Raypak VERSA 055B Operating And Installation Manual

OPERATING AND INSTALLATION INSTRUCTIONS

Models 055B

VERSA

SPA and HOT TUB HEATER

CATALOG NO. 6100.52-K Effective: 3-01-00 Replaces: 3-15-99

WARNING: If the information in these instructions are 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.

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. 240428

Contents

2 PART ONE - Owner's Operating Instructions

2 SECTION 1 / START-UP PROCEDURES 2 Before Start-Up 3 Lighting Instructions & Shut-Off Procedures

(manually lighted pilot MV)

4 Operating Instructions & Shut-Off Procedures

(automatically lighted pilot IID)

5 After Start-Up

5 SECTION 2 / CAUTION

5 SECTION 3 / MAINTENANCE & CARE PROCEDURES 6 Pool & Spa Water Chemistry 6 Winterizing the Pool and Spa Heater

7 PART TWO - Installation / Service Instructions

7 SECTION 1 / RECEIVING EQUIPMENT

7 SECTION 2/GENERAL SPECIFICATIONS

7 SECTION 3 / INSTALLATION INSTRUCTIONS 7 Code Requirements 7 Base Installation 7 Clearances 9 Combustion Air 9 Venting Connections 11 Gas Supply Connections 12 Plumbing for Water Connections 13 Electrical Wiring

17 SECTION 4 / SERVICING INSTRUCTIONS 17 General Location of Controls 17 Control Adjustments / Replacements

18 Pressure Switch 18 Flame Roll-Out Safety Switch 18 High Limit 18 High Limit Removal 18 Pilot Safety 19 Burner Drawer Removal 19 Gas Valve 19 Main Burner & Orifice 19 Pilot Removal & Cleaning 19 Heat Exchanger Removal 20 Desooting Procedure 20 Combustion Chamber Removal 20 Control Immersion Well Replacement 20 Unitherm Governor Replacement

21 SECTION 5 / TROUBLESHOOTING GUIDE 21 Mechanical 22 Electrical MV Units 24 Electrical IID Units

26 SECTION 6 / REPLACEMENT PARTS

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

BEFORE START-UP

BURNERS

Clean main burners 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

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

Fig. #8139s

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 lighted by

hand. When lighting the pilot, follow these instructions exactly.

B. BEFORE LIGHTING smell all around the appli-

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

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

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

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

WHAT TO DO IF YOU SMELL GAS:

*Do not try to light any appliance. *Do not touch any electric switch; do not use any phone in your building.

*Immediately call your gas supplier from a neigh bor's phone. Follow the gas supplier's instruc tions.

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 left side of the burner drawer. For burner drawer location, see location of control section, page 18.

Gas control knobs shown in "Off" position

HONEYWELL

GAS VALVE MILLIVOLT

Fig. #8081.0

ROBERTSHAW GAS VALVE

MILLIVOLT

Fig. # 8199

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.

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 under water.

ROBERTSHAW PILOT

Fig. #8084.0 Fig. #8083.0

HONEYWELL PILOT

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

9. Push in control knob all the way and hold in.

Immediately place flame to pilot to light. Continue to hold control knob in for about 1 minute after the pilot is lighted, release knob and it will pop back up. Pilot should remain lighted. If it goes out, repeat steps 5 through 9. *If knob does not pop up when released, stop and immediately call your service technician or gas supplier. *If the pilot does not stay lit after several tries, turn the gas control knob to "Off" and call your service technician or gas supplier.

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

control knob counter clockwise to "On".

11. Replace heater door panel.

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

13. Set thermostat to the desired setting.

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 IGNITION 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. Push in gas control knob slightly and turn clockwise to "Off". Knob cannot be turned to "Off" unless it is pushed in slightly. Do not force.

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. Gas control lever shown in the "On" position.

8. Turn gas control knob counterclockwise to "On".

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

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

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

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

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

Gas control knob shown in "ON" position.

GAS VALVE-IID

Fig. # 8112

9. Replace heater door panel.

10. Turn on all electrical power to 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.

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.

TO TURN OFF GAS TO APPLIANCE

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

5. Replace heater door panel.

AFTER START-UP

Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot.

SECTION 2 / CAUTION

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

WARNING: Should overheating occur or the gas sup- ply fail to shut off, turn off the manual gas control valve 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. # 8144.0

MAIN BURNER FLAME

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 subse-

quently 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

four degrees Fahrenheit (2.2°C).

5. Persons with a medical history of heart disease,

circulatory problems, diabetes, or blood pres

sure problems should obtain a physician's

advice before using pools or hot tubs.

6. Persons taking medications which induce

drowsiness, such as tranquilizers, antihista

mines, or anticoagulants, should not use spas or

hot tubs.

