 350 ft 892 ft

(30.8 kW) (8 m) (20 m) (30 m) (77 m) (107 m) (272 m)

1

50,000 BTU/hr

1

3 ft

3

4 ft

5

1 ft

1

30 ft

1

80 ft

4

59 ft

(43.9 kW) (4 m) (10 m) (16 m) (40 m) (55 m) (140 m)

* Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in WC Pressure Drop

(Gaz Naturel 3154.5 W/m3 0.60 Densité @ 0.124 kPa Pressure Drop)

* Propane Gas 2500 BTU/FT3 1.53 Specific Gravity @ 0.5 in WC Pressure Drop

(Le Gaz Propane 7886.3 W/m3 1.53 Densité @ 0.124 kPa Pressure Drop)

1/2 in. (1.27cm)

3/4 in. (1.91cm)

1 in. (2.54cm)

Model

Tubing

Input

CuCu106

156

Table G: Maximum Equivalent Pipe Length

Water Connections

The heater requires water flow and positive pressure
to fire and operate properly. It must therefore be
installed downstream of the discharge side of the filter
pump. A typical installation is plumbed as follows:

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

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

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

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

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

Polymer Headers

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

Fig. 10: In/Out Header for 2" Installation

Flow Rates

Model No. Minimum Maximum

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

*When flow rates exceed maximum 70 GPM, an external auxiliary
bypass valve is required. See External Auxiliary Bypass Valve sec­tion for details.

Table H: Water Flow Rates

Fig. 11: Optional In/Out Header for 1-1/2" (3.8 cm)

15

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

If there is any possibility of back-siphoning when the

B

ypass Disc

Spring

Bypass Body

From Heater

T

o

H

e

a

t

e

r

To Pool/Spa

Bypass Valve

From

Pool/Spa

Full Port

Ball Valve

or Globe

Valv e

PIPE ONTO DISCHARGE SIDE OF PIPING

pump stops, it is recommended that a check valve (or
valves) also be installed in the system.

Internal Automatic Bypass Valve

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

NOTE: Do not use a gate valve as an auxiliary

ypass valve.

b

Auxiliary Bypass Valve Adjustment

To set bypass: With clean filter, adjustment is made by

eeling the inlet and outlet pipes at the heater. Outlet

f
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" (1.9 cm)
pressure relief valve, having a capacity equal to or
greater than the BTUH input of the heater to be
installed, is recommended for this heater. The maxi­mum pressure relief valve setting is 125 psi (862 kPa).
This relief valve needs to be installed on the outlet pipe
from the header as noted in Fig. 14 below.

External Auxiliary Bypass Valve

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

Fig. 12: Internal Automatic Bypass Valve

Fig. 13: Auxiliary Bypass Valve

Fig. 14: Pressure Relief Valve Installed

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

WARNING: To avoid water damage or scalding due
to relief valve operation, drain pipe must be
connected to valve outlet and run to a safe place of
discharge. Drain pipe must be the same size as the
valve discharge connection throughout its entire
length and must pitch downward from the valve. No
shut-off valve shall be installed between the relief
valve and the drain line.

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

16

240V HOOK-UP

HEATER

L1

L2

RED RED

BLACK

HOT

HOT

BLACK

GREENGREEN

WHITE

SUPPLY

SIDE

Heat Exchanger Pressure Drop
Table

Flow (GPM) Pressure Drop (ft of Head)

20 7.6

0

3

.2

8

40 8.7

50 9.3

60 9.8

70 10.4

Table I: Pressure Drop

Electrical Connections

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

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

Si un des fils original fourni avec l'appareil doit être
remplacé, utilisez un fil 302°F (150°C), ou l'équivalent.

The heater comes standard with a 120 VAC 3-prong
power cord. For 240 VAC applications, see figure 16.
Power source must be a wired ground, with ground
fault circuit interruption circuitry.

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.)

OTE: Input power to the heater (120 VAC) can be

N

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

WARNING: Risk of electrical shock. More than
one disconnect switch may be required to de­energize the equipment before servicing.

CAUTION: Label all wires prior to disconnection
when servicing controls. wiring errors can cause
improper and dangerous operation.

