Raypak VERSA 155C User Manual

INSTALLATION
AND OPERATING
INSTRUCTIONS

VERSA

SWIMMING POOL
and
SPA HEATER

Model

CATALOG NO. 6000.50R
Effective: 04-01-04
Replaces: 06-01-03

155C

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. 240472

CONTENTS

3 PART ONE - Owner's Operating Instructions

3 SECTION 1 / START-UP PROCEDURES

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

(Manually Lighted Pilot MV)

5 Operating Instructions & Shut-Off Procedures

(Automatically Lighted Pilots IID)

6 After Start-Up

6 SECTION 2 / CAUTION

7 SECTION 3 / MAINTENANCE & CARE PROCEDURES

7 Pool & Spa Water Chemistry
8 Cold Weather Operation
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

7 Code Requirements
9 Base Installation
10 Clearances
12 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
22 Pressure Switch
22 High Limit Removal
22 Flame Roll-Out Safety Switch
23 Pilot Safety (MV Units)
23 Pilot Safety (IID Units)
23 Gas Valve Removal
23 Main Burner & Orifice Removal
23 Pilot Removal & Cleaning
24 Heat Exchanger Removal
24 Control Immersion Well Replacement
24 Tube Cleaning Procedure (Typical)
25 Tube Replacement Procedure
25 Desooting Procedure
25 Combustion Chamber Removal

26 SECTION 5 / TROUBLESHOOTING GUIDE

26 Mechanical
28 Electrical IID Units

30 SECTION 6 / REPLACEMENT PARTS

2

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

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

Fig. # 8111.0

3

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

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.

*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 qualified service technician. Force or
attempted repair may result in a fire or explosion.

WHAT TO DO IF YOU SMELL GAS:

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

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat on the lowest setting.

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

4. Remove heater door panel.

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

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

unless knob is pushed in slightly. Do not
force.

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

7. Locate pilot mounted on the right side panel
of the burner drawer. For burner drawer
location, see location of control section,
page 22.

GAS CONTROL KNOBS SHOWN IN "OFF"
POSITION.

Honeywell Gas Valve

Millivolt

Fig. #8081.0 Fig. #8079.0

Robertshaw Gas Valve

Millivolt

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

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 underwater.

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 it
in. Immediately place flame to end of pilot
tube to light pilot. 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.

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.

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 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.

WHAT TO DO IF YOU SMELL GAS:

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

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.

5. Remove heater door panel.

6. For Honeywell valve: 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.
For Robertshaw valve: Push in and move
gas control lever counter-clockwise
to "OFF" position.

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

8. Turn gas control knob counter-clockwise

to "On" (Honeywell).
Move gas control lever clockwise
to "ON" position (Robertshaw).

9. Replace heater door panel.

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

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

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

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

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

GAS CONTROL KNOBS
SHOWN IN "ON" POSITION

Honeywell
Gas Valve
IID

Fig. # 8082.0

GAS CONTROL
LEVER SHOWN
IN "OFF" POSI­TION

GAS INLET

Robertshaw
Gas Valve
IID

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.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.

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

3. Remove heater door panel.

4. For Honeywell valve: Push in gas control

knob slightly and turn clockwise to
"Off".
For Robertshaw valve: Push in and move
gas control lever counter-clockwise
to "OFF" postion.

5. Replace heater door panel.

5

AFTER START-UP

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

WARNING: Should overheating occur or the gas
supply fail to shut 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.

MAIN BURNER FLAME

Pressure
Switch
Location

Fig. # 8110.1

SECTION 2 / CAUTION

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

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

Fig. # 8964

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.

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

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

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

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

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

6

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 and "V" baffles), 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 a 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.

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.

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.

AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the
heater and void the warranty.

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

BASIC TIPS IF HEATER WILL NOT FIRE:

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.

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 concentrates 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.

7

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.

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 .

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

WINTERIZING THE POOL & 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 inlet/outlet header,

(under water pipes). Tilt heater to completely

drain all the water from the heat exchanger.

PRESSURE SWITCH
COMPRESSION FITTING

RETURN HEADER

Fig. # 8955

8

m

M

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 the heater. When ordering under
warranty conditions, you must also specify date of
installation.

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

SECTION 2 / GENERAL
SPECIFICATIONS

These heaters are design certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American

National Standard/CSA Standard for gas fired pool
heaters.

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

SECTION 3 / INSTALLATION
INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING: This product

contains chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.

IMPORTANT NOTICE

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

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

CODE REQUIREMENTS

NOTE: The heater should not be located in an area

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

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

BASE INSTALLATION

Millivolt Heater with Honeywell Gas Valve

+32°F to +175°F

Millivolt Heater with Robertshaw Gas Valve

0°F to +175°F

Electronic Ignition Heater *

-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

Heater must be mounted on a level base, such as
cement slab, cement blocks or another non-combustible
surface. An optional non-combustible base is available
for all models. An alternate method for providing a base
for combustible floors is illustrated. Heaters may not be
installed on carpeting.

ALTERNATE METHOD FOR PROVIDING A NON-COMBUSTIBLE BASE

12"

12"

inimum

HEATER

Minimu

combustion performance.

Fig. # 8148.1

4"

Minimum

Sheet Metal

24 Gauge

Hollow concrete cinder block,
align holes and leave ends open.

9

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 the following chart.

CLEARANCES FROM COMBUSTIBLE CONSTRUCTION

INDOOR INSTALLATION OUTDOOR INSTALLATION

Top*(Drafthood) - 42" Right Side - 6" Top *(Stackless Top or Outdoor Stack) - Unobstructed
Vent - 6" Left Side - 12" Back - 12"
Back-12" Front - Alcove 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 back 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 tops designated

for outdoor use.

HEATER WITH OUTDOOR
STACKLESS TOP

Fig# 8116

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

10

Heaters must not be installed under an overhang of less than three (3) feet from the top of 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

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.

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 illustration below.

The outdoor stack serves the same function as the
low profile stackless top and should be installed in
accordance with the same clearance requirements.

Fig. # 8245.1

11

Fig. # 9304