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 servicing instruction in Section 4 of this manual.)

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

SECTION 3 / MAINTENANCE AND CARE PROCEDURES

To be followed one month after start-up and then

semi-annually.

1. Inspect top of heater and draft hood for soot, (a sticky black substance around finned tubes, baffle and open flue gas passageways).

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 this occur, shut the heater off and contact your gas supplier or qualified service agency.

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 and other flammable and corrosive vapors and liquids.

POOL & SPA WATER CHEMISTRY

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.

COLD WEATHER OPERATION

MODERATE CLIMATE: Heater operation can con-

tinue during short term cold spells. When temperatures are below freezing, flow (continuous pump operation) must be maintained.

BASIC TIPS IF HEATER WILL NOT FIRE:

1. If you have no electrical power; it may be your "circuit breakers" have tripped. Try re-setting them.

2. If you have electrical power but the heater will not fire

check the following:

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

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

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

6. The pump may have lost it's prime. It may be running dry, check the pressure gauge 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.

CAUTION: Do not use the heater to maintain water temperatures just above freezing or for freeze protection. When heaters are 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° can seriously damage the heater, and is not covered by the warranty.

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

WINTERIZING THE SPA HEATER

When heaters installed outdoors in freezing climate areas are to be shut down for the winter, observe the following step-by-step procedure:

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

cal supply to the heater.

2. Open drain cock located on the return header.

3. Disconnect compression fittings from the pressure

switch and header that connect to the 1/4"

copper tube and allow the tube to drain.

PART 2 - INSTALLATION / 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.

On occasion, we ship some items loose. 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 SPECIFICATION

These heaters are design certified and tested under the requirements of ANSI Z21.56/CSA 4.7 American National Standard / CSA standards for gas-fired pool

heaters

The heater is interchangeable and 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 heaters contain 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

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. For Canada, reduce input 10% when installed at 2000-4500 foot elevation.

SECTION 3 / INSTALLATION INSTRUCTIONS

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 editions of the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70. For Canada, the latest edition of CAN/CGA B-149.1 and B-149.2

BASE INSTALLATION

Heater must be mounted on a level surface. It can be installed on combustible flooring. Heaters may not be installed on carpeting.

CLEARANCES

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 heavy internal rusting or damage some electrical components and this would void the warranty.

ALL HEATERS

For clearances from combustible surfaces, see

chart below.

OUTDOOR HEATERS

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

Clearances from Combustible construction. Indoor Installation:

Top* (Drafthood) - 35"; Vent - 6";

Heater with outdoor Top

Back - 2"; Right Side - 6"; Left Side - 6"; Floor - 0.

Outdoor Installation:

Top* (Stackless Top) unobstructed; Back - 2"; Sides - 6".

* Clearance from Top of Vent Terminal

Fig. # 8139

WARNING: Do not install within 3 feet of a Heat Pump

For servicing, provide at least 24" in front of the heater for burner tray removal, and at least 18" on the left side of the heater to inspect and delime the heat

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

exchanger.

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 to a 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 revision of CAN/CGA-B149.1 and B149.2.

foot

Minimum

foot

Minimum

Forced Air Inlet

U.S. Installation Only

Minimum

foot

Minimum

foot

Minimum

foot

Minimum

Fig # 8245.1

HIGH WIND CONDITIONS (OUTDOOR UNITS ONLY)

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

INDOOR HEATERS

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 for venting details. Minimum allowable space is shown on the nameplate.

Heater with Indoor Top

VENTING CONNECTIONS

VENT TERMINAL (Outdoor)

STEP 1: Remove the (4) screws which fasten

jacket top to heater.

STEP 2: Lower outdoor top onto unit lining up

slots in outdoor top with screw holes in jacket top.

STEP 3: Reinstall (4) screws to secure jacket top

and outdoor top to unit.

Outdoor Top

Jacket Top

Fig. # 8138

COMBUSTION AIR (INDOOR UNITS ONLY) Air For combustion And Ventilation (Indoor Units Only)

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings, one 12 inches from ceiling for ventilation and one 12 inches from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code, Z223.1(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.

a. All Air From Inside The Building:

Each opening shall have a minimum of 50 net free

square inches.

b. All Air From Outdoors:

When air is supplied directly from outside of

building, each opening shall have a minimum of 13

net free square inches.

Fig. # 8137

VENT TERMINAL (Indoor)

Locate and assemble as shown. Secure with

screws supplied in envelope inside carton.

Draft Hood

Mounting Screws

Fig. # 8143

VENT PIPING

WARNING: Indoor boilers require a draft hood 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.