Installation Instructions—240 Volt

CAUTION: This heater has provisions to be

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

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

2. Remove knurled screw from the lower front panel.

3. Remove the front panel and set aside.

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

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

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

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

8. Install a wire nut on the white transformer wire.
(See Fig 16)

9. Wire nut the 240V supply lines to the red and
black wires on the transformer. (See Fig 16)

ATTENTION. Au moment de l'entretien des
commandes, étiquetez tous les fils avant de les
débrancher. Des erreurs de câblage peuvent
entraîner un fonctionnement inadéquat et
dangereux.

Fig. 15: Electronic Heater Power

Fig. 16: 240V Hook-Up

17

10. Wire nut the supply ground line to the green trans-

HOT

COOL

Knobstop Ring

Knobstop Set Screw

former wire. (See Fig 16)

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

12. Re-install front panel and knurled screw.

OWNER’S OPERATING
INSTRUCTIONS

Control Adjustments—Analog

The pool or spa water temperature is controlled by the
thermostat on the upper front panel of the heater. The
control center contains an On/Off toggle switch and a
thermostat. The switch functions as a means for turn­ing the heater On or Off.
The thermostat is fitted with a means of limiting the
upper temperature limit below the maximum level. The
knob stop adjustment ring shown in Fig. 17 is
adjustable by loosening the set screw, rotating the
knobstop ring to the desired location, and retightening
the set screw.

Fig. 18: Digital Control Adjustment

MENU/SET Button

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

Fig. 17: Water Temperature Thermostat

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

Control Adjustments—Digital

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

Temp Buttons

If the heater is in POOL or SPA mode, the desired
water temperature (SETPOINT) will also 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 firing, “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.

ALTERNATING DISPLAYS DURING HEATING

18

19

Thermostat Operation—
Advanced Flame Technology (AFT) Board

Program
button

Service Menu and Fault History

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

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.

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/off cycles of the heater, as measured by the
number of times the pilot valve has been powered.

RUN TIME INDICATOR

Press the DOWN button. The Fault History can dis­play 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 buffer, the second line reads “All Faults Clear.”

SUPPLY VOLTAGE INDICATOR

FAULT HISTORY

20

Program Button

1) Remove the two screws holding the control cover,
and swing the panel down so the back side of the

oard is visible (see page 19). Locate the Program

b
Mode button (marked as SW1) as shown on page

19. Press and hold the button (5-7 seconds) until
Set Factory Defaults appears on the display.
Release the program button.

Fahrenheit or Celsius

Refer to step one above to access the program
screen. Press the MENU/SET button until Fahrenheit

r Celsius appears on the digital display. The digital

o
display is capable of displaying Celsius as well as
Fahrenheit temperatures. The UP or DOWN buttons
will select Fahrenheit or Celsius on the temperature
display. Choose the desired temperature scale.

2) Press the MENU/SET button sequentially until the

desired program event is reached. There are 5 dif­ferent events that can be programmed. They
appear in the sequence listed 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.

Set Factory Defaults

Refer to step one above to access the program
screen. Set Factory Defaults should appear on the
screen. If it does not, press the MENU/SET button until
Set Factory Defaults 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 (18.5°C) and both POOL and SPA maximum
temperature settings will be 104°F (40.0°C). The
Control Lockout PIN will be cleared and the control will
resume normal operation.

Clear Faults

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

Spa Max Temp – Spa Set Point Maximum
Adjustment

Refer to step one above to access the program
screen. Press the MENU/SET button until Spa Max
Temp appears on the digital display. Using the UP and
DOWN buttons will change the Maximum Temperature
Setting to your desired value. The control can be set
for a maximum of 107°F (41.7°C).

Pool Max Temp – Pool Set Point Maximum
Adjustment

Refer to step one above access into the program
screen. Press the MENU/SET button until Pool Max
Temp appears on the digital display. Using the UP and
DOWN buttons will change the Maximum Temperature
Setting to your desired value. The control can be set
for a maximum of 107°F (41.7°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 MENU/SET button for 5 seconds.
Choose a three digit PIN, using the UP and DOWN
buttons to select the digits and the MENU/SET button
to lock in selections. Confirm 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 directions on this
page for details.

NOTE: Both the POOL and SPA setpoints will revert
back to 65°F (18.5°C) and the POOL and SPA maxi­mum temperature settings will be 104°F (40.0°C).
These setpoints will need to be readjusted to desired
settings.

