Raypak Versa 105B User Manual

INSTALLATION
AND OPERATING
INSTRUCTIONS

Models
105B Brass

VERSA

ABOVE GROUND POOL
and
SPA HEATER

CATALOG NO. 6100.61E
Effective: 02-01-05
Replaces: 03-01-03

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. 240790

Contents

4 PART ONE - Owner's Operating Instructions

4 SECTION 1 / START-UP PROCEDURES

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

(manually lighted pilot MV)

6 Operating Instructions & Shut-Off Procedures

(automatically lighted pilot IID)

7 After Start-Up

7 SECTION 2 / CAUTION

7 SECTION 3 / MAINTENANCE & CARE PROCEDURES

8 Pool & Spa Water Chemistry
8 Winterizing the Pool and Spa Heater

9 PART TWO - Installation / Service Instructions

9 SECTION 1 / RECEIVING EQUIPMENT

9 SECTION 2/GENERAL SPECIFICATIONS

9 SECTION 3 / INSTALLATION INSTRUCTIONS

9 Code Requirements
9 Base Installation
10 Clearances
11 Combustion Air
12 Venting Connections
14 Gas Supply Connections
15 Plumbing for Water Connections
17 Electrical Wiring

21 SECTION 4 / SERVICING INSTRUCTIONS

21 General Location of Controls
21 Control Adjustments / Replacements
21 Pressure Switch
22 High Limit
22 Pilot Safety
23 Burner Drawer Removal
23 Gas Valve Removal
23 Main Burner & Orifice Removal
23 Pilot Removal & Cleaning
23 Heat Exchanger Removal
24 Tube Cleaning Procedure
24 Tube Replacement Procedure
24 Desooting Procedure
24 Combustion Chamber Removal
25 Immersion Well Removal
25 Unitherm Governor Removal

26 SECTION 5 / TROUBLESHOOTING GUIDE

26 Mechanical
27 Electrical MV Units
28 Electrical IID Units

29 SECTION 6 / REPLACEMENT PARTS

3

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. #9258

4

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

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

instructions exactly.

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

B. BEFORE LIGHTING smell all around the 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.

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 right side panel 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.

5

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. Turn gas control knob clockwise to "Off".

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

8. Turn gas control knob counter-clockwise
to "On".

9. Replace heater door panel.

10. Turn on all electrical power to appliance.

11. Set thermostat to desired setting.

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

*If you cannot reach your gas supplier, call the
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
INLET

HONEYWELL VR8300 GAS VALVE IID

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

2. Turn off all the electric power to the appliance if

service is to be performed.

3. Remove heater door panel.

4. Turn gas control knob clockwise to "Off".
Make sure knob rest against stop.

5. Replace heater door panel.

6

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 supply
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. # 8144.1

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.

Fig. # 8958

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 circu-
lation 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.

7

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
corrosive chemical fumes which can damage the
heater.

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

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 amy have lost it's prime. It may be

running dry, check the pressure gauge on the
filter. If there is
moving water (or your gauge is broken). Try to
get the pump to run at it's normal flow rate.

no pressure; then you are not

POOL & SPA WATER CHEMISTRY

Chemical imbalance can cause severe damage to

your heater and associated equipment. Maintain your
water chemistry according to the chart on page 2. 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
severly 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 continue

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

CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze protec­tion. When 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
electrical supply to the heater.

2. Open drain cock located on the inlet/outlet
header, (under water pipes)

IN/OUT

HEADER

Fig. # 9272

DRAIN VALVE

8

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.

The manufacturer recommends that this manual be
reviewed thoroughly before installing your pool/spa
heater. If there are any questions that this manual does
not answer, please contact the factory or your local

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 Satndard 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.

SECTION 3
INSTALLATION INSTRUCTIONS

CALIFORNIA PROPOSITION 65

WARNING:

This product contains chemicals known to the

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

IMPORTANT NOTICE

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

WARNING: Improper installation, adjustment, altera­tion, service or maintenance may damage the equip­ment, create a hazard resulting in asphyxiation, explo­sion or fire, and will void the warranty.

CODE REQUIREMENTS

NOTE: The heater should not be located in an area

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

Installation must be in accordance with local codes,
or, in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70.

BASE INSTALLATION

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

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

9

CLEARANCES

ALL HEATERS

For clearances from combustible surfaces, see

chart below.

Clearances from Combustible construction.
Indoor Installation:

Top* (Drafthood) - 30"; Vent - 6";
Back - 5"; Right Side - 6";
Left Side - 6"; Floor - 0.

Outdoor Installation:

Top* (Stackless Top) ­unobstructed; Back - 5"; Sides - 6".

* Clearance from Top of Vent Terminal

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
exchanger.

OUTDOOR HEATERS

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

WARNING: The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet louvers and into the
heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.

Heater with outdoor top Fig # 9259

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:

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.

4

foot

Minimum

4

foot

Minimum

4

foot

Minimum

3

foot

Minimum

1

10

foot

Minimum

foot

Minimum

Forced Air Inlet

10