Vent piping the same size or larger than the draft

hood outlet is recommended, however, when the total vent height is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter 10 of the latest edition of the National Fuel Gas Code, ANSI Z 223. (Canada-CAN/CGA- B149.1 and B149.2). As much as possible avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontalor or non-vertical runs, the vent pipe must have a and should be supported at not less than five foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacer through the roofs and walls.

For protection against rain or blockage by snow, the

vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such codes, to the latest edition of the National Fuel Gas Code, ANSI

Z223.1-1988 (Canada-CAN/CGA-B149.1 and B149.2).

The discharge opening must be a minimum of two

feet vertically from the roof surface and at least two feet higher than any part of the building within ten feet. Vent stack shall be at least five feet in vertical height above the draft hood outlet. The vent cap location shall have a minimum clearance of 4 feet horizontally from, and in no case above or below, unless a 4-foot 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 draft hood. Support must be provided in compliance with applicable codes. The heater top and draft hood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from 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 Z 223.1-1988 (Canada-CAN/CGA-

B149.1 and B149.2).

minimum of 1/4 inch per foot rise

10' OR LESS

2' MIN

VENT PIPE

DRAFT HOOD

HEATER

VENT CAP

2' MIN

5' MIN

GAS SUPPLY CONNECTIONS

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. All gas piping should be tested after installation in accordance with local codes.

Manual Shut Off Valve

Gas Pressure

Manual Shut

Gas Valve

Sediment Trap

Fig. # 8156

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 (3.45 KPA). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test. Do NOT use open flame.

NOTE: Do not use teflon tape on gas line pipe thread. A flexible sealant is recommended.

A minimum of 7" W.C. and a maximum of 14" W.C. upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 12" W. C. and a maximum of 14" for propane gas.

PIPE SIZING FOR GAS CONNECTIONS

Gas Pressure Test at Gas Valve

Gas Pressure Test at Heater

Fig. # 8149.0s

ROBERTSHAW MV W.C Adjustment

W.C Adjustment

Fig. # 8199

HONEYWELL VALVE MV & IID W. C. Adjustment

W.C Adjustment

MAXIMUM EQUIVALENT PIPE LENGTH

Natural Gas 1000 BTU/ FT . 60 Specific Gravity

@ 0.5" WC Pressure Drop

Propane Gas 2500 BTU/ FT l.53 Specific Gravity

@ 0.5" WC Pressure Drop

1/2" 3/4"

MODEL N P N P

055B 90 200 200 250

GAS PRESSURE REGULATOR

The gas pressure regulator is preset and sealed at 4" W.C. for natural gas, and ll" W. C. for propane gas. Between the gas valve and the burners is a l/8" pipe plug. The pressure at this point, taken with a manometer, should be about 3.7" W. C. natural gas and l0.5" W.C. propane gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise to increase pressure or counter-clockwise to decrease pressure.

Fig. # 8081.0

PLUMBING FOR WATER CONNECTIONS

LOCATION

The VERSA heater requires water flow and posi-

tive 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 spa. The pump, filter and

heater are thus plumbed in series. Plumbing from the heater back to the spa must not

have any valves or restriction that could prevent flow when the pump is operating. To do so will void the warranty.

Heater must be located so that any water leaks will

not damage the structure of adjacent area. High temperature plastic pipe (CPVC) may be connected directly into the heater if local codes permit.

FLOW RATES

PIPE SIZE: 1 1/4"-1 1/2" MIN.GPM: 20, MAX.GPM: 60*

*When flow rates exceed 60 GPM an external auxiliary bypass valve is required. See External auxiliary bypass valve section for details.

COMPANION FLANGE CONNECTIONS

The inlet/outlet header flange accepts a 1 1/2" copper tube or 1 1/4" galvanized pipe as a slip connection directly into the manifold. The flange is also threaded for 1 1/2" pipe thread. 1-1/2" CPVC adapters (when available) can also be used.

CAUTION: Never install PVC directly in header flanges. The initial connection must be made with a higher temperature material such as CPVC or Copper. PVC may be utilized immediately after the initial connection.

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 (i.e. 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.

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

UNITHERM GOVERNOR OPERATION

The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105° - 115°F despite continually changing flow rates from the filter and changing pool temperatures. This narrow range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time below 100°F. It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.

DO NOT use petroleum base assembly fluids (such as Petroleum Jelly or lubricating oil). If assembly lube is required, use a silicone base compound, such as Amoral, etc.

Inlet/Outlet Header

Flange Gasket

Header Flange

Pipe

Unitherm Governor

Fig.#8158.1

Outlet Inlet

Fig. # 8118.0

EXTERNAL AUXILIARY BYPASS VALVE

(Where required)

An auxiliary bypass valve should be used when flow rates exceed 60 GPM (usually a high performance pump size larger than 1 1/2 HP 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 down below 55°F. It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets, etcetera.