21

OTE: The LCD temperature display may not agree with the temperature reading of your pool or spa ther-

N

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

STATUS AND DIAGNOSTICS

The digital thermostat models are programmed to display a variety of status and diagnostic messages, depend­ing on the operating conditions.

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

Display Condition

Heating

Spark Spark operating

No Demand Heat demand is satisfied

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

Call for heat established, flame
present

Display Condition

Sensor
Failure

Sensor Open

Sensor Short

Flame w/o
CFH

PV Output
Fault

MV Output
Fault

Thermistor temperatures disagree
by more than 2°F (1.1°C)

Thermistor sensor failed open.
(Below -20°F (-29°C))

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

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

Pilot gas valve output is not in com­manded state.

Main gas valve output is not in com­manded state.

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

Display Condition

Water Sw
Open

Vent/Field
Sw #1

Hi Limit 1
Fault

Hi Limit 2
Fault

Rollout Sw
Open

Flow/Field
SW #2

Ignition
Lockout
(Propane Tab
Broken)

Ignition
Failure
(Propane Tab
Not Broken)

Water pressure switch open.

Vent spill switch/field switch #1
open.

High limit 1 open.

High limit 2 open.

Rollout switch open.

Field-supplied flow switch/field
switch #2 open.

Alternating with “No pilot
sensed” - Pilot flame not estab-

lished within the required time (15
sec or 90 sec).

Alternating with “Main Ign
Failure” - Pilot flame lost during the

8 second trial to ignite the main
burner.

Alternating with “No pilot
sensed” - Pilot flame not estab-

lished within 90 seconds.

Internal Fault Board fault, replace board.

EEPROM
Fault

Clock/
Fireman Sw

Low Temp
Lockout

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

Time clock/fireman switch circuit is
open.

Water temperature below 36°F
(2°C).

Ign 6min
Delay
(Propane Tab
Not Broken)

22

Alternating with “Main Ign
Failure” - Pilot flame lost 4 times

within the 8 second trial to ignite the
main burner. Heater will lockout for
6 minutes before retrying.

REMOTE CONTROL INSTALLATION AND OPERATION

CAUTION: Before installing remote controls to the AFT thermostat model heaters, read the following:

The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the

ctual pool temperature, operating status, and service codes (See examples below). The touch pad on the con-

a
trol 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.

OFF Mode

7-PIN Remote

Interface Harness

Heating in the POOL Mode

Pool Common

(BLK/ORN)

Spa Common

(ORN/BLK)

24VAC HOT

(BLU)

REMOTE OPERATION

The AFT model heaters are equipped with the ability
to work with external remote controls. The supplied 7­pin 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 Off. 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.

Heating in the SPA Mode

Remote Mode

ACTIVATING THE REMOTE

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

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 off (“No
Demand”).

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

Note: 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 finger 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.

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

23

REMOTE CONTROL WIRING

Important Installation Notes for Remote or External Wiring Configuration

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

• For runs over 30 feet (9.1m), the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to

.5 inch (3.8 to 6.4cm) lay that is shielded and jacketed.

2

• Maximum cable length is 200 feet.

• For both two- and three-wire remote systems, the provided 7-pin wiring connector must be utilized. Please
refer to the wiring instructions.

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-Off)

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

1. Turn on power to the heater.

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

its own sensor, push the MENU/SET button to the

“POOL” or “SPA” mode and set the desired setpoint (eg. 102 °F (39°C) for Spa).

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

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

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

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.

To activate the remote control, see page 23.

3-Wire Remote Control Using Three-Position Switch (Pool-Off-Spa, or Low-Off-High)

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

1. Turn on power to the heater.

2. Push the menu/set button to the "POOL" or "SPA" mode and set the desired temperature for each (eg. 80°F
(27°C) for Pool and 102°F (39°C) for Spa).

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

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.

5. Install the "Remote Interface Harness" to the P8 connector and turn power "ON" to the heater.

To activate the remote control, see page 23.