From Heater To Heater

To Pool From Pool

Auxiliary Bypass Valve (do not use gate valve)

Fig. # 8150.0s

AUXILIARY BYPASS VALVE ADJUSTMENT

To set bypass: With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater. Outlet pipes should be slightly warmer than inlet and comfortable to the touch. If pipe is hot, close bypass; if cold, open bypass

PRESSURE RELIEF VALVE INSTALLATION

To conform to local building codes, it may be necessary to install a pressure relief valve. A 3/4" pressure relief valve having a capacity equal to BTU/ HR output of the model to be installed is recommended for this appliance.

Drain Pipe Drain Pipe

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. Valve lever should be tripped at least once a year to ensure that waterways are clear.

ELECTRICAL WIRING

NOTE: If it is necessary to replace any of the original

wiring, it must be replaced with 105 °C wire or its equivalent, except all black wire must be replaced with 150 °C wire or its equivalent.

MILLIVOLT SYSTEM

The Millivolt System Residential Heater is equipped with a self-generating electrical system in which the electric current is provided by means of a pilot generator. No external electrical connections are required.

ELECTRONIC INTERMITTENT IGNITION DEVICE SYSTEM (IID)

NOTE: When the electrical hookup to the heater requires both 24V and 115V or 240V, each input voltage must be isolated in separate conduit.

The Electronic Intermittent Ignition Device auto- matically lights the pilot and main burners upon a call for the heat. The heater is supplied with a dual voltage transformer for 120V or 240V input power hookup.

NOTE: IID Propane Units Only Heater is equipped with an electronic ignition device with a 100% safety lockout feature. If the heater fails to start or lockout. Reset the ignition device by interrupting the power to the heater for 60 seconds.

CAUTION: If service replacement of the electronic ignition device is required. Replace only with a 100% safety lockout device with 90 second trial for pilot ignition.

Heater Outlet Heater Outlet

NOTE: To avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outlet and run to a safe place of discharge. Drain pipe must be the same size as the valve discharge connection

Fig. # 8157.0s

Fig. # 8929.1

Robertshaw Intermittent Ignition Device

Honeywell Intermittent Ignition Device

Fig. # 8085

For 120 V input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the white wire to the “L2” or neutral leg of the power supply. Attach the wire nut to the red wire. There should be no

connection to the red wire for 120V operation.

Fig. #9240

For 240 V input power to the unit, connect the black wire to the “L1” or hot leg of the power supply. Connect the red wire to the “L2” or second hot leg of the power supply. Attach the wire nut to the white wire. There should be no connection to the white wire for 240V operation.

WIRING DIAGRAM KEY

PINK CONNECTOR BLUE CONNECTOR

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 C221.1, Part 1 and 2).

NOTE: Input power to the heater (120/240V) should be supplied from the load (Pump) side of time clock or switch. Connecting heater to continuous power source will allow "Fail" indications (service and pressure switch) when pump is not operating.

Fig. # 8096

S86 S8600

Fig. # 9241

SPK

Fig. # S86/S8600

WIRING DIAGRAM MILLIVOLT UNITS WITH MECHANICAL THERMOSTAT

Fig. # 1934e

WIRING DIAGRAM MILLIVOLT UNITS WITH SOLID STATE THERMOSTAT

Fig. # 2246e

WIRING DIAGRAM 152178 Model 055 IID

SECTION 4 / SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

HIGH LIMITS (Located in the Inlet/Outlet header)

Pressure Switch

Burner & Pilot

Thermal Fuse

Drain Valve

Solid State Thermostat & Ignition Control

CONTROLS/ADJUSTMENTS/REPLACEMENTS

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

DANGER - SHOCK HAZARD -make sure electrical power to the heater is disconnected to avoid potential serious injury of damage to components.

TEMPERATURE CONTROLS

The water temperature is controlled by the heater 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 illustrated below is adjustable by loosening the set screw, rotating the knobstop ring to the desired location and retightening the set screw.

Gas Valve

Fig. # 8160.1s

Typical Comfortable

Typical Comfortable Spa

Pool Temperature Range

Temperature Range

Knobstop Ring Set Screw

PRESSURE SWITCH

The pressure switch, or heater actuator, insures that the heater operates only when the filter pump is in operation. It is factory set at 1.75 PSI for deck level installations. When the heater is located below the level of the spa or pool, it may be necessary to reset the pressure switch to compensate for the no-flow static head. If it is necessary to reset the pressure switch, we recommend that following procedure:

PRESSURE SWITCH ADJUSTMENT:

FLAME ROLL-OUT SAFETY SWITCH

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

knob ( gas valve.

2. Turn adjustment knob (counter clockwise) 1/4

turn.

3. Turn pump off and on several times. Heater

should shut off immediately. If it does not, repeat steps above until proper adjustment is made.

Adjustment Knob

Fig. # 8069.1

Heat Exchanger Height

The heater is 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.

Fig. #9177

HIGH LIMITS

The heater is equipped with two automatic high limits. Set to operate at 135°F and 140°F.

NOTE: An erratic high limit is often characteristic of internal heat exchanger problem, i.e. scale buildup, U.G. operation. Refer to troubleshooting section.

5' Max.

Heat Exchanger Height

Pool or Spa

Fig. # 8152.0s

NOTE: If heater is installed outside of the limits shown, a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater.

TWO SPEED PUMPS

In some cases, the flow on the low-speed is insufficient to operate the heater. This is apparent when the pressure switch cannot be further adjusted or if the heater makes banging noises. 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 pressure switch.

Fig. # 8159.0s

HIGH LIMIT REMOVAL

1. Disconnect top portion of unit. (See heat exchange removal procedure step 1 thru 7 and step 10)

2. Remove defective high limit and replace with new high limit.

3. Reverse above procedure to reinstall.

PILOT SAFETY (Millivolt System)

The heaters equipped with the standing pilot (milli-

volt system), have pilot generators which act as a safety device to shut off the flow of gas to the main burners and the pilot burner in case the pilot flame is extinguished. The pilot burner must be manually relighted to place the heater in operation again. Refer to the lighting instructions provided on the heater label.

PILOT SAFETY (IID Units) ELECTRIC IGNITION

The heater employs a pilot safety which closes the

main gas valve within 8/10ths of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit.

BURNER DRAWER REMOVAL

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

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

6. Disconnect wires that terminate at gas valve, and thermal fuse.

7. Slide out burner tray.

8. Reverse above procedure to reinstall.

Pilot Pilot

Air Opening

GAS VALVE REMOVAL

1. Remove burner tray. (See burner tray removal procedure).

2. Disconnect pilot tubing from gas valve.

3. Remove gas valve with manifold from burner tray.

4. Remove manifold from gas valve.

5. Reverse above procedure to re-install.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove burner drawer. (See burner drawer removal procedure).

2. Remove screws and burner hold down bracket.

NOTE: If the heat exchanger is sooted badly, the burner hold down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts.

3. Lift burners from slotted spacers and slide from orifices. Clean with a wire brush.

4. Orifices usually do not need to be replaced. To clean, run either copper wire or wood toothpick through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove from manifold. DO NOT overtighten when reinstalling.

PILOT REMOVAL AND CLEANING

1. Remove burner drawer. (See burner drawer removal procedure).

2. Disconnect pilot tubing, disconnect wires from gas valve.

3. Disconnect pilot bracket from burner shield.

4. Remove pilot from bracket.

5. Remove pilot orifice and air opening (Honeywell MV unit only), and clean with wire or small brush. CAUTION! DO NOT enlarge hole in pilot orifice.

6. Reverse above procedure to re-install.

Orifice

Fig. # 8102.0s

Fig. # 8045.1

HONEYWELL PILOT ROBERTSHAW PILOT

HEAT EXCHANGER REMOVAL

1. Shut water, gas, and electricity off, close valves and relieve pressure.

2. Drain heat exchanger.

3. Loosen and remove flange bolts.

4. Remove flange and inlet/outlet pipes from the header. Remove drain valve from rear header

5. Remove outdoor stackless top or indoor stack top from unit.

6. Remove jacket top, flue collector, and baffle.

7. Remove upper front jacket panel, and disconnect wires at toggle switch.

8. Remove capillary bulb from inlet/outlet header.

9. Disconnect press switch tube from inlet/outlet header.

10. Disconnect hi-limit wire from thermostat, and pressure switch.

11. Lift heat exchanger straight up from combustion chamber, using caution not to damage refractory.

12. Reverse above procedure to re-install.

DESOOTING PROCEDURE

CAUTION: SOOT IS COMBUSTIBLE. EXERCISE EXTREME CARE. NEVER USE A WIRE BRUSH.

Soot can 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. Disconnect top portion of unit. (See heat exchanger

removal procedure steps 1 through 6).

2. Remove burner tray (See burner tray removal

procedure.)

3. Take a garden hose and wash heat exchanger,

making sure soot is removed completely from be-

tween fins. Avoid excessive water against refrac-

tory.

NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is steam cleaning at the local car wash. DO NOT WIRE BRUSH.

COMBUSTION CHAMBER REMOVAL

1. Remove heat exchanger (See heat exchanger

removal procedure).