2-Wire Remote Control 3-Wire Remote Control

24

Wiring Diagrams

Fig. 19: Wiring Diagram—Analog Models

Fig. 20: Wiring Diagram—Digital Models

25

Time Clock/Fireman’s Switch

To operate the heater with a time clock, connect the

imer to the fireman’s switch connection in the heater’s

t
wiring. The time clock should be of the dual switch
type and set to shut off the call for heat to the pool
heater (chauffe-piscine) 15 to 20 minutes prior to shut-

ing down the pool pump. On analog heaters, splice

t
into the red/white wire to connect the time clock. For
digital heaters the fireman’s switch connection is locat­ed on the 14-pin header connected to the digital
control board. Splice into the red wire jumper tagged
“Where necessary add “Fireman’s” switch circuit here”
to connect the time clock. The fireman’s switch con-

nection on both analog and digital heaters must be
a dry contact and must not supply power to the
heater. Powering the fireman’s switch connection
externally may damage the heater, and is not
ered by warranty.

cov-

Fig. 21: IID Pilot Location

Cold Weather Operation

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

NOTE: When using a time clock, the heater will
display “Clock/ Fireman Sw” when the fireman’s
switch is open, indicating that the time clock has shut
off the call for heat.

Post Start-Up Inspection

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

N'utilisez pas cet appareil s'il a ete plonge dans l'eau,
meme partiellement. Faites inspecter l'appareil par un
technicien qualifie et remplacez toute partie du sys­teme de controle et toute commande qui ont ete
plonges dans l'eau.

WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.

AVERTISSEMENT: En cas de surchauffe ou si
l'alimentation en gaz ne s'arrete pas, fermez
manueiiement ie robinet d'arret de l'admission de
gaz.

Moderate Climate

Heater operation can continue during short-term cold
spells. When temperatures are between 0° (-17°C)
and 32°F (0°C), 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 (10°C) is not recommended. When starting the
heater with water temperatures below 50°F (10°C),
operate the heater continuously until higher tempera­tures are reached. Operating the heater for prolonged
periods with pool water below 50°F (10°C) can seri­ously damage the heater, and is not covered by the
warranty.

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

Winterizing the Pool/Spa Heater
(chauffe - piscine)

Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
With the heater on, remove the door and make a visual
check of the burner.

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

26

1. Turn off gas valve, manual gas valve, and electri-

In/Out Header

Drain Plug

Adjustment Knob

cal supply to the heater.

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

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

Fig. 22: In/Out Header Drain Plug Location

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

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

SERVICE

Verify proper operation after servicing.

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

Water Pressure Switch

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

MAINTENANCE

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

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

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

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

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

CAUTION: Do not adjust the pressure switch until
all air has been evacuated from the system and the
water flow rate meets the requirements listed in
Table H.

Water Pressure Switch Adjustment

Fig. 23: Water Pressure Switch Adjustment

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

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

27

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

NOTE: If heater is installed outside of the limits
shown, a higher pressure rated 11 psi (76 kPa)
switch may be used. A flow switch, mounted and
wired adjacent to the heater, may be used in place of
the factory mounted pressure switch. See Illustrated
Parts List for 11 psi (76 kPa) water pressure switch.

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

High Limits

Two-Speed Pumps

In some cases, the flow on the low-speed is insuffi­cient to operate the heater. This is apparent when the
water pressure switch cannot be further adjusted or if
the heater makes banging noises or shuts off on high
limit. In these cases, the pump must be run at high
speed when heating the water.

CAUTION: Do not operate the heater without the
function of a properly adjusted water pressure switch
or flow switch.

Pilot Safety

The heater employs a pilot safety which closes the
main gas valve within 8/10ths of a second whenever
the pilot flame is interrupted. The pilot flame 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.

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

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

High Limit Removal

Fig. 25: High Limit Switch

Flame Roll-Out Safety Switch

Fig. 24: Flame Roll-Out Safety Switch

1. Shut off main electrical power switch to heater.

2. Remove rear In/Out inspection panel.

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

4. Replace inspection panel.

28

Fig. 26: Burner Tray Assembly

Burner Tray Removal

Shut off main electrical power switch to heater.1

Shut off gas upstream of heater.2

Remove front door3

Disconnect gas line from gas valve. 4

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

Remove bracket an set aside. 6

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

Disconnect wiring from gas valve. 8

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

Flipthe control panel forward. 10

Disconnect ignition wire and remove with burner11
tray.

Reverse above procedure to reinstall.12

Gas Valve Removal

Remove burner tray.1

Disconnect pilot tubing from gas valve2

Rotate the gas valve counter clockwise to3
remove valve from nipple.