2. Lift up and remove front and rear refractory shield.

3. Remove refractory panels.

4. Reverse above procedure to re-install.

CONTROL IMMERSION WELL REPLACE

1. Remove plumbing and top portion of unit (See heat exchange removal procedure steps 1 through 6).

2. Remove U.G. spring, U.G. and copper shield.

3. Collapse well tube at open end with chisel.

4. Push well up through header.

5. Insert new well and roll in place. If a roller is not available, solder the well in place with silver solder.

Immersion Well

Fig . # 8126.0s

UNITHERM GOVERNOR (U.G.) REPLACEMENT

1. Shut water, gas and electricity off, close valves and

relieve pressure.

2. Drain heat exchanger.

3. Disconnect inlet & outlet pipes with flange from in/

out header.

4. Grasp retainer spring from inlet side of header, and

slide thru inlet hole.

5. Remove shield.

6. Remove U.G. with seating gasket, and stainless

steel baffle (not shown).

7. Reverse above procedure to re-install.

Refactory Panel Top View

Fig . # 8155.0s

U.G.

U.G. Shield

Retainer Spring

Outlet Inlet Inlet/Outlet Header

Fig . # 8158.1

To test the operation of the Unitherm Governor, place in hot water (over 110°F) and watch for movement against spring. If there is no movement, replace unit.

SECTION 5 / TROUBLE SHOOTING GUIDE

IMPORTANT NOTICE

These instructions are primarily intended for the use of 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. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.

MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)

PROBLEM CAUSE SOLUTION

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

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.................................. Backwash filter.

continously. 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 on Pool water................................. Recommended pH should be between 7.4 and

7.8 heat exchanger. 7/8 total alkalinity 100-150 PPM maximum. Hardness 150-400 PPM maximum.

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

adjust by putting thermometer in header (1/4" NPT) drain opening. Set bypass so thermometer reads between 105° and 110°F.

U.G. Inoperative......................... Check movement by putting in hot water (110°F

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

Restricted pilot........................... Clean pilot.

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

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

*Insects or debris clogging

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

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

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

Excessive sooting of heat

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

Takes long time to heat Calculate temperature in °/hr......... Heat rise (°/hr.)=

pool or spa. 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.

Heater Output

(* Usually occurs on initial start-up.)

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

replace.

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

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

properly.

Leaking at heat exchanger. Overacid.................................. Replace heat exchanger and maintain

chemistry properly. Gasket brittle and leaking - Heater running after pump

(overheated). shuts off................................... See pressure switch adjustment.

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

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

ELECTRICAL ( MILLIVOLT)

RAYPAK POOL OR SPA HEATER ELECTRICAL

CHECK WITH MV GAS VALVE

CAUTION: For qualified service personnel only.

1. Filter must be on with adequate water flow through heater.

2. Gas valve must be "ON" position. Thermostat set higher than pool water temperature.

3. Jumpers are for temporary check only. If left in place, they could cause the heater to burn up.

Light pilot

If pilot burner remains lit.

Jump across both "TH"

wires on gas valves

If main burner fires,

remove jumper

Jump across pressure

switch terminals

If main burner fires,

remove jumper

Clean filter

Check for adequate water

flow from filter

Replace pressure switch

If main burner fires,

remove jumper

If main burner does not

fire, remove jumper

If main burner does not

fire, remove jumper

Jump across thermostat

Replace

gas

valve

If pilot burner stays on

Problem is a wire or

component short to

If main burner does

NOT fire...

If pilot burner goes out when main burner lights or when gas valve knob

is released

Remove both "TH"

wires from gas valve.

Relight pilot

cabinet or low gas

pressure

If below 500mV, check

gas pressure. Also check

for insects or debris in

the pilot burner

If output is still low,

replace pilot generator.

If pilot burner does not light

Check gas supply, gas line size, gas pressure.

Also check for insects

or debris in pilot output.

If burner does not remain

lit, attach millivolt meter

and read pilot output.

If above 500mV,

replace gas valve

Replace thermostat

Jump across each high

limit and remove jumper

Replace high limit that

caused heater to fire

ELECTRICAL (SOLID STATE THERMOSTAT MILLIVOLT)

If the pool/spa/hot tub water is too cold, troubleshoot the system as follows:

Check voltage at + and - terminals.

VOLTAGE BETWEEN + 0.2 V and 0.75 V. (Polarity is critical) Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE BELOW 105°F Disconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS. Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT. Disconnect potentiometer leads from circuit board. Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting: 9k to 11k at maximum setting,

replace circuit board.

Above 11k ohms, replace

potentiometer.

0 ohms (short circuit), replace

potentiometer.

Reconnect all leads and check out system.

VOLTAGE OUTSIDE RANGE + 0.2 V and 0.75 V. Check pilot generator, correct as necessary.

TEMPERATURE 105-108° F. Control ok. NOTE: 108°F is the upper control limit.

RESISTANCE O OHMS (SHORT CIRCUIT) OR OPEN CIRCUIT GREATER THAN 14 K. Check system for shorted wires or open circuits. Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCE DON'T MATCH. Replace sensor. Reconnect all leads and check out system.

If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:

Check voltage at + and - terminals

VOLTAGE BETWEEN + 0.2 V and 0.75 V. (Polarity is critical) Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE ABOVE 108°F Disconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS. Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT. Disconnect potentiometer leads from circuit board. Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting; 9k to 11k at maximum setting,

replace circuit board.

Above 11k ohms, replace

potentiometer.

0 ohms (short circuit), replace

potentiometer.

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

Temperature (deg. F) 61 68 70 77 86 88 95 104 106 Resistance (k ohms) 14.92 12.49 11.88 10.00 8.06 7.69 6.53 5.33 5.10

VOLTAGE OUTSIDE RANGE + 0.2 V and 0.75 V. Check pilot generator, correct as necessary.

TEMPERATURE 105-108° F. Control ok. NOTE: 108°F is the upper control limit.

RESISTANCE ABOVE 15k OHMS (OPEN CIRCUIT) OR SHORT CIRCUIT. Fix loose or broken wires. Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCE DON'T MATCH. Replace sensor. Reconnect all leads and check out system.

ELECTRICAL (ELECTRONIC IGNITION IID)

Intermittent Pilot System

TROUBLESHOOTING HONEYWELL S8600

234567890123456789012345678901212345678901234567890123456789

For qualified Technicians ONLY

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

WARNING

HIGH VOLTAGE

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO MODULE

(24 V NOMINAL)

YES

SPARK ACROSS

IGNITER/SENSOR GAP

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

SPARK STOPS WHEN

PILOT IS LIT?

YES

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

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring.

Pull ignition lead and check spark at module.

Spark Okay? YES

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

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

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

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

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

NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G. models.

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

• Check electrical connections between flame rod and module.

• Check for cracked ceramic flame rod insulator.

• Check that pilot flame covers flame rod and is steady and blue.

• Adjust pilot flame.

• If problem persists, replace module.

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

TROUBLESHOOTING

ENDS

Repeat procedure until trouble free operation is obtained.

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

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

NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

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

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace module.

• Check for proper thermostat (controller) operation.

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

ELECTRICAL (SOLID STATE THERMOSTAT IID)

If the pool/spa/hot tub water is too cold, troubleshoot the system as follows:

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V. Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE BELOW 105°F Disconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS. Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT. Disconnect potentiometer leads from circuit board. Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting; 9k to 11k at maximum setting,

replace circuit board. Above 11k ohms but less than 15 k ohms, replace potentiometer. Above 15k ohms, fix loose or broken wires; replace potentiometer if necessary.

Reconnect all leads and check out system.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V. Check transformer, 120 V supply, correct as necessary

TEMPERATURE 105-106° F. Control ok.

RESISTANCE O OHMS (SHORT CIRCUIT) Check system for shorted wires or open circuits. Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCE DON'T MATCH. Replace sensor. Reconnect all leads and check out system.

If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:

Check voltage at 24 V terminals.

VOLTAGE BETWEEN 21.5-28.5 V. Set control to max. temperature. After 2-3 cycles, check water temperature.

TEMPERATURE ABOVE 108°F Disconnect sensor leads from circuit board. Measure sensor resistance with ohmmeter.

RESISTANCE 1-14k OHMS. Check water temperature; estimate expected sensor resistance from chart below.

MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT. Disconnect potentiometer leads from circuit board. Measure resistance with ohmmeter. If resistance is:

0-100 ohms at minimum setting: 9k to 11k at maximum setting,

replace circuit board.

Above 11k ohms, replace

potentiometer.

0 ohms (short circuit), replace

potentiometer.

Reconnect all leads and check out system.

VOLTAGE OUTSIDE RANGE 21.5-28.5 V. Check transformer, 120 V supply, correct as necessary.

TEMPERATURE 105-106° F. Control ok.

RESISTANCE ABOVE 15k OHMS (OPEN CIRCUIT) OR SHORT CIRCUIT. Fix loose or broken wires. Replace sensor if necessary.

MEASURED AND ESTIMATED RESISTANCE DON'T MATCH. Replace sensor. Reconnect all leads and check out system.