Reverse above procedure to reinstall.4

Fig. 27: Gas Valve Removal

29

Pilot Removal & Cleaning

Remove burner tray from heater1

Disconnect tubing from gas valve.2

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

Remove the pilot assembly by pushing the pilot4

Remove the locating pilot screw from the bracket5
to release the pilot assembly.

Reverse above procedure to reinstall6

Fig. 29: Pilot Bracket Screws

Fig. 28: Spark to Hood Pilot

30

Heat Exchanger Removal

Extension Pieces (2)

Auger with Carbide Tip

Wire Brush

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

. Remove the (8) top jacket holding screws.

2

Remove the jacket top.

Soot will clog areas between fins and cause eventual
tube failure. Any sign of soot at the base of the burners
or around the outer jacket indicates a need for clean­ing.

1. Remove top and flue collector from cabinet.

2. Remove burner tray.

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

4. Remove upper in/out access panel.

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

6. Remove temperature sensor from in/out header.

7. Disconnect flange nuts on In/Out header.

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

9. Reverse above procedure to reinstall.

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.

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

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

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

4. Reverse above procedure to reinstall.

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

Replacement Parts

NOTE: When ordering parts, it is important that the

heater model number, serial number, and type of gas
are specified.

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

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

MANUFACTURER:

2151 EASTMAN AVENUE

OXNARD, CA 93030

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

De-sooting Procedure

CAUTION: Soot may be combustible. Wet sooted

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

Fig. 30: Tube Cleaning Kit

31

TROUBLESHOOTING

Mechanical

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

PROBLEM CAUSE SOLUTION

Harmonics, or whining noise U.G. inoperative................................... Check movement by putting in hot water (110°F (43.3°C) or

higher).
If no movement, replace.

*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 flow............................................... Scale forming in heat exchanger - clean heat exchanger and

check pool pH and total alkalinity.

Heater going on and off Dirty filter.............................................. Clean or replace filter.

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

External bypass setting out of

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

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

Liming or scale forming in Pool water............................................ See Water Chemistry on page 5.

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

U.G. not functioning............................. Replace if no movement when heated.

Sooting High flow rates..................................... Reduce by adding manual bypass valve.

Adjust manual bypass valve until heater outlet water
temperature is between 105°F and 110°F (40.5°C and 43.3°C).

U.G. Inoperative................................... Check movement by putting in hot water (110°F (43.3°C) or

higher).
If no movement, replace.

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

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

*Insects or debris clogging

burner intake ports............................. Clean burners.

Pilot outage or Low gas pressure................................ Adjust gas pressure.

“Weak Flame” signal Restricted/dirty pilot............................. Clean pilot and/or electrode.

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

Yellow lazy flame Low gas pressure................................ Adjust gas pressure.

*Insects or debris clogging

burner intake ports............................... Clean burners.

Outer jacket very hot *Broken refractory caused by
(paint blistered) shipping damage or improper

combustion......................................... Replace refractory panels.

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

Takes too long to heat Under-sized heater............................... Calculate heating capacity of heater:

pool or spa Htr. output(BTUH)

Pool gallonage x 8.33 or refer to heater sizing chart.
This does not take into account heat loss due to weather.

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

Dirty filter.............................................. Clean filter.

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

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

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

Gasket brittle and leaking - Heater running after pump shuts off.... See Pressure Switch Adjustment.

(overheated) Refractory damage.............................. Replace refractory.

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

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

32

Power On

Is the water

t

emperature displayed?

NO

YES

Push MODE
switch to select
"

Pool" or "Spa"

Push Temp

arrow to scroll to

desired temperature

NO

Water temperature

and set

temperature

displayed?

YES

“Heating” will

display briefly

NO

NO

YES

YES

Flame icon displayed

and flashing?

OR

Water temp displayed?

(pilot lit and rectified)

Heater Fired?

END

•

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)

“

Remote” and Water Temperature displayed

(a remote control is controlling the heater)

Note: Disconnect the remote by turning the

remote function off. See page 36 for instructions.

NO

YES

Is a fault code displayed and flashing?

Diagnostic Readouts

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

Temperature sensor out of range (replace sensor)

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

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

“Spark”

Temp Degrees F 40 50 60 70 80 90 100 106
Temp Degrees C 4.4 10 15.6 21.1 26.7 32.2 37.8 41.1
Resistance (k)

261.1 199.0 153.1 118.8 93.0 73.3 58.3 51.0

If okay, replace Circuit Board

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

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

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

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

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

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

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

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

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

ELECTRONIC CONTROL LOGIC - FLOW CHART

33

S

TAR T

T

urn knob to a desired

temperature zone.

Turn switch on.

NO

After six (6) seconds,

does the pilot spark?

YES

Is the pilot lit?

NO

NO

YES

YES

Do the burners light?

END

NO

YES

Is there power to the heater?

Check the gas valve. There must be 24VAC

between PV and MV/PV.

The home circuit breaker may have tripped.

Check and reset if necessary.

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

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

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

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

Does the pilot spark after performing the above steps?

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

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

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

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

NO

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

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

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

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

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

YES

ANALOG CONTROL LOGIC - FLOW CHART

34

1-J

1-G

1-R

1-S

2-S

3-S

2-M

3-M

4-M

1-J

2-J

2-J

3-J

4-J

4-J

1

-V

2-V

3-V

4-V

11-M

12-M

1-B

10-S

5-S

6

-S

7-S

8-S

9-S

9-S

3-B

6-C

8-C

9-C

2-H

3-H

4-H

5

-H

6-H

6-H

7-H

7-H

2-C

3-C

10-M

9-M

8-M

5

-V

5-C

4-S

7-C

4-C

10-C

ILLUSTRATED PARTS LIST

35

1-M

1-C

5-M

(OPTIONAL)

9-C

8-H

10-H

11-H

12-H

13-H

14-H

(OPTIONAL)

15-H

16-H

17-H

9-H

1-P

2-P

3-P

4-P

5-P

1-H

36

37

C

ALL

O

UT

D

ESCRIPTION

1

06A

1

56A

M MISCELLANEOUS COMPONENTS

1-M Pressure Switch 1.75 PSI 006737F 006737F

Pressure Switch 11 PSI Special-See Adj in Service Manual 009133F 009133F

2-M Thermostat Knob 009499F 009499F
3

-M Knob Stop 006886F 006886F
4-M Dial Plate (Analog) 014912F N/A
5-M PRV 125 PSI (Optional) 008091F 008091F
6

-M Deliming Kit (not shown) 052871F 052871F
7-M Wire Harness Analog (not shown) 014884F N/A

Wire Harness Digital (not shown) N/A 014885F

8

-M Control Bezel Digital (Includes Switch Decal) N/A 014886F
9-M Switch/Decal-Membrane N/A 014887F
10-M Control Bezel Cover N/A 014888F
11-M Line Cord 011609F 011609F
12-M Roll-Out Safety Switch 005899F 005899F
13-M Touch-up Paint

Cool Dark Gray 750256 750256

Warm Dark Gray 750258 750258

PPILOT

1-P Pilot Nat. 002003F 002003F

Pilot Pro. 002003F 002003F
2-P Pilot Orifice Nat. 003903F 003903F
Pilot Orifice Pro. 004308F 004308F
3-P Pilot Mounting Bracket 014889F 014889F
4-P Pilot Tube 004078F 004078F
5-P Hi Tension Wire w/Pilot Electrode N/A N/A

RREFRACTORY

1-R Refractory Kit 014890F 014891F

SSHEETMETAL

1-S Jacket Top 014892F 014893F
2-S Jacket Left 014894F 014895F
3-S Jacket Right 014896F 014897F
4-S Jacket Upper Front 014898F 014898F
5-S Jacket Lower Rear 014899F 014899F
6-S Flue Collector 014900F 014901F
7-S Door Panel

Raypak 014902F 014902F

Rheem 014903F 014903F

Ruud 014902F 014902F
8-S Access Panels 014904F 014904F
9-S Control Panel

Analog 014905F N/A

Digital N/A 014906F
10-S Control Cover

Analog 014778 N/A

Digital N/A N/A

VVENTING

1-V Stackless Top (Outdoor) 014907F 014908F
2-V Access Panel (Hot) 014909F 014909F
3-V Drafthood w/Adapter (Indoor) 014357 014358

Outdoor Stack w/Adapter (Outdoor) 014718 014719
4-V Stack N/AN/A
5-V Stack Adapter 014910F 014911F

CONVERSION KITS** 106A 156A

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

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

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

38

39

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]

Litho in U.S.A.

40