SENSOR RESISTANCE AT VARIOUS TEMPERATURES

Temperature (deg. F) 61 68 70 77 86 88 95 104 106 Resistance (k ohms) 14.92 12.49 11.88 10.00 8.06 7.69 6.53 5.33 5.10

SECTION 6/REPLACEMENT PARTS LIST

NOTE: To supply the correct part it is important that

you state the model number, serial number and type of gas when applicable.

Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK 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, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued.

RAYPAK, INC

31111 AGOURA ROAD

WESTLAKE VILLAGE, CA 91361-4699

For Canada:

RAYPAK CANADA LTD. 2805 SLOUGH STREET

MISSISSAUGA, ONTARIO

L4T 1G2

1-V

1-S

2-V

2-S

7-C

11-H

12-H

6-H

2-M

13-H

5-H

1-C

1-M

2-C

4-H

10-H

3-C

8-H

3-B

5-C

2-B

2-H

7-M

6-C

3-H

1-G

7-H

1-R

9-M

3-S

4-S

5-M

4-M

3-M

6-S

1-B

6-M

5-S

4-C

11-P

9-P

Fig. #8132.0

5-P

1-P

14-P

12-P

IID

3-P

13-P

7-P

14-P

15-P

Fig. #8133.0

LIMITED WARRANTY

RAYPAK RESIDENTIAL SWIMMING POOL & SPA HEATERS

GENERAL

Raypak, Inc. warrants that all parts of this product will be free from defects in materials and workmanship under normal use and service for a period of TWO YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR A SINGLE FAMILY RESIDENCE (ONE YEAR IF OTHER THAN FOR SINGLE FAMILY RESIDENCE USE). In accordance with the terms of this warranty, we will furnish a Raypak replacement for any defective part or repair the part at our option. The replacement or repair will be warranted for only the unexpired portion of the original warranty. Labor costs for removal or reinstallation of parts are not covered by this warranty, nor are shipping charges to or from Raypak's designated repair center. This warranty does not cover rusting or corrosion on cabinet or burners that does not affect heater's operation.

WARRANTY CONDITIONS

This warranty applies only to the heater at its original place of installation. This warranty will be void if the heater is installed in violation of applicable local codes and ordinances or if the rating plate or serial number is altered or removed.

WARRANTY EXCLUSION

This warranty does not cover defects or malfunctions resulting from:

1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions;

2. Abuse, alteration, accident, fire, flood, freeze and the like:

3. Misuse or neglect, including but not limited to, freeze-ups, operating the heater with the cabinet door off, having flow restrictions or obstructions between the heater outlet and the spa, or not maintaining a proper chemical balance (PH level must be between 7.4 and 7.8 and total alkalinity between 100 and 150 PPM. Total dissolved solids (TDS) must be no greater than 3000 PPM);

4. Use of non-factory authorized accessories or other components in conjunction with the heater.

HOW TO MAKE A CLAIM

Immediately notify the dealer from whom the heater was purchased, supplying model and serial numbers of the unit, date of purchase, and a description of the problem. The dealer should then promptly contact Raypak about the warranty claim, and for the location of Raypak's nearest designated repair center. (If the dealer for any reason is not available, call or write Raypak directly at the address shown below, Attention: Warranty Service). After such notification has been given and Raypak has advised the location of its designated repair center (which may be the dealer), bring or ship, transportation prepaid, the defective part for replacement or repair to the designated repair center. However, Raypak reserves the right at all times to inspect the claimed defect and verify warranty coverage at its factory.

MISCELLANEOUS

No one is authorized to make any other warranties on our behalf, ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED ABOVE. RAYPAK'S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL BE AS SET FORTH IN THIS WARRANTY AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGE FROM WATER LEAKAGE) ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

We suggest you immediately complete the information below and retain this Warranty Certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty must be presented; otherwise, the effective date will be based upon the date of manufacture plus THIRTY (30) Days.

This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

________________________________________________ ________________________________________________

Name of Owner Name of Dealer

________________________________________________ ________________________________________________

Address Address

________________________________________________ ________________________________________________

Model No. Serial No.

Date of Purchase____________________________________________________________________________________

RAYPAK, INC., 31111 Agoura Road, Westlake Village, CA 91361 (818) 889-1500 FAX (818) 889-4522 Litho in U.S.A.

RAYPAK CANADA LTD., 2805 Slough Street, Mississauga, Ontario L4T 1G2 (905) 677-7999 FAX (905) 677-8036

Raypak, Inc., 31111 Agoura Road, Westlake Village, CA 91361-4699 (818) 889-1500 FAX (818) 889-4522

Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036

Raypak Australia Pty. Ltd, 7 Geddes St., Mulgrave, Victoria, Australia 3170 (6139) 560 4944 FAX (6139) 560 4974

www.raypak.com

Litho in U.S.A.

Raypak VERSA 055B Operating And Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual