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INSTALLATION & OPERATING

INSTRUCTIONS

Gas-Fired Pool & Spa Heater

Atmospheric Models

206A, 266A, 336A & 406A

WARNING: If 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.

207A, 267A, 337A & 407A

Lo NOx Models

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

Catalog No. 6000.59X Effective: 08-25-11 Replaces: 04-26-11 P/N 241236 Rev. 25

WATER CHEMISTRY

(Corrosive water voids all warranties)

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

Recommended Level(s) Fiberglass Pools Fiberglass Spas

Other Pool & Spa

Types

Water Temp. (Deg. F) 68 to 88 89 to 104 68 to 104

pH 7.3 to 7.4 7.3 to 7.4 7.6 to 7.8

Total Alkalinity (PPM) 120 to 150 120 to 150 80 to 120

Calcium Hardness (PPM) 200 to 300 150 to 200 200 to 400

Salt (PPM) 4500 MAXIMUM 4500 MAXIMUM 4500 MAXIMUM

Free Chlorine (PPM)* 2 to 3 2 to 3 2 to 3

Total Dissolved Solids (PPM) 3000 MAXIMUM** 3000 MAXIMUM** 3000 MAXIMUM**

* Free Chlorine MUST NOT EXCEED 5 PPM!

** In salt water chlorinated pools, the total TDS can be as high as 6000 ppm.

• Occasional chemical shock dosing of the pool or spa water should not damage the

heater providing the water is balanced.

• Automatic chemical dosing devices and salt chlorinators are usually more efficient

in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater, and which is not covered under warranty. A check valve should be installed between the heater outlet and a chlorinator or other chemical dosing device.

• Further advice should be obtained from your pool or spa builder, accredited pool

shop, or chemical supplier for the correct levels for your water.

Rev. 25 reflects the following: Changes to: Water chemistry instructions on page 2, Automatic Chlorinator instructions on page 8, Hurricane Tie-Down

instructions on pages 13 and 14, Minimum Net Free Area table on page 18, Supply Pressures on pages 19-20, Illustrated Parts List on pages 48-55.

Additions: Control Lockout instructions on page 34. Deletions: None

CONTENTS

4 PART ONE

OWNER'S OPERATING INSTRUCTIONS

4 SECTION 1

START-UP PROCEDURES

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

Manually Lighted Pilots MV

7 After Start-Up

7 SECTION 2

8 SECTION 3

8 Pool & Spa Water Chemistry 8 Automatic Chlorinators & Chemical Feeders 9 Cold Weather Operation 9 Winterizing the Pool & Spa Heater

10 PART TWO

10 SECTION 1

11 SECTION 2

11 SECTION 3

11 Code Requirements 12 Clearances 12 Outdoor Heater Installation 14 Florida and Texas Building Codes 15 Indoor Heater Installation 15 Outdoor Stack/Indoor Stack 16 Atmospheric Specifications and Dimensions 17 Lo NOx Specifications and Dimensions 18 Combustion and Ventilation Air 18 Vent Piping 19 Gas Supply Connections 20 Gas Pressure Regulator 20 Gas Pressure Adjustment Locations 20 Pipe Sizing For Gas Connections 21 Flow Rates 21 Heat Exchanger Pressure Drop Tables 22 Polymer Headers 22 Cast Iron Headers 22 Unitherm Governor Operation 23 Internal Automatic Bypass Valve 23 External Auxiliary Bypass Valve 23 Auxiliary Bypass Valve Adjustment 23 Pressure Relief Valve Installation 24 Plumbing—Water Connections 25 Heat Exchanger Reversal Procedure 26 Electrical Wiring 26 Millivolt Models 26 Advanced Flame Technology (AFT) Models 27 Transformer Wiring 28 Wiring Diagram - Millivolt (Mechanical Therm.) 29 Wiring Diagram - AFT Models, Atmospheric

Operating Instruction & Shut-Off Procedures Automatically Lighted Pilots IID

CAUTION

MAINTENANCE & CARE PROCEDURES

INSTALLATION & SERVICE INSTRUCTIONS

RECEIVING EQUIPMENT

GENERAL SPECIFICATIONS

INSTALLATION INSTRUCTIONS

30 Wiring Diagram - AFT Models, Lo NOx

31 SECTION 4

SERVICING INSTRUCTIONS

31 General Location of Controls 32 Control Panel Removal 32 Control Adjustments - AFT Models 32 Control Adjustments - Millivolt Models 33 Thermostat Operation - AFT Board

5 Status and Diagnostics

3 36 Remote Control Installation and Operation 36 Remote Operation 36 Activating the Remote 37 Remote Control Wiring 37 2-Wire Remote Control 37 3-Wire Remote Control 38 Time Clock / Fireman’s Switch 38 Water Pressure Switch 38 Flame Roll-Out Safety Switch 38 High Limits 39 Pilot Safety 39 Burner Tray Removal (ATM) 39 Gas Valve Removal (ATM) 39 Main Burner and Orifice Removal (ATM) 39 Pilot Removal and Cleaning 40 Heat Exchanger Removal 40 Tube Cleaning Procedure 40 Desooting Procedure 40 Combustion Chamber Removal 40 Immersion Well Replacement 41 Unitherm Governor (U.G.) Replacement 41 Lo NOx Pool Heaters 41 Operation 41 Start-Up Procedures 41 Visual Inspection 41 Electrical 41 Flame Roll-Out Safety Switch 42 Burner Tray Removal 42 Gas Valve Removal 42 Main Burner and Orifice Removal 42 Pilot Removal 42 Combustion Blower Removal

43 SECTION 5

TROUBLESHOOTING

43 Mechanical 44 Electrical - Standing Pilot Millivolt 45 Electrical - Electronic Ignition (IID) 46 Control Logic - Flow Chart

47 SECTION 6

REPLACEMENT PARTS

48 Illustrated Parts List 51 Part Numbers

PART ONE OWNER'S OPERATING INSTRUCTIONS

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

SECTION 1 - START-UP PROCEDURES

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

OFF

If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater contains the control center that allows you to turn the heater On or Off and adjust the temperature settings for the pool or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). See figure above for location of toggle switch to turn the heater On and Off. Section 4 of this manual contains more details about the use of the controls in the Control Adjustments subsection (page 32).

BEFORE START-UP

BURNERS

Clean main burners, combustion fan (if equipped) 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 ventilation air.

WATER

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

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

MILLIVOLT SYSTEM

MANUALLY LIGHTED PILOT)

(

If you cannot reach your gas supplier, call the

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

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 tray.

HONEYWELL MILLIVOLT GAS VALVE

INVENSYS/ ROBERTSHAW MILLIVOLT GAS VALVE

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.

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.

HONEYWELL PILOT

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

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

control knob all the way and hold to light pilot. Continue to hold control knob in for about one minute after the pilot is lighted, release knob and it will pop back up. Pilot should remain lighted. If it goes out, repeat steps 5 through 9. If knob does not pop up when released, stop and immediately call your service technician or gas supplier.

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

gas control knob counter-clockwise

to "On".

11. Replace heater door panel.

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

13. Set thermostat to the desired setting.

ROBERTSHAW PILOT

1. Set the thermostat to the lowest setting.

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

3. Remove heater door panel.

SHUT-OFF PROCEDURE

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

ELECTRONIC IGNITION SYSTEM

(AUTOMATICALLY LIGHTED PILOT)

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do

*If you cannot reach your gas supplier, call the

fire department.

not try to light the pilot by hand.

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

B. BEFORE OPERATING, smell all around the

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

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

explosion. WHAT TO DO IF YOU SMELL GAS: *Do not try to light any appliance. *Do not touch any electric switch; do not use

any phone in your building.

*Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

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

under water. Immediately call a qualified

service technician to inspect the appliance and

to replace any part of the control system and

any gas control which has been under water.

instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

HONEYWELL VR 8300 GAS VALVE IID

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

GAS

INLET

5. Remove heater door panel.

6. For Honeywell valve: Turn gas control knob clockwise to "Off".

For Robertshaw valve: Models 266-406:

Turn gas control knob clockwise to "Off". Model 206: Push in and move gas con-

ROBERTSHAW 7000 GAS VALVE IID

trol 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 safe-

ty information above. If you don't smell gas, go to the next step.

8. Turn gas control knob counter-clockwise

to "On". (Honeywell VR 8300 and

Robertshaw 7000)

9. Replace heater door panel.

ROBERTSHAW 7200 GAS CONTROL LEVER SHOWN IN “OFF” POSITION

10. Turn on all electrical power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

GAS INLET

instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

SHUT-OFF PROCEDURES

1. Set the thermostat at the lowest setting.

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

3. Remove heater door panel.

4. For Honeywell VR 8300 and Robertshaw

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

For Robertshaw 7200 gas valve.

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

5. Replace heater door panel.

7000 gas valve.

Turn gas control knob clockwise

FTER 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 to the heater.

VISUAL INSPECTION - ATMOSPHERIC HEATERS

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

MAIN BURNER FLAME

MILLIVOLT 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 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 serv- ice person at the time of installation and periodically checked thereafter. Refer to Pressure Switch Adjustment on pg. 38 of this manual).

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

SECTION 2 - CAUTION

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

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

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.

SECTION 3 - MAINTENANCE AND CARE PROCEDURES

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

WARNING: Check the heater for possible rodent nests after long periods of non-use.

To be followed one month after start-up and then semiannually.

1. Inspect top of heater and drafthood for soot, a sticky black substance around finned tubes and "V" baffles, and open flue gas passageways. Any visible soot should be cleaned for proper operation.

CAUTION: Soot may be combustible. Wet sooted surfaces completely prior to cleaning. Do not use steel wire brush.

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

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

4. Make visual check of the burner and pilot flames. Flame pattern on the main burner and pilot is illustrated on page 7. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supplier or qualified service agency.

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

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

4. The pump may have lost its prime and be running dry. Check the pressure on the filter. If there is no pressure; then you are not moving water (or your gauge is broken). Try to get the pump to run at its normal flow rate.

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 damaging the heater. If the pH drops below 7.2, this will cause corrosion of the heat exchanger and severely damage the heater. Heat exchanger damage resulting from

chemical imbalance is not covered by the warranty.

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

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical back-up into the heater when the pump is shut off. A check valve should be installed between the heater outlet and the chlorinator.

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

IF HEATER WILL NOT FIRE:

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

If you have electrical power but the heater will not fire check the following or see Troubleshooting section:

1. The time clock must be in the "ON" position.

See plumbing diagrams on page 24.

NOTE: High chemical concentrates from feeders and

chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not

covered under the warranty.

LO NOx BURNERS

The Lo NOx burners and orifice areas should be inspected annually. Dirt and debris can affect the operation of the heater and could damage the burners or prevent the heater from firing. DO NOT clean the burners with a wire brush.

COLD WEATHER OPERATION

WINTERIZING THE POOL & SPA HEATER

IMPORTANT FREEZE INFORMATION

MODERATE CLIMATE: Heater operation can contin-

e during short-term cold spells. When temperatures

u are between 0° and 32°F, flow (continuous pump operation) must be maintained.

CAUTION: Do not use the heater to maintain water temperatures just above freezing or for freeze protection. When heater is used during freezing weather, care must be taken to avoid freeze-ups. Continuous pump operation is a must. Additional protection may be required. The heater is not warranted against freeze-ups.

COLD CLIMATE: Prolonged operation with water temperatures below 50°F is not recommended. When starting the heater with water temperatures below 50°F, operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F can seriously damage the heater, and is not covered by the warranty.

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

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

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

. Open drain plug located on the inlet/outlet header,

(under water pipes). Remove the heat exchanger inspection panel on the side opposite water piping to gain access to the drain plug on the return header. Open drain plug on return header.

Return Header

Drain Plug

3. For ASME Heaters only: Disconnect compression

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

PART TWO INSTALLATION AND SERVICE INSTRUCTIONS

SECTION 1 - RECEIVING EQUIPMENT

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

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

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

1. "Pagoda" top 1. "Pagoda" top

2. 2" CPVC union with "O" rings (2) 2. In/Out flanges (2)

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

4. Bonding lug with mounting screw 4. 2" flange gaskets (2) (AFT models only) 5. Flange bolts (4)

6. Pressure relief valve

7. 2" CPVC adapters (2)

8. Plastic pipe finish flange for gas line.

9. Bonding lug with mounting screw. (AFT models only)

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

When ordering parts, you must specify the model and serial numbers of the heater. See below for location of serial number. When ordering under warranty conditions, you must also specify date of installation.

The Model & Serial No. can also be found inside

the bezel above the display

Model & Serial No. Located on Rating Plate

(Alternate Location)

LABEL ON CARTON

Serial No.

SECTION 2 - GENERAL SPECIFICATIONS

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

tandard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors. The appropriate top

S designated for each type of use is required. If necessary, 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 VAC.

Ambient Temperature Rating of Heater Components

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

M Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F Electronic Ignition Heater* -32°F to + 175°F *Requires 120 or 240VAC Power Supply

Atmospheric heaters:

Rated inputs are suitable for up to 2,000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1,000 feet above sea level, as high elevation reduces combustion performance.

Lo NOx heaters:

Rated inputs are suitable for up to 5,000 feet elevation. For elevations above 5000 feet, consult the factory.

SECTION 3 - INSTALLATION INSTRUCTIONS

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

to cause cancer, birth defects or other reproductive harm.

WARNING: This unit contains refractory ceramic fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high temperatures (>2192F), the RCF can transform into crystalline silica (cristabolite). The International Agency for Research on Cancer (IARC) has classified the inhalation of crystalline silica (cristabolite) as carcinogenic to humans.

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

IMPORTANT NOTICE These instructions are intended only for the use by qualified personnel, specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation

and service personnel may be required by some states to be licensed. If your state is such, be sure your contractor bears the appropriate license. Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these instructions.

WARNING: Improper installation, adjustment, alteration, service or maintenance may damage the equip-

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

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 heater or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict combustion air flow.

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/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1 Part 1 and Part 2.

CLEARANCES

ALL HEATERS

or clearances from combustible surfaces, see the

F chart below.

CLEARANCE FROM

OMBUSTIBLE CONSTRUCTION

hen installed according to the listed minimum clear-

W ances from combustible construction, the pool heater can still be serviced without removing permanent construction around the heater.

INDOOR INSTALLATIONS:

Top* - 30” (Drafthood) Back - 6” Front - Alcove (Open) Right Side - 12” (Water Side) Vent - 6” Left Side - 6” Floor** - 0” (Opposite Water Side)

OUTDOOR INSTALLATION:

Top* - Unobstructed (Outdoor Stack) Top*** - 36” (Stackless Top) Floor - 0” Right Side - 12” (Water Side) Back - 6” Left Side - 6”

(Opposite Water Side)

*Clearance from top of vent terminal. **Do not install on carpeting.

However for ease of servicing, we recommend a clearance of at least 24” in the front, and at least 18" on the water connection side. This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater.

Clearances less than these (6” minimum), may require removal of the heater to service either the heat exchanger or the burner tray. In either case, the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater.

FLOORING: This heater can be installed on combustible flooring.

***Clearance from top of heater.

OUTDOOR HEATER INSTALLATION

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

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

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

HEATER WITH OUTDOOR STACKLESS TOP

Pagoda Top

Pagoda Top Installation

1. Insert tabs into keyhole (4 places).

Pagoda Top (Shipped inside

box in heater carton)

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

Heaters must not be installed under an overhang of less than three 3 ft from the top of the heater. Three sides

4 ft

Minimum

4 ft

Minimum

1 ft

Minimum

4 ft

Minimum

3 ft

Minimum

10 ft

Minimum

Forced Air Inlet

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 4 ft below, 4 ft horizontally from, or 1 ft above any door, window or gravity inlet into any building. The top surface of the heater shall be at least 3 ft above any forced air inlet, or intake ducts located within 10 ft horizontally.

or installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 ft

below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA-B149.

For installations in Florida and Texas, that must comply with the Florida or Texas Building Code, follow the directions on page 14 for the installation of hurricane tie-down brackets for all models.

T O

28”

40”

3” Min. Conc. Pad by others

Min. Edge Distance

(1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) Ea. Pallet Anchor Bracket Use hole closest to unit (4 total)

2” x 6” x 1/8” Pallet Anchor Bracket (4 Total) (Kit# 011636)

1/4” x 1-3/4” S.S. Tapcon Bolt & Washer (Field Supplied) NOTE: Use hole closest to unit with washer overlapping edge of unit.

6”

MODEL # B

206 20”

266 23”

336 26”

FLORIDA AND TEXAS BUILDING CODES

WIND SPEED = 150 MPH, 3 SECOND GUST

EXPOSURE = C

206/266/336/406 Atmospheric

9”

INDOOR HEATER INSTALLATION

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

For Canada, indoor installation is restricted to an enclosure that is not occupied and does not directly commu-

icate with an occupied area. Refer to the latest edition of CAN/CSA-B149 for specific requirements. Locate

n heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside. See Vent Piping section (pg. 18-19) for details. Minimum allowable space is shown on the nameplate.

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

OUTDOOR STACK / INDOOR STACK

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

OUTDOOR STACK KIT INCLUDES:

(1) Drafthood, painted

(1) Adapter plate

(3) Mounting brackets (clips)

(1) Top panel cover

(2) 1-foot sections of metal tape

(3) Screws

(1) Instructions

OUTDOOR

STACK

Clips

INDOOR STACK

Model Part No. Part No.

206A/207A

266A/267A

336A/337A

406A/407A

009834 009835 009836 009837

009838 009839 009840 009841

INDOOR STACK KIT INCLUDES:

(1) Drafthood, unpainted (1) Adapter plate (3) Mounting brackets (clips) (3) Screws (1) Instructions

Clips

** REFER TO INSTALLATION INSTRUCTIONS

INSIDE BOX FOR INSTRUCTIONS ON HOW TO INSTALL OUTDOOR/INDOOR STACK.

SPECIFICATIONS AND DIMENSIONS

INDOOR

DRAFTHOOD

38"

13-1/4"

GAS

CONNECTION

26-5/8"

(

28-5/8" ASME)

32-11/16"

LECTRICAL

CONNECTION

40"

TAC KLESS

OUTDOOR TOP

28"

4-3/8"

(3-3/8" ASME)

8-7/8"

(6-5/8" ASME)

FLUE

ATMOSPHERIC UNITS

Amp Draw

20 Volt240 Volt

AFT 4 2

(D)

(J)

Min. Gas

Conn.

Water Conn.

Heater Model

BTUH

Input (000)

(A)

Cabinet

Width

(B)

Flue

Dia.

(C)

Indoor

Drafthood

R206A 199.5 20” 6” 61-5/8” 10.0” 11-3/4” 3/4” 2” 187 206 14

Shipping Weights (lbs)

Standard

Heater

w/Stackless

Top

w/Stackless

ASME

Heater

Top

Indoor

Draft-

hood

R266A 266.0 23” 7” 62” 11.5” 11” 3/4” 2” 210 229 16

R336A 332.5 26” 8” 63” 13.0” 10-5/8” 3/4” 2” 230 249 19

R406A 399.0 29” 9” 64-9/16” 14.5” 12-1/8” 3/4” 2” 249 268 21

Designation for an AFT heater using propane gas is “EP”; an AFT heater using natural gas is “EN”. Designation for a Millivolt heater using propane gas is “MP”; a Millivolt heater using natural gas is “MN”. Prefix “C” is for cast iron (ASME) headers; “P” is for plastic (polymer) headers. Suffix “X” is for cupro-nickel tubing; “C” is for copper tubing. EXAMPLE: P-R406A-EN-X = Plastic headers, 406 model size, AFT, natural gas, cupro-nickel. Reduce input 4% for each 1000 ft above sea level when installed above 2000 ft elevation. For Canada, no de-rating is required for elevations up to 4500 ft Plastic (polymer) headers cannot be used for ASME installations. *Note: For outdoor stack, use J dimension in the table above for appropriate size PLUS six (6) inches.

NDOOR

DRAFTHOOD

31-13/16"

7-3/4"

CONNECTION

20-1/2"

(

22-1/2" ASME)

34”

STAC KLE SS

OUTDOOR

TOP

28”

26-1/2”

ELECTRICAL CONNECTION

-3/8”

(

3-3/8 ” ASM E)

8-7/8”

(6-5/8” ASME)

FLUE

SPECIFICATIONS AND DIMENSIONS

O NOx UNITS

Amp Draw

120 Volt 240 Volt

6 3

Heater

Model

BTUH

Input (000)

(A)

Cabinet

Width

(B)

Flue

Dia.

(C)

Indoor

Drafthood

R207A 199.5 20” 6” 55-5/8” 10.0” 11-3/4” 3/4” 2” 174 193 14

R267A 266.0 23” 7” 56” 11.5” 11” 3/4” 2” 197 216 16

(D)

(J)

Min. Gas

Conn.

Water Conn.

w/Stackless

R337A 332.5 26” 8” 57” 13.0” 10-5/8” 3/4” 2” 219 238 19

R407A 399.0 29” 9” 58-1/2” 14.5” 12-1/8” 3/4” 2” 237 256 21

Designation for an AFT heater using natural gas is “EN”. Prefix “C” is for cast iron (ASME) headers; “P” is for plastic (polymer) headers. Suffix “X” is for cupro-nickel tubing; “C” is for copper tubing. EXAMPLE: P-R407A-EN-X = Plastic headers, 407 model size, AFT, natural gas, cupro-nickel. For altitudes above 5,000 ft., consult the factory. For Canada, no de-rating is required for elevations up to 4500 ft. Plastic (polymer) headers cannot be used for ASME installations. *Note: For outdoor stack, use J dimension in the table above for appropriate size PLUS six (6) inches.

Shipping Weights (lbs)

Standard

Heater

ASME

Heater

w/Stackless

Top

Indoor

Draft-

hood

COMBUSTION AND VENTILATION AIR (Indoor Units Only)

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

A. All Air From Inside The Building:

Each opening shall have a minimum net free area as noted:

Model Square Inches Model Square Inches

206/207 200 336/337 333

266/267 266 406/407 399

B. All Air From Outdoors:

When air is supplied directly from outside the building, each opening shall have a minimum net free area as noted:

Model

Unrestricted Opening (sq. in.)

Typical Screened or

Louvered Opening (sq. in.)

Typical Screened and

Louvered Opening (sq. in.)

206/207 50 75 100

266/267 67 101 134

336/337 84 126 168

406/407 100 150 200

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

VENT PIPING

WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to

the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.

Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter

10 of the National Fuel Gas Code, ANSI Z223.1 (Canada - CAN/CSA-B149). As much as possible, avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal runs, the vent pipe must have a minimum of 1/4 in. per ft rise and should be supported at not more than five foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of insulated vent pipe spacers through the roofs and walls. Another option for installation that requires horizontal runs is using the D-2 power vent kit option.

Power Vent Kit

Model

120 VAC

Part No.

240 VAC

Part No.

206/207 010744 009832

266/267 010744 009832

The D-2 Power Vent operates with a positve vent static pressure and with a vent gas temperature that prevents excessive condensate production in the vent, and as such, is a CATEGORY III appliance.

336/337 010745 009833

406/407 010745 009833

Optional Raypak D-2

Power Vent

For more information consult the D-2 Power Vent manual, (Catalog No. 6000.57.1).

The power vent assembly is a fan-assisted combustion system designed for application to models 206-407. The unit, when installed as directed, is capable of operating in applications such as through-the-wall venting and reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factory-wired for 240 VAC, with capability of rewiring for 120 VAC.

For protection against rain or blockage by snow, the

5' MIN

2' MIN

10' OR LESS

2' MIN

VENT CAP

VENT PIPE

DRAFT HOOD

HEATER

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 (Canada - CAN/CSA-B149).

The discharge opening must be a minimum of 2 ft vertically from the roof surface and at least 2 ft higher than

ny part of the building within 10 ft. Vent stack shall be

a at least 5 ft in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 ft horizontally from, and in no case below, unless a 4 ft horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

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

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

B149).

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.

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 psi (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 PRESSURIZED 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: With venting application of two or more heaters, contact the factory.

NOTE: Do not use Teflon tape on gas line pipe thread. A pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

SUPPLY PRESSURES

A minimum of 6 in. WC for atmospheric units (5 in. WC for Lo NOx units), and a maximum of 14 in. WC upstream pressure under load and no-load conditions must be provided for natural gas. A minimum of 12 in. WC and a maximum of 14 in. WC are required for propane gas under load and no-load conditions.

GAS PRESSURE REGULATOR

MANUAL

SHUT-OFF

VALVE

UNION

MANOMETER

GAS PRESSURE TEST AT GAS VALV E

The gas pressure regulator is preset at 4.0 in. WC for natural gas (3.1 in. WC for Lo NOx), and 10.5 in. WC. for propane gas. The pressure at the gas valve, taken with a manometer, should be about 4.0 in. WC natural gas (3.1 in. WC for Lo NOx) and 10.5 in. WC propane gas. If an adjustment is needed, remove seal and turn adjustment screw clockwise to increase pres-

ure or counter-clockwise to decrease pressure.

NOTE: Lo NOx gas valves are non-adjustable; settings are fixed by the manufacturer (Invensys/Robertshaw).

ELECTRONIC IGNITION GAS VALVES-CONTINUED

Gas Pressure

Adjustment

Robertshaw 7200

(Heater Model 206)

Robertshaw 7000 BDER (Heater Models 266-336)

Gas Pressure

Adjustment

Robertshaw 7000 DERHC

(Heater Model 406)

GAS PRESSURE ADJUSTMENT LOCATIONS

MILLIVOLT GAS VALVES

Gas Pressure Adjustment

Robertshaw 7000 (Heater Models 206-406)

ELECTRONIC IGNITION GAS VALVES

Gas Pressure

Adjustment

Non-Adjustable

Gas Valve

Robertshaw 7000 BDERF

(Heater Models 207-407)

PIPE SIZING FOR GAS CONNECTIONS

Maximum Equivalent Pipe Length (ft)

Natural Gas 1000 BTU/FT30.60

Specific Gravity @ 0.5 in. WC Pressure Drop

Propane Gas 2500 BTU/FT31.53

Specific Gravity @ 0.5 in. WC Pressure Drop

Input 3/4” 1” 1-1/4” 1-1/2”

Model (KBTU) N P N P N P N P

206/207 199.5 25 60 90 215 360

266/267 266.0 15 35 50 125 210 480 445

336/337 332.5 10 20 30 80 140 320 290

Honeywell VR8304 (Heater Models 206406 and 207-407)

406/407 399.0 * 15 20 55 95 225 215 480

*A 3/4” gas line can be used for up to 5 ft maximum length from the gas valve in addition to the sediment trap.

FLOW RATES

MODEL PIPE SIZE MIN. GPM MAX. GPM*

206/207 1-1/4”–1-1/2” - 2” 20 125

66/267

2 336/337 1-1/4”–1-1/2” - 2” 35 125

06/407

-1/4”–1-1/2” - 2”

POLYMER HEADERS CAST IRON HEADERS (ASME)

HEAT EXCHANGER PRESSURE DROP TABLES

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

POLYMER HEADER (STANDARD MODELS)

PLASTIC INTERNAL BAFFLE

(Manufactured after 11/08)

FLOW

GPM

20 4.0

25 4.0 4.6

30 4.0 5.2

35 4.0 5.8 5.2

40 4.6 5.8 5.2 5.2

50 4.6 6.3 6.9 6.9

60 4.6 6.9 6.9 6.9

70 4.6 8.1 9.2 9.2

80 4.6 9.2 9.8 9.8

90 6.9 10.4 10.4 10.4

100 8.1 11.0 12.1 12.1

110 10.4 11.5 13.3 13.3

120 11.0 12.7 17.9 17.9

125 11.5 13.8 20.2 20.2

PRESSURE DROP (FT OF HEAD)

206/207 266/267 336/337 406/407

CAST IRON HEADER (ASME MODELS)

FLOW

GPM

20 1.8

30 2.2 8.0

40 2.5 9.0 9.0 9.0

50 2.7 9.8 9.8 9.8

60 3.3 10.5 10.5 10.5

70 4.3 11.0 11.0 11.0

80 5.5 11.5 11.5 11.5

90 6.8 14.0 14.0 14.0

100 8.2 17.0 17.0 17.0

PRESSURE DROP (FT OF HEAD)

206/207 266/267 336/337 406/407

POLYMER HEADERS (STANDARD MODELS)

efore attaching the 2-inch unions to the inlet/outlet

B header, make sure the O-rings are properly seated in the grooves. Use AquaLube or equivalent non-petroleum-based lubricant on the O-ring. Hand tighten the

nions. Glue PVC piping directly to the unions.

INLET/OUTLET HEADER - POLYMER

O-Ring

Header Flange (CPVC)

Header Flange Nut (CPVC)

required, use a silicon base such as AquaLube etc.

There are two sets of flange gaskets supplied with your heater. Use the appropriate gaskets for all your heater connections. Discard unused set.

GASKET DESIGN #1: Accepts 1-1/2" copper tube or

-1/4" galvanized pipe as a slip connection.

1 GASKET DESIGN #2: Accepts 2" copper tube as a slip connection. The flange is threaded for 2" screw in pipe connections. Also used with the 2" CPVC adapters.

#1 #2

INLET/OUTLET HEADER - ASME

High-temperature CPVC header flanges and header flange nuts are provided. If there is any possibility of back-siphoning when the pump stops, it is suggested that a check valve (or valves) also be installed in the system.

CAST IRON HEADERS (ASME MODELS)

Heater must be located so that any water leaks will not damage the structure of adjacent area. High temperature 2" plastic pipe (CPVC) may be threaded directly into the header flanges. This is not the same as the Schedule 80 PVC pipe which is also gray. PVC may be used immediately after the supplied CPVC adapters.

Header

Header Flange

(Supplied)

CPVC Connector

(Supplied)

Plumbing

Flange Gasket

Header Flange

UNITHERM GOVERNOR OPERATION

CAUTION:

The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105° and 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.

WARNING: NEVER install PVC directly into header flanges. Use the 2" CPVC adapter supplied loose with the heater.

NOTE: The State of Texas requires the addition of a flow switch and T&P gauge on ASME installations. Kit # 012011 can be ordered that will allow a standard ASME unit to comply with the Texas code requirements.

DO NOT use petroleum-based assembly fluids (such as petroleum jelly or lubricating oil). If assembly lube is

U.G. Plug (Polymer)

Unitherm Governor

Gasket

INTERNAL AUTOMATIC BYPASS VALVE

PRESSURE RELIEF VALVE INSTALLATION

In addition to the Unitherm Governor, a built-in automatic bypass valve is provided in the in/out header. While the Unitherm Governor responds to the changes in water temperature in the heater, the internal bypass valve automatically responds to changes in water pressure in the piping system. Proper amount of water flow

s maintained through the heater under varying pres-

i sures dictated by the conditions of the pump and filter.

Bypass Disc

Spring

Bypass Body

EXTERNAL AUXILIARY BYPASS VALVE

(Where Required) An auxiliary bypass valve should be used when flow rates exceed 125 GPM. Usually a high-performance pump size larger than two horsepower will exceed this flow rate. This valve is required to complement the function of the automatic bypass valve, particularly when starting the heater in winter or early spring when the spa or pool temperature is below 50°F. It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets, etc.

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 the BTUH output of the model to be installed, is recommended for this heater. The maximum acceptable pressure relief

alve setting is 125 psi.

A 3/4" NPT connection is provided in the Polymer header for installation of a pressure relief valve. The valve shall be installed in a vertical position. Do not overtighten. Install pressure relief valve hand tight plus 1/2 turn.

POLYMER HEADER (STANDARD MODELS)

Pressure Relief Valve

PRV Discharge

Connection

In/Out Header

Fig. #2004

A 3/4" NPT connection is provided in the header for installation of a pressure relief valve. The valve shall be installed in a vertical position.

From Heater To Heater

To Pool/ From Pool/ Spa Spa

AUXILIARY BYPASS VALVE

(DO NOT USE GATE VALVE)

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.

CAST IRON HEADER

PRV

(ASME MODELS)

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 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.

PLUMBING—WATER CONNECTIONS

ingle Pool Heater

S Installation

Multiple Pool Heater Installation

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

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

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

3. The outlet of the heater is plumbed to the return line to the pool or spa. The pump, filter and heater are thus plumbed in series (Salt generators and chemical feeders must be down stream of the pool heater).

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

CAUTION: An additional source of heated water, e.g. a solar system, must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source. If the primary system provides adequate heat to maintain set-point, the heater will not fire. Be advised that the control panel will then display sensed water temperatures downstream of the primary heating system, rather than the temperature of the water exiting the pool.

Heater must be located so that any water leaks will not damage the structure of adjacent area. PVC pipe may be glued directly into header unions (Standard models only).

HEAT EXCHANGER REVERSAL PROCEDURE - STANDARD MODELS

1. Remove right and left side access panels (Figure 1).

. Disconnect wires at high limit, AGS (automatic gas

shut-off), and pressure switch on the in/out header (Figure 2).

3. AFT Models: Remove the thermostat temperature sensor by loosening the compression fitting nut (Figure 3). Re-route the sensor to the left side of the heater.

4. Millivolt Models: Remove the temperature sensor bulb and retainer clip from the sensor well (Figure 4). Re-route the sensor bulb to the left side of the heater.

5. Remove (12) bolts holding the inlet/outlet and return headers to the tube sheets. Clean off tube sheet area where the gasket seats. Also clean off the header and the gasket. Apply a non-petroleum-based lubricant to the gasket such as AquaLube. Re-attach the headers to the opposite sides, making sure they are installed in an upright position (Figure 5). Do not over tighten. Torque should not exceed 7 ft/lb.

6. Reconnect high limit, AGS, and pressure switch wires.

7. AFT Models: Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting. Tighten 1/2 turn past hand-tight.

8. Millivolt Models: Insert sensor bulb and retainer clip into sensor well.

9. Allow for water flow through the heater and check for leaks.

10. Re-attach access panels to the opposite sides.

ig. #1

Fig. #2

For ASME Models call your factory representative.

Fig. #4

Fig. #3

Fig. #5

ELECTRICAL WIRING

OPTION LOCATION LEFT SIDE FIELD WIRING

CONTROL BOX (FACTORY MOUNTED LOCATION)

SWAY BRACE

BONDING LUG (STANDARD LOCATION)

BONDING LUG (OPTIONAL LOCATION)

OPTION LOCATION LEFT SIDE FIELD WIRING

CONTROL BOX (FACT ORY MOUNTED LOCATION)

SWAY BRACE

BONDING LUG (STAN DARD LOCATION)

BONDING LUG (OPTIONAL LOCATI ON)

NOTE: If it is necessary to replace any of the original wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring.

MILLIVOLT MODELS

The Millivolt models are equipped with a self-generating electrical system in which the electrical current is provided by a pilot generator. No external electrical connections are required.

When installing a remote switch, do not exceed 10 ft of wiring from the heater. Use 18-gauge stranded wire.

ADVANCED FLAME TECHNOLOGY (AFT) MODELS

WARNING:

Heaters are factory-wired for 240 VAC power supply. DO NOT attempt to operate at 208 VAC.

The standard field-wiring connection is on the right side of the heater.

CAUTION: Heater must be electrically grounded and bonded. Bonding lug is provided loose with the heater. Install bonding lug on lower right or left side of jacket as necessary for bonding the heater. Mounting hole is provided on the jacket.

NOTE: Failure to ground the heater electrically could affect the heater’s electronics.

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

NOTE: See page 38 for further instructions if using a time clock/fireman’s switch.

To wire the heater from the left side, follow these steps :

1. Remove the two (2) screws that hold the front door to the heater. Remove and set aside door for better access to wiring.

2. Remove the four (4) screws that hold down the junction box to the sway brace.

3. Remove the transformer cover located on the far right by removing one (1) screw.

4. Remove the two (2) screws that hold down the transformer.

5. Remove the one (1) screw that holds down the ground wires.

6. Disconnect P6 connector from PC board.

7. Remove transformer from its current location and relocate it on the far left side of the heater.

8. Re-route all high-voltage wires and ground wires through the left jacket side of heater.

9. Re-install P6 connector, ground wires (SPG), transformer, junction box, front door, and plug right side with the left side’s grommet plug.

NOTE: 7/8" dia. holes not utilized on jacket and control box can be used for fireman switch, auxiliary control interface or power vent (D-2) wiring.

ATMOSPHERIC

Wiring locations

LO NOx

Wiring locations

TRANSFORMER WIRING

120V ATMOSPHERIC HEATER 120V LOW NOx HEATER

SUPPLY

IDE

SUPPLY

IDE

ETURN

NEUTRAL

RETURN

NEUTRAL

EATER

4 WI RES

HEATER 7

WIR ES

ROUND

RED

BLACK

LACK BLACK

BLACK

LACK

GREEN

GREEN GREEN

GREEN

HITE

WHITE WHITE

WHITE

HITE

24 0V ATMO SP HER IC HE ATER

240V LOW NOx HEATER

HEATER 4WIRES

HEATER 7WIRES

GROUND

RED RED

BLACK

HOT

RED

HOT

BLACK

HOT

BLACK

GREENGREEN

GREEN GREEN

WHITE

SUPPLY

SIDE

SUPPLY

SIDE

120 VAC WIRING

For 120 VAC 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 “Ret” or neutral leg of the power supply. Attach the wire nut to the red wire. There should

e no connection to the red wire for 120 VAC operation. For Lo NOx pool heaters attach a wire nut to each

red wire independently.

240 VAC WIRING

For 240 VAC 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 240 VAC operation. For Lo NOx pool heaters attach a wire nut to each white wire independently.

WARNING: DO NOT attempt to operate the heater at 208 VAC.

Heater must be electrically grounded and bonded in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70. (Canada - Canadian Electrical Code, CSA C22.1, Part 1 and Part 2.)

NOTE: If the transformer’s primary side is wired for 120 VAC and 240 VAC is applied, damage to the transformer and PC board may result. Such damages are not covered under manufacturer’s limited warranty.

NOTE: Input power to the heater (120 or 240 VAC) can be supplied from the load (pump) side of time clock or directly from the GFCI power source. It is preferred that full-time power be supplied to the heater from the

GFCI power source, and that the heater be controlled by the fireman’s switch connection or using a two or three-wire remote. See pages 36-38. If using a switched GFCI power source, the heater could display false

service indicators on the display panel if the pump is turned off.

WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT)

WIRING DIAGRAM - ATMOSPHERIC

WIRING DIAGRAM - LO NOx

SECTION 4 - SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

ATMOSPHERIC

Drain Plug

(Located in rear header)

AFT Thermostat

Circuit Board

Roll-Out

Switch

Mounted On Top

Of Header

HL1 - High Limit

L2 - High Limit

H Pressure Switch Temp Sensor/Well

Unitherm Governor

Drain Plug

Transformer

LO NOx

Gas Valve

Pilot

Drain Plug

(Located in rear header)

AFT Thermostat

Circuit Board

Blower Hose

Blower

Roll-Out

Switch

(Manual)

Gas Valve

Draw Plug

Mounted On Top

Of Header HL1 - High Limit HL2 - High Limit Pressure Switch Temp Sensor/Well

Unitherm

Governor

Air

Switch

Pilot

Transformer

CONTROL PANEL REMOVAL

KNURLED SCREW

1. Remove screw from front door. Set aside door for serviceability.

CONTROL ADJUSTMENTS - MILLIVOLT MODELS

he water temperature is controlled by the heater ther-

T mostat on the upper front panel of the heater. The control center contains an On/Off switch and one thermostat.

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 knob stop ring to the desired location and re-tightening the set screw.

2. Remove (4) screws from sides of control panel.

3. Rotate control panel down until panel stops. Do not force.

NOTE: Caution must be used to not damage controls

or wiring.

CONTROL ADJUSTMENTS -

ADVANCED FLAME TECHNOLOGY

(AFT) MODELS

Temp Adjust Buttons

Mode Button

OFF

SPA TEMPERATURE RANGE

KNOB STOP RING

KNOB STOP SHOWN ABOVE IS

IN THE SPA TEMPERATURE RANGE

SET SCREW

POOL TEMPERATURE

RANGE

STAND-BY

TEMPERATURE

LCD Display

THERMOSTAT OPERATION - ADVANCED FLAME TECHNOLOGY (AFT) BOARD

LCD Display

Temp Buttons

Mode Button

Program button

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

Mode Button

The MODE button is used to select either POOL or SPA operation. It also allows the user to turn the heater off electronically, allowing the LCD display to remain energized and to continue showing the actual water temperature.

Temp Buttons

If the heater is in POOL or SPA mode, the desired water temperature (SETPOINT) will also be displayed and may be adjusted using the UP or DOWN buttons.

Operation

In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SETPOINT). When the water temperature is above the setpoint, “Water Temp” will alternate with “No Demand.” When the water temperature is below the setpoint and the heater is firing, “Water Temp” will alternate with “Heating.”

the pilot flame current using a bar graph and numerical display. A signal of less than 4 indicates a weak flame signal and may require service. Refer to Section 5 – Troubleshooting for possible causes and corrections.

FLAME STRENGTH INDICATOR

Press the DOWN button. The Supply Voltage screen indicates the voltage supplied to the control board. Normal readings range from 24 to 29 volts.

SUPPLY VOLTAGE INDICATOR

Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured by the amount of time that the main gas valve has been powered. The Cycle count indicates the number of on/off cycles of the heater, as measured by the number of times the pilot valve has been powered.

To adjust the setpoint temperature, make sure the control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons.

ALTERNATING DISPLAYS DURING HEATING

Service Menu and Fault History

To access the Service Menu and fault history, press the MODE and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate normally while in the Service Menu. The first screen displayed is the Flame Strength indicator, which indicates

RUN TIME INDICATOR

Press the DOWN button. The Fault History can display up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, and proceeds through ten most recent messages in chronological order. The second line of the display shows the fault message. If there are no faults in the history buffer, the second line reads “All Faults Clear.”

FAULT HISTORY

Program Button

1) Remove the four screws holding the control cover, and swing the panel down so the back side of the board is visible (see page 31). Locate the Program Mode button (marked as SW1) as shown on page

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

Fahrenheit or Celsius

Refer to step one above to access the program screen. Press the Mode button until Fahrenheit or Celsius appears on the digital display. The digital display is capable of displaying Celsius as well as Fahrenheit temperatures. The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display. Choose the desired temperature scale.

2) Press the Mode button sequentially until the

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

Resets board to factory default settings.

Resets faults in the History File.

Change from Fahrenheit to Celsius.

SPA setpoint maximum adjustment.

POOL setpoint maximum adjustment.

Set Factory Defaults

Refer to step one above to access the program screen. Set Factory Defaults should appear on the screen. If it does not, press the Mode button until Set Factory Defaults appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until Defaults Set appears. This operation resets the operating program to its factory default values. Both the POOL and SPA setpoints will revert to 65°F (18.5°C) and both POOL and SPA maximum temperature settings will be 104°F (40.0°C). The Control Lockout PIN will be cleared and the control will resume normal operation.

Clear Faults

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

Spa Max Temp – Spa Set Point Maximum Adjustment

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

Pool Max Temp – Pool Set Point Maximum Adjustment

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

Control Lockout

The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings. To lock out the controls, press the DOWN button and Mode button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the Mode button to lock in selections. Confirm your selection and record your PIN.

To unlock the controls, press any button to bring up the Enter PIN menu. Enter the PIN that was used to lock the control. Note that power cycling will not clear the lockout. Successfully unlocking the control will display “Lockout Cleared.” Failure to enter the correct PIN will display “Invalid PIN.”

In the event that the user-selected PIN is lost or does not clear the Control Lockout, use the Program Button to Set Factory Defaults. This will clear the PIN and allow normal operation and selection of a new PIN if desired. See the Program Button directions on this page for details.

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

NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool

r spa, the water temperature at the inlet to the heater may differ from that observed at a given location in the

o pool or spa.

STATUS AND DIAGNOSTICS

he digital thermostat models are programmed to display a variety of status and diagnostic messages, depend-

T ing on the operating conditions.

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

Display Condition

Heating

Spark Spark operating

No Demand Heat demand is satisfied

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

Call for heat established, flame present

Display Condition

Sensor Failure

Sensor Open

Sensor Short

Flame w/o CFH

PV Output Fault

MV Output Fault

LoNox Tab Fault

Internal Fault Board fault, replace board.

EEPROM Fault

Clock/ Fireman Sw

Low Temp Lockout

Thermistor temperatures disagree by more than 2°F

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

Thermistor sensor failed short. (Above 217°F)

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

Pilot gas valve output is not in commanded state.

Main gas valve output is not in commanded state.

Voltage is sensed at the Lo NOx terminal on a non-Lo NOx heater (Lo NOx tab is intact).

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

Time clock/fireman switch circuit is open.

Water temperature below 36°F.

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

Display Condition

Water Sw Open

Vent/Field Sw #1

Hi Limit 1 Fault

Hi Limit 2 Fault

Rollout Sw Open

Flow/Field SW #2

Fan Lockout

Fan 5 Min Delay

Ignition Lockout (Propane Tab Broken)

Ignition Failure (Propane Tab Not Broken)

Ign 6min Delay (Propane Tab Not Broken)

Water pressure switch open.

Vent spill switch/field switch #1 open.

High limit 1 open.

High limit 2 open.

Rollout switch open.

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

3 fan switch faults within same heat demand cycle, power must be cycled to clear the fault.

Heater shut down for 5 minutes because LoNox fan switch didn't close.

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

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

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

8 second trial to ignite the main burner.

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

lished within 90 seconds.

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

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

REMOTE CONTROL INSTALLATION AND OPERATION

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

The digital thermostat model is remote-ready in most cases. The digital liquid crystal display (LCD) shows the actual pool temperature, operating status, and service codes (See examples below). The touch pad on the con-

rol panel allows you to select the desired pool or spa temperature. It also indicates when a remote system is

t controlling the heater by displaying Remote in the display. When connecting the heater to a remote system, identify whether it is a two- or three-wire remote system. Select the appropriate instruction listed below to properly install the remote to the heater.

OFF Mode

7-PIN Remote

Interface Harness

Heating in the POOL Mode

Pool Common

(BLK/ORN)

Spa Common

(ORN/BLK)

24VAC HOT

(BLU)

REMOTE OPERATION

The AFT model heaters are equipped with the ability to work with external remote controls. The supplied 7pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote. The remote works by either making or breaking the circuit created by the remote wiring. Typically, a remote does not supply power to the heater, it only provides a switching function to turn the heater On or Off. If your remote is supplying its own

voltage to the heater, it will not work with this heater and may damage the digital circuit board.

Heating in the SPA Mode

Remote Mode

ACTIVATING THE REMOTE

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

Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds.

The second line of the display will alternate even when the unit is off (“No Demand”).

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

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

Note: Electrostatic Discharge (ESD) damage can be caused by direct or indirect contact with the wiring or circuit board. When one walks to the heater area, an electrostatic charge accumulates on the body. Contact of a finger allows the body to discharge, possibly causing device damage. This damage can be limited if the service person discharges himself, following ESD preventive/removal practices, and holds on to the heater enclosure for 5 seconds before proceeding.

REMOTE CONTROL WIRING

P8 Connector

Wire Nut - BLK/ORN To Pool (COMM)

ORN/BLK - To Spa (COMM)

BLU - 24VAC

AFT Board

P8 Connector

ORN/BLK - To Spa (COMM)

BLU - 24VAC

BLK/ORN - To Pool (COMM)

AFT Board

Important Installation Notes for Remote or External Wiring Configuration

• Remote wiring must be run in a separate conduit.

• Remote wiring must not be run parallel to high voltage lines.

• For runs of under 30 feet, remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, able twisting 1.5 to 2.5 in. lay and jacketed.

• For runs over 30 feet, the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5 to 2.5 inch

lay that is shielded and jacketed.

• Maximum cable length is 200 feet.

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

refer to the wiring instructions.

NOTE: The remote wires must be connected to the 7-pin connector before the connector is plugged into the board.

2-Wire Remote Control (On-Off)

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

1. Turn on power to the heater.

2. For a 2-Wire Remote Control from a remote without its own sensor, push the mode button to the “POOL” or

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

3. For a 2-Wire Remote Control from a remote with its own sensor, push the mode button “POOL” or “SPA”

mode and set the temperature to the highest setting available on the control. The actual setpoint will be controlled by the remote control.

4. Turn the mode button to "OFF" and remove power from the heater.

5. On the "Remote Interface Harness", connect the BLUE wire to one side of the "REMOTE" switch and con-

nect the other side to either the ORANGE/BLACK wire for "SPA" operation or the BLACK/ORANGE wire for "POOL" operation.

6. Attach wire nut on unused wire to the "Remote Interface Harness."

7. Install the "7-Pin Remote Interface Harness" to the P8 connector and turn power “On” to the heater.

To activate the remote control, see page 36.

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

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

1. Turn on power to the heater.

2. Push the mode button to the "POOL" or "SPA" mode and set the desired temperature for each (eg. 80°F for

Pool and 102°F for Spa).

3. Turn the mode button to "OFF" and remove power from the heater.

4. On the "Remote Interface Harness" connect the BLUE wire to one side of the "REMOTE" switch and con-

nect the ORANGE/BLACK wire for "SPA" operation and the BLACK/ORANGE wire for the "POOL" operation.

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

To activate the remote control, see page 36.

2-Wire Remote Control 3-Wire Remote Control

5 FT. M

POOL OR SPA

MAY REQUIRE ADJUSTMEN T

FOR LOWER P RESSURE

MAY REQUIRE ADJUSTMEN T

FOR HIGHER PRESSURE

5 FT. MAX

TIME CLOCK/FIREMAN’S SWITCH

To operate the heater with a time clock, connect the

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

t wiring. The time clock should be of the dual switch type and set to shut off the call for heat to the pool heater 15 to 20 minutes prior to shutting down the pool

ump. On millivolt heaters the fireman’s switch con-

p nection is a wire nut located in the Violet/Black wiring between the manual toggle switch and the gas valve. For AFT heaters the fireman’s switch connection is located on the 14-pin header connected to the digital control board. Splice into the red wire jumper tagged “Where necessary add “Fireman’s” switch circuit here” to connect the time clock. The fireman’s switch con-

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

cov-

ered by warranty.

Millivolt heaters: Do not exceed 15ft of total wiring using 14 AWG stranded copper wire rated for 105ºC (221ºF) minimum.

4. Turn the heater ON.

5. Manually turn the pressure adjustment knob clockwise until the heater shuts off. (A flat screwdriver may be necessary if knob is too tight.)

6. Slowly turn the adjustment knob counter-clockwise until the heater calls for heat again.

7. Turn an additional 1/2 turn counter-clockwise.

8. While the heater is running, check the adjustment

y turning the pump off and on several times. The

b burners should shut off immediately when the pump is turned off. If it does not, repeat the above steps until proper operation is observed.

PRESSURE SWITCH ADJUSTMENT RANGE

AFT heaters: Do not exceed 50ft of total wiring using 18 AWG stranded copper wire rated for 105ºC (221ºF) minimum.

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

WATER PRESSURE SWITCH

The water pressure switch ensures that the heater operates only when the filter pump is in operation. It is located on the inlet/outlet header. 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 adjust the pressure switch to compensate for the no-flow static head. If it is necessary to adjust the water pressure switch, utilize the following procedure:

WATER PRESSURE SWITCH ADJUSTMENT

Adjustment Knob

1. Make sure the pool filter is clean before adjusting the switch.

2. Set the heater control to the OFF mode.

3. Turn the filter pump on and confirm that the pressure

switch is closed (use a multimeter to check). If the pressure switch fails to close, either the switch setting is too high or not enough pressure is being supplied by the filter pump.

NOTE: If heater is installed outside of the limits shown, a higher pressure rated (11 psi) switch may be used. A flow switch, mounted and wired adjacent to the heater, may be used in place of the factory-mounted pressure switch. See Parts List (page 52) for 11 psi water pressure switch.

TWO-SPEED PUMPS

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

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

FLAME ROLL-OUT SAFETY SWITCH

Atmospheric heaters are equipped with a thermal cutoff device to prevent flame roll-out in the event the heat exchanger becomes blocked. This is a "single-use" type fusible link or thermal fuse, that must be

replaced when disabled by an over-temperature condition, caused by excessive restriction in the heat exchanger flue passage.

HIGH LIMITS

The heater is equipped with two automatic high limits. Both are located in the inlet/outlet header. Both are set to open at 135°F.

PILOT

BURNER

HOLD-DOWN

BRACKET

GAS ORIFICE

GAS VALVE

NOTE: An erratic high limit is often characteristic of an internal heat exchanger problem, e.g. scale build-up, defective bypass. Refer to Troubleshooting section (starting on page 43).

MAIN BURNER AND ORIFICE REMOVAL -

ATMOSPHERIC MODELS

1. Remove burner tray.

2. Remove screws and burner hold-down bracket.

HIGH LIMIT REMOVAL

1. Shut off main electrical ower switch to heater.

2. Remove inlet/outlet

inspection panel.

3. Remove defective high

limit and replace with a new high limit.

4. Replace inspection panel.

PILOT SAFETY - Millivolt Models

Heaters equipped with the standing pilot (millivolt 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 re-lighted to place the heater in operation again. Refer to the lighting instructions provided on the heater label.

PILOT SAFETY - AFT Models

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

BURNER TRAY REMOVAL -

ATMOSPHERIC MODELS

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,

and (2) screws that secure gas valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Disconnect hi-tension wire from PC board.

8. Slide out burner tray.

9. Reverse above procedure to reinstall.

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

ecessitates 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.

206-406 Atmospheric

PILOT REMOVAL AND CLEANING

1. Disconnect pilot tubing and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Remove pilot from bracket.

4. 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.

5. Reverse above procedure to reinstall.

HONEYWELL MILLIVOLT

PILOT

ROBERTSHAW MILLIVOLT

PILOT

GAS VALVE REMOVAL -

ATMOSPHERIC MODELS

1. Shut off gas supply to the heater. Remove gas piping to gas valve inlet.

2. Disconnect wires, pilot tubing and bleed line, if required.

3. Remove burner tray from heater.

4. Turn vertical gas pipe from manifold slightly and unscrew gas valve.

5. Reverse above procedure to reinstall.

Pilot Pilot

Air Opening

Orifice

Extension Pieces (2) Auger with Carbide Tip Wire Brush

HEAT EXCHANGER REMOVAL

1. Shut water, gas and electricity off, close valves nd relieve pressure, then remove relief valve.

a Remove side inspection panels.

. Remove top jacket holding screws.

3. Remove rear top panel.

4. Remove screws mounting the rain shield to the

rear panel. Also remove the screws that mount the rain shield to the sway brace. Remove rain shield.

5. Remove the four (4) screws holding down the flue

collector. Remove the flue collector.

6. Disconnect flange nuts on Inlet/Outlet header,

loosen union(s) at gas pipe and slide heater away from piping.

7. Lift heat exchanger straight up using caution not to

damage refractory.

8. Reverse above procedure to reinstall. Make sure

the insulation strips are properly replaced on top of the refractory retainer.

TUBE CLEANING PROCEDURE

Establish a regular inspection schedule, the frequency depending on the local water conditions and the severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness.

The heater may be cleaned from the return header side, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the ground-up lime dust does not get into the system.

Note that you do not remove the top panel or the heater exchanger, generally.

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

5. Reverse above procedure to reinstall.

OTE: In extreme cases it may be necessary to do

steam cleaning at the local car wash. DO NOT WIRE BRUSH.

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber, you must first have removed the heat exchanger.

Atmospheric Heaters

Lo NOx Heaters

REFRACTORY PANELS - TOP VIEW

IMMERSION WELL REPLACEMENT

(Millivolt and ASME)

1. Shut off water to heater and drain heat exchanger.

2. Remove access panel on water connection side.

3. Remove old immersion well with bushing and

sleeve.

4. Install replacement well in header.

NOTE: Installation in polymer header should be hand

tight plus 1/2 turn.

After reaming, mount the wire brush in place of the auger and clean out debris remaining in the tubes.

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

DESOOTING PROCEDURE

WARNING: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE.

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

1. Remove top and flue collector from cabinet.

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray. (See page 39).

Well Assembly

UNITHERM GOVERNOR (U.G.) REPLACEMENT

. Shut water, gas and electricity off, close valves

and relieve pressure.

2. Drain heat exchanger.

3. Remove retainer plug located next to the outlet ipe connection.

4. Unsnap old U.G. to remove from retainer plug.

Snap in new U.G.

5. Reinstall retainer plug, taking care to lubricate

gasket with a non-petroleum based grease such as AquaLube.

LO NOx POOL HEATERS

Retainer Plug

U.G.

Spring

Gasket

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.

The Lo NOx pool heaters are certified and tested under the ANSI Z21.56/CSA 4.7 Standard for GasFired Pool Heaters.

The heater should be installed to meet all local codes, and the latest editions of the National Fuel Gas Code Z223.1 and the National Electrical Code, ANSI/NFPA

70.

OPERATION

On call for heat, the ignition system, consisting of an electronic spark module, gas valve and pilot system, is energized. Providing the pilot is proven, the blower will start running, the main gas valve will open and the heater will operate. When the operating control is satisfied the heater will shut down.

START-UP PROCEDURES

1. Turn on power to the heater with gas supply off.

2. Turn on gas supply.

3. Set controller to call for heat.

4. System should start as follows:

a. Spark will turn on, pilot gas valve will open, and

the blower will begin running.

b. Once the blower provides pressure, the main

gas valve will open.

c. Heater will operate until call for heat is satisfied.

NOTE: Door must be in place for proper operation.

deck under cold-start conditions.

After about five minutes of operation, the flames should settle down and blue tips should become visible. Lifting of flames beyond five minutes would indicate too much combustion air.

VISUAL INSPECTION

Flames can be observed through the opening below the plenum. Flame color is blue and evenly spread on the top surface of the burner. At least every three months a visual inspection should be made of the burners.

ELECTRICAL

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

FLAME ROLL-OUT SAFETY SWITCH

Lo NOx heaters are equipped with a thermal cut-off device to prevent flame roll-out in the event the heat exchanger becomes blocked. It is a "manual reset" type roll-out switch that must be reset by a service technician after any over-temperature conditions have been fixed. Excessive restriction in the heat exchanger flue passage may cause the switch to disable the heater.

BLOWER ADJUSTMENT

This Lo NOx pool heater is equipped with a combustion air plate (baffle) mounted on the air intake to the combustion air blower. The baffle has a hole that is utilized to control the air inlet to the blower.

When the combustion air setting is proper, there will be some lifting of the flames on some areas of the burner

Manual Reset Switch

LO NOx HEATERS (CONTINUED)

BURNER HOLD-DOWN B

RACKET

LOW NOx B

URNER

ILOT

BAFFLE MOUNTED INLET SIDE

COMBUSTION A

IR BLOWER

GAS ORIFICE

GAS VALV E

207-407 Lo NOx Burner Tray

AIN BURNER AND ORIFICE REMOVAL

1. Remove burner tray, following above procedure. . Remove pilot. See pilot removal procedure.

3. Remove (8) total screws from the burner hold-

own brackets, front and rear of tray.

4. Remove (8) total screws from the left and right

sides of the manifold assembly. Detach the air/gas manifold assembly from the burner tray assembly.

5. Remove burners by raising them straight up off the

rear end slots.

6. Use a long 9/16” socket wrench to remove orifice

from the gas manifold.

7. Reverse above procedure to reinstall.

Electrode Alignment Detail

BURNER TRAY 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 the base of the unit, and (2) screws that mount the blower box to the burner tray, and (1) screw that secures the anti-rotation bracket to the heater.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the pilot assembly.

9. Disconnect wire connector from the combustion blower.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

GAS VALVE REMOVAL

1. Remove burner tray, following above procedure.

2. Disconnect, pilot tubing from gas valve.

3. Remove (2) screws that mount anti-rotation bracket to the burner tray.

4. Turn vertical gas pipe from manifold slightly and unscrew gas valve.

5. Reverse above procedure to reinstall.

Lo NOx Horizontal Pilot

PILOT REMOVAL

1. Disconnect pilot tubing from gas valve.

2. Remove the pilot wire from the pilot assembly.

3. Remove (2) screws that mount the pilot assembly to the burner tray.

4. Pull the pilot assembly downwards and outwards.

5. Reverse above procedure to reinstall.

COMBUSTION BLOWER REMOVAL

1. Remove the (2) screws that secure the blower box to the burner tray.

2. Remove (2) screws that mount the blower box to the base of the heater.

3. Disconnect wire connector from the combustion blower.

4. Carefully remove blower box with combustion blower.

5. Remove (2) screws that secure combustion blower to blower box.

6. Reverse above procedure to reinstall.

SECTION 5 - TROUBLESHOOTING

MECHANICAL

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

PROBLEM

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

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

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

Liming or scale forming in Pool water............................................ See Water Chemistry on page 2.

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

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

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

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

CAUSE SOLUTION

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.

External bypass setting out of

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

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

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

Adjust manual bypass valve until heater outlet water

temperature is between 105°F 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.

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

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

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

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

pool or spa Htr. output(BTUH)

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

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

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

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

Combustion fan not running Fan relay.............................................. Replace fan relay.

“Fan 5 min Delay” signal or Fan........................................................ Loose connection or failed motor.

“Fan Lockout” signal Burned motor ...................................... Incorrect wiring, replace blower.

*Insects or debris clogging

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

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

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

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.

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

Air pressure switch............................... Replace air switch.

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

ELECTRICAL - STANDING PILOT MILLIVOLT

If pilot burner remains lit

Jump across pressure

switch terminals

If main burner does not

fire, remove jumper

Check for adequate water

flow from filter

Replace pressure switch

Jump across thermostat

If main burner fires,

remove jumper

If main burner does

NOT fire...

Jump across each

high limit and remove

jumper

Replace thermostat

Replace high limit that

caused heater to fire

Jump across both "TH"

wires on gas valves

Check gas supply, gas

line size, gas pressure.

Also check for insects

or debris in pilot output

f pilot burner

does not light

Light pilot

If pilot burner goes out

when main burner lights

or when gas valve knob

is released

If burner does not remain

lit, attach millivolt meter

and read pilot output

If below 500mV, check

gas pressure. Also check

for insects or debris in

the pilot burner

If main burner fires,

remove jumper

Replace

gas

valve

If main burner does not

fire, remove jumper

Remove both "TH"

wires from gas valve.

Relight pilot

If pilot burner stays on

Problem is a wire or

component short to

cabinet or low gas

pressure

If above 500mV,

replace gas valve

Clean filter

If main burner fires,

remove jumper

If output is still low,

replace pilot generator

POOL OR SPA HEATER

ELECTRICAL CHECK WITH MILLIVOLT GAS VALVE

AUTION: For qualified service personnel only.

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

2. Gas valve must be in "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.

Raw Output (700mV± 100)

Pilot generator disconnected from valve (knob must be held down to keep pilot on). White – Negative Red + Positive

Pilot Load (500mV± 100) Pilot generator connected to valve-Power applied to pilot solenoid. TP(Thermopile-Robertshaw) PP(Power Pile-Honeywell) TH TP – Common TH PP – Common

Main Valve Load (200mV± 100)

Control/Limit circuit closed (All switches "ON") TP(Thermopile-Robertshaw) PP(Power Pile-Honeywell) TH TP – Common TH PP – Common

ELECTRICAL - ELECTRONIC IGNITION IID

OTE: 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.

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO PC BOARD?

(24 V NOMINAL)

YES

SPARK ACROSS

IGNITER/SENSOR GAP?

YES

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

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Make sure that the line voltage is NOT 208 VAC.

Pull ignition lead and check spark at PC board. Spark Okay? YES NO

• 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.

WARNING HIGH VOLTAGE

or qualified technicians ONLY

Replace the PC board.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

• 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 PC board and pilot operator on gas control.

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

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

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

• Check electrical connections between PC board and gas control. If okay, replace

gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.

NOTE: IF PC board 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 PC board.

• Check for proper thermostat (controller) operation.

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

TROUBLESHOOTING

ENDS

Power On

Is the water

emperature displayed?

YES

Push MODE

switch to select

Pool" or "Spa"

Push Temp

arrow to scroll to

desired temperature

Water temperature

and set

temperature

displayed?

YES

“Heating” will

display briefly

YES

Flame icon displayed

and flashing?

Water temp displayed?

(pilot lit and rectified)

Heater Fired?

END

• Check On/Off switch (under lid on control panel)

•

Check for 120/240 volts to the transformer

(time clock, circuit breaker, wire connections)

• Check for 24 volts to Circuit Board (P6 connector)

“Remote” and Water Temperature displayed

(a remote control is controlling the heater)

ote: Disconnect the remote by turning the

remote function off. See page 36 for instructions.

YES

Is a fault code displayed and flashing?

Diagnostic Readouts

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

Temperature sensor out of range (replace sensor)

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

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

“Spark”

Sensor Failure

Inspect thermister, wires, and connector at Terminal P1 Check resistance value of the thermister. Reference to chart below. Replace thermister if not within 10% of values shown below. If okay, replace Circuit Board.

Temp Degrees F 40 50 60 70 80 90 100 106 Resistance (k)

261.1 199.0 153.1 118.8 93.0 73.3 58.3 51.0

If okay, replace Circuit Board

Sensor resistance at various temperatures

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

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

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

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

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

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

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

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

ONTROL LOGIC - FLOW CHART

SECTION 6 - REPLACEMENT PARTS

OTE: To supply you with the correct part, it is impor-

tant that you supply the heater model number, serial number and type of gas when applicable.

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

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

MANUFACTURER:

151 EASTMAN AVENUE

2 OXNARD, CA 93030

4-V

16-M

7-C

3-V

1-V

-V

14-M

I-S

I3-S

2-S

5-HP

4-HP

7-HP

6-HP

I2-S

6-HP

I5-HM

3-HP

7-S

3-R

4-S

17-HM

11-S

4-C

9-M

8-S

13-M

12-M

3-S

4-B

2-B

5-M

5-B

1-B

1-G

1-J

4-S

5-S

6-S

14-M

1-R

2-R

2-J

7-HP

3-B

10-S

10-M

4-M

2-M

3-M

5-C

11-M

8-C

ATMOSPHERIC HEATERS

12-M

5-C

3-V

-V

2-V

9-M

-S

I3-S

-S

5-HP

4-HP

-HP

I2-S

-HP

I5-HM

3-HP

7-S

3-R

4-S

17-HM

11-S

4-C

6-M

8-S

8-M

7-M

3-S

3-B

4-B

1-G

10-S

1-B

2-B

2-M

3-J

10-M

6-B

5-B

7-C

1-J

4-S

5-S

6-S

9-M

1-R

2-R

2-J

13-M

-V

12-M

8-C

LO NOx HEATERS

16-HM

5-HM

12-HM

9-HM

10-HM

2-C

3-M

11-HM

8-HM

(OPTIONAL)

POLYMER IN/OUT HEADER AND ACCESSORIES

1-M

-C

6-C

5-HM

17-HM

14-HM

13-HM

2-HM

4-HM

-HM

3-HM

6-HM

2-S

9-S

4-S

HONEYWELL IID ATMOSPHERIC PILOT

2-P

7-P

9-P

8-P

1-P

5-P

6-P

3-P

9-P

HONEYWELL MILLIVOLT PILOT

1-P

2-P

4-P

IID LO NOx PILOT

6-P

18-HM

CALL

OUT DESCRIPTION 206A 266A 336A 406A

B BURNER TRAY

1-B Burner Tray w/Burners (sea level)* 010391F 010392F 010393F 010394F

Burner Tray w/o Burners (sea level)* 010395F 010396F 010397F 010398F Burner Tray w/Gas Valve Nat Millivolt 010399F 010400F 010401F 010402F Burner Tray w/Gas Valve Pro Millivolt 010403F 010404F 010405F 010406F Burner Tray w/Gas Valve Nat IID 010407F 010408F 010409F 010410F

Burner Tray w/Gas Valve Pro IID 010411F 010412F 010413F 010414F 2-B Burner Spacer/Hold Down Kit 010415F 010416F 010417F 010418F 3-B Burner 301210/13 301210/18 301210/22 301210/27 4-B Burner Orifice Nat. #50 (Sea Level)* 350079F/13 350079F/18 350079F/22 350079F/27

Burner Orifice Pro. #57 (Sea Level)* 350083F/13 350083F/18 350083F/22 350083F/27 5-B Burner Tray w/o Manifold w/o burners 010421F 010422F 010423F 010424F

CCONTROLS

1-C Thermostat Auto R eset 135 Deg Surface Mount 006725F 006725F 006725F 006725F 2-C AGS 135° (Auto Gas Shut-Off) - Red Epoxy 600892B 600892B 600892B 600892B 3-C High Limit 140° - Black Epoxy 600893B 600893B 600893B 600893B 4-C P. C. Board/Control 013464F 013464F 013464F 013464F 7-C LCD Display

Units manufactured prior to 5/2011 N/A N/A N/A N/A

Units manufactured From 5/2011 013640F 013640F 013640F 013640F 8-C Fuse 5 AM P 013733F 013733F 013733F 013733F 5-C Thermostat Control MV Units Mechanical 003346F 003346F 003346F 003346F 6-C Temperature Sensor IID Units 009577F 009577F 009577F 009577F

G GAS VALVE

1-G Combination Valve - Nat. MV 003898F 003898F 003898F 003898F

Combination Valve - Pro. MV 003899F 003899F 003899F 003899F

Combination Valve - Nat. IID 003900F 003900F 003900F 003900F

Combination Valve - Pro. IID 004306F 004306F 004306F 004306F

HP HEAT EXCHANGER - POLYMER

1-HP Heat Exchange Assy Copper 010043F 010044F 010045F 010046F

Heat Exchange Assy Cupro Nickel 010356F 010357F 010358F 010359F 2-HP Inlet/Outlet Header Complete 006827F 006827F 006827F 006827F

Inlet/Outlet Header (Includes 6-HP) 006706F 006706F 006706F 006706F 3-HP Return Header (Includes 6-HP) 006707F 006707F 006707F 006707F 4-HP Tube Bundle Copper ** 010059F 010060F 010061F 010062F

Tube Bundle Cupro Nickel ** 010364F 010365F 010366F 010367F 5-HP Baffle 010038F 005261F 010040F 010041F 6-HP Flange Nut Kit 008259F 008259F 008259F 008259F 7-HP O Ring Gasket (2) 006713F 006713F 006713F 006713F 8-HP Sensor Adapter Digital Electronic 006714F 006714F 006714F 006714F

Sensor Well Millivolt 006805F 006805F 006805F 006805F 9-HP Bypass Kit 006715F 006715F 006715F 006715F 10-HP Bypass Valve 006716F 006716F 006716F 006716F 11- HP Bypass Dam / Shaft 006717F 006717F 006717F 006717F 12-HP Bypass Spring (All Sizes Included) 006718F 006718F 006718F 006718F 13-HP Unitherm Governor 006719F 006719F 006719F 006719F 14-HP Unitherm Governor Plug 006720F 006720F 006720F 006720F 15-HP Drain Plug 006721F 006721F 006721F 006721F 16-HP Inlet/Outlet Header Dam

N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP

17-HP 2" PVC Connector & Nut (2) 006723F 006723F 006723F 006723F 18-HP O Ring (2) 006724F 006724F 006724F 006724F 19-HP Inlet/Outlet Header Baffle w/Header Dam 006826F 006826F 006826F 006826F

*FOR INSTAL LATION AT OVER 2,000 FEET A BOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL. **WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.

ATMOSPHERIC HEATERS

CALL

OUT DESCRIPTION 206A 266A 336A 406A

M HEAT EXCHANGER - METAL

1-HM Heat Exchange Assy.Copper AS ME CI 010051F 006727F 010053F 010054F

Heat Exchange Assy.Cupro Nickel AS ME CI 010360F 010361F 010362F 010363F 2-HM Inlet/Outlet Header ASM E CI Complete 006730F 006730F 006730F 006730F

Inlet/Outlet Header ASME CI 012319F 012319F 012319F 012319F 15-HM Inlet & Outlet Flange 003766F 003766F 003766F 003766F 16-HM Flange Gasket 1 1/2" Connections 062236B 062236B 062236B 062236B

Flange Gasket 2" Connections 800080B 800080B 800080B 800080B 3-HM Return Header ASM E CI 006731F 006731F 006731F 006731F 4-HM Tube Bundle Copper ASME * 010055F 006733F 010057F 010058F

Tube Bundle Cupro Nickel ASM E * 010368F 010369F 010370F 010371F 5-HM Baffle 010038F 005261F 010040F 010041F

6-HM Stud Bolt Kit 007870F 007870F 007870F 007870F 7-HM Header Gasket (9) 800014B 800014B 800014B 800014B 8-HM Unitherm Governor 062234B 062234B 062234B 062234B 9-HM U.G. Retainer Spring 013792F 013792F 013792F 013792F 18-HM U.G. Plug 013738F 013738F 013738F 013738F 10-HM Bypass Valve 062235B 062235B 062235B 062235B 11- HM Bypass Spring 850252 013794F 013794F 013794F 12-HM Drain Valve 013793F 013793F 013793F 013793F 13-HM Sensor Well 003765F 003765F 003765F 003765F 14-HM Well Retaining Clip 300203 300203 300203 300203 1

7-HM Rear Drain Plug & Cover 005264F 005264F 005264F 005264F

JCONTROL BOX

1-J Transformer 120/240/24V 006736F 006736F 006736F 006736F 2-J Rocker Switch 009493F 009493F 009493F 009493F

MMISCELLANEOUS COMPONENTS

1-M Pressure Switch 1.75 PSI 006737F 006737F 006737F 006737F

Pressure Switch 11 PSI Special-See Water Pressure Switch Adj. 009133F 009133F 009133F 009133F

2-M Thermostat Knob 009499F 009499F 009499F 009499F 3-M Thermostat Shaft MV 800307 800307 800307 800307 4-M Knobstop 006886F 006886F 006886F 006886F 5-M Thermal Fuse 005899F 005899F 005899F 005899F 6-M PRV 125 PSI (Optional) 008091F 007224F 007224F 007224F 7-M Deliming Kit 052871F 052871F 052871F 052871F 8-M Wire/Harness Millivolt 010386F 010386F 010386F 010386F

Wire/Harness IID 009490F 009490F 009490F 009490F 9-M Control Bezel MV (Includes Dial Decal) 009489F 009489F 009489F 009489F 10-M Dial Decal MV 009858F 009858F 009858F 009858F 11-M Control Bezel (Includes Switch Decal)

Units manufactured prior to 5/2011 009491F 009491F 009491F 009491F

Units manufactured From 5/2011 013491F 013491F 013491F 013491F 12-M Switch/Decal-Membrane

Units manufactured prior to 5/2011 009492F 009492F 009492F 009492F

Units manufactured From 5/2011 013492F 013492F 013492F 013492F 13-M Control Bezel Cover 009487F 009487F 009487F 009487F 14-M Gasket Insulation (Swaybrace & Jacket Top) 010350F 010350F 010350F 010350F 15-M Touch-up Paint (Green) 750125 750125 750125 750125

Touch-up Paint (Dark Gray) 750126 750126 750126 750126

Touch-up Paint (Cool Dark Gray) 750256 750256 750256 750256

Touch-up Paint (Warm Dark Gray) 750258 750258 750258 750258 16-M Tie Down Bracket (Optional) 011636 011636 011636 011636 17-M Texas Code Add/ On (ASME Only) 012011 012011 012011 012011

PPILOT

1-P Pilot Nat. MV 600525B 600525B 600525B 600525B

Pilot Pro. MV 600575B 600575B 600575B 600575B 2-P

Pilot Nat & Pro IID 002003F 002003F 002003F 002003F

3-P Pilot Orifice Nat. MV 003901F 003901F 003901F 003901F

Pilot Orifice Pro. MV 003902F 003902F 003902F 003902F 4-P Pilot Orifice Nat. IID .020 003903F 003903F 003903F 003903F

Pilot Orifice Pro. IID .012 004308F 004308F 004308F 004308F 5-P Pilot Generator MV 600019B 600019B 600019B 600019B 6-P Pilot MTG Bracket MV 010352F 010352F 010352F 010352F 7-P Pilot Mounting Bracket IID 306692 306692 306692 306692 8-P Lighter Tube (MV Units Only) 062996 062996 062996 062996 9-P Pilot Tube 004078F 004078F 004078F 004078F 10-P Hi Tension Wire IID with Pilot Electrode 007864F 007864F 007864F 007864F 11-P Pilot Shield 010351F 010351F 010351F 010351F

RREFRACTORY

1-R Refractory Common Lt & Rt 010088F 010088F 010088F 010088F 2-R Refractory Uncommon (Front & Rear) 010089F 010090F 010091F 010092F 3-R Refractory Retainer Kit 010387F 010388F 010389F 010390F

*WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.

ATMOSPHERIC HEATERS

CALL

OUT DESCRIPTION 206A 266A 336A 406A

SSHEETMETAL

1-S Jacket Top (Louvered) 010047F 010048F 010049F 010050F 2-S Flue Collector (Units with Polymer Header) 010071F 010072F 010073F 010074F

Flue Collector (Units with Metal Header) 010075F 010076F 010077F 010078F 3-S Door Assy

Raypak

Green 010378F 010379F 010380F 010381F

Cool Dark Gray 013859F 013860F 013861F 013862F

Rheem

Green 010382F 010383F 010384F 010385F

Cool Dark & Warm Dark Gray 013863F 013864F 013865F 013866F

Ruud

Green 010382F 010383F 010384F 010385F

Warm Dark Gray 013867F 013868F 013869F 013870F 4-S Access Panel Set (3 Pcs Units with Polymer Header) 010311F 010311F 010311F 010311F

Access Panel Set (3 Pcs. Units with Metal Header) 010312F 010312F 010312F 010312F 5-S Jacket Side Panel Right 010376F 010376F 010376F 010376F 6-S Jacket Side Panel Left 010377F 010377F 010377F 010377F 7-S Jacket Rear Panel (2 Pcs.) 010372F 010373F 010374F 010375F 8-S Poolstat Cover/Lock 009505 009505 009505 009505 9-S High Limit Cover 010319F 010319F 010319F 010319F 10-S Base Heat Shield 010320F 010320F 010320F 010320F 11-S Up Front Control Panel

Green 010321F 010322F 010323F 010324F

Cool Dark Gray 013887F 013888F 013889F 013890F

Warm Dark Gray 013891F 013892F 013893F 013894F 12-S High Limit Shield 010342F 010342F 010342F 010342F 13-S Weather Shield 010325F 010326F 010327F 010328F

VVENTING

1-V Indoor Stack Kit (Includes inner adapter panel) 009838 009839 009840 009841

utdoor Stack Kit (Includes inner adapter panel) 009834 009835 009836 009837 2-V Stack A dapt er 010330F 010331F 010332F 010333F 4-V Outer Stack A dapt er 011461F 011462F 011463F 011464F 3-V "Pagoda" Top

Green 010334 010335 010336 010337 Cool Dark Gray 013883F 013884F 013885F 013886F

Atmospheric CONVERSION KITS* 206A 266A 336A 406A

Gas Conversions Nat. to Pro. MV Pilot 004690B 004690B 004692B 004692B Pro. to Nat. MV Pilot 010419F 010419F 010420F 010420F Nat. to Pro. IID Pilot ** ** ** ** Pro. to Nat. IID Pilot ** ** ** **

** Conversion must be made with complete burner tray and gas valve (see item 1-B).

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

ATMOSPHERIC HEATERS

ALL

OUT DESCRIPTION 207A 267A 337A 407A

BB BURNER TRAY***

-B Burner Tray w/Burners (0-5000) 010343F 010344F 010345F 010346F Burner Tray w/o Burner (0-5000) 010084F 010085F 010086F 010087F

2-B Burner Hold Down Kit 010254F 010255F 010256F 010257F 3-B Burner 310732/3 310732/4 310732/5 310732/6 4-B Burner Orifice Nat. #26 (0-5000)* 351632/3 351632/4 351632/5 351632/6

urner Orifice Nat. #31 (above 5000 ft.)* 351523/3 351523/4 351523/5 351523/6 5-B Blower 010042F 010042F 010042F 010042F 7-B Cooling Fan 010871F 010871F 010871F 010871F 6-B Combustion Air Orifice Plate 010338F 010339F 010340F 010341F

CCONTROLS

-C Thermostat Auto Reset 135 Deg Surface Mount 006725F 006725F 006725F 006725F 2-C AGS 135° (Auto Gas Shut-Off) - Red Epoxy 600892B 600892B 600892B 600892B 3-C High Limit 140° - Black Epoxy 600893B 600893B 600893B 600893B 4-C P. C. Board/Control 013464F 013464F 013464F 013464F

5-C LCD Display

Units manufactured prior to 1/2011 N/A N/A N/A N/A

Units manufactured From 1/2011 013640F 013640F 013640F 013640F 8-C Fuse 5 AMP 013733F 013733F 013733F 013733F 6

-C Temperature Sensor 009577F 009577F 009577F 009577F

7-C Blower Pressure Switch 008062F 008135F 010354F 010355F

G GAS VALVE

1-G Combination Valve - Gas On/Off -Nat 010329F 010329F 010329F 010329F

P HEAT EXCHANGER - POLYMER

1-HP Heat Exchange Assy Copper 010043F 010044F 010045F 010046F

eat Exchange Assy Cupro Nickel 010356F 010357F 010358F 010359F

2-HP Inlet/Outlet Header Complete 006827F 006827F 006827F 006827F

Inlet/Outlet Header (Includes 6-HP) 006706F 006706F 006706F 006706F 3-HP Return Header (Includes 6-HP) 006707F 006707F 006707F 006707F 4-HP Tube Bundle Copper ** 010059F 010060F 010061F 010062F

Sensor Well Millivolt 006805F 006805F 006805F 006805F 9-HP Bypass Kit 006715F 006715F 006715F 006715F 10-HP Bypass Valv e 006716F 006716F 006716F 006716F 11-HP Bypass Dam / Shaft 006717F 006717F 006717F 006717F 12-HP Bypass Spring (All Sizes Included) 006718F 006718F 006718F 006718F 13-HP Unitherm Governor 006719F 006719F 006719F 006719F 14-HP Unitherm Governor Plug 006720F 006720F 006720F 006720F 15-HP Drain Plug 006721F 006721F 006721F 006721F 16-HP Inlet/Outlet Header Dam

N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP N/A Use 19-HP

17-HP 2" PVC Connector & Nut (2) 006723F 006723F 006723F 006723F 18-HP O Ring (2) 006724F 006724F 006724F 006724F 19-HP Inlet/Outlet Header Baffle w/Header Dam 006826F 006826F 006826F 006826F

HM HEAT EXCHANGER - METAL

1-HM Heat Exchange Assy.C opp er ASME CI 010051F 006727F 010053F 010054F

Heat Exchange Assy.Cupro Nickel ASME CI 010360F 010361F 010362F 010363F 2-HM Inlet/Outlet Header ASME CI (Complete) 006730F 006730F 006730F 006730F

Inlet/Outlet Header ASME CI 012319F 012319F 012319F 012319F 15-HM Inlet & Outlet Flange 003766F 003766F 003766F 003766F 16-HM Flange Gasket 1 1/2" Connections 062236B 062236B 062236B 062236B

Flange Gasket 2" Connections 800080B 800080B 800080B 800080B 3-HM Return Header ASME CI 006731F 006731F 006731F 006731F 4-HM Tube Bundle Copper ASME ** 010055F 006733F 010057F 010058F

Tube Bundle Cupro Nickel ASME ** 010368F 010369F 010370F 010371F 5-HM Baffle 010038F 005261F 010040F 010041F 6-HM Stud Bolt Kit 007870F 007870F 007870F 007870F 7-HM Header Gasket (9) 800014B 800014B 800014B 800014B 8-HM Unitherm Governor 062234B 062234B 062234B 062234B 9-HM U.G. Retainer Spring 013792F 013792F 013792F 013792F 18-HM U.G. Plug 013738F 013738F 013738F 013738F 10-HM Bypass Val ve 062235B 062235B 062235B 062235B 11-HM Bypass Spring 850252 013794F 013794F 013794F 12-HM Drain Valve 013793F 013793F 013793F 013793F 13-HM Sensor Well 003765F 003765F 003765F 003765F 14-HM Well Retaining Clip 300203 300203 300203 300203 17-HM Rear Drain Plug & Cover 005264F 005264F 005264F 005264F *FOR INSTALLATION S AT OVER 5,000 FEET ABOVE SEA LEVEL, CONSULT THE FACTORY **WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part. ***Replacement burner trays are built for sea level, natural gas applications unless otherwise specified at the time the order is placed.

LO NOx HEATERS

CALL

OUT DESCRIPTION 207A 267A 337A 407A

CONTROL BOX

1-J Transformer 120/240/24V 006736F 006736F 006736F 006736F 2-J Rocker Switch 009493F 009493F 009493F 009493F 3-J Relay Low Nox 008784F 008784F 008784F 008784F

MISCELLANEOUS COMPONENTS

1-M Pressure Switch 1.75 PSI 006737F 006737F 006737F 006737F

Pressure Switch 11 PSI Special-See Water Pressure Switch Adj. 009133F 009133F 009133F 009133F

2-M Roll-Out Switch 300ºF 006035F 006035F 006035F 006035F 3

-M PRV 125 PSI (Optional) 008091F 007224F 007224F 007224F 4-M Deliming Kit 052871F 052871F 052871F 052871F 5

-M Wire/Harness 010347F 010347F 010347F 010347F 6-M Control Bezel (Includes Switch Decal)

Units manufactured prior to 1/2011 009491F 009491F 009491F 009491F

Units manufactured From 1/2011 013491F 013491F 013491F 013491F

7-M Switch/Decal-Membrane

Units manufactured prior to 1/2011 009492F 009492F 009492F 009492F Units manufactured From 1/2011 013492F 013492F 013492F 013492F

-M Control Bezel Cover 009487F 009487F 009487F 009487F 9-M Gasket Insulation (Swaybrace & Jacket Top) 010350F 010350F 010350F 010350F 10-M Blower / Air Pressure Switch Sample Tube 010348F 010348F 010348F 010348F 11-M Touch-up Paint (Green) 750125 750125 750125 750125

ouch-up Paint (Dark Gray) 750126 750126 750126 750126 Touch-up Paint (Cool Dark Gray) 750256 750256 750256 750256 Touch-up Paint (Warm Dark Gray) 750258 750258 750258 750258

12-M Tie Down Bracket (Optional) 011636 011636 011636 011636 13-M Roll-Out Switch 250ºF (Optional) 011745F 011745F 011745F 011745F

Roll-Out Switch 250ºF (Upgrade) 011733F 011733F 011733F 011733F

4-M Texas Code Add/On (ASME Only) 012011 012011 012011 012011

P PILOT

-P Pilot Nat. IID Low Nox 010232F 010232F 010232F 010232F 2-P Pilot Electrode N/A N/A N/A N/A 3-P Pilot Mounting Bracket 010233F 010234F 010235F 010236F 4-P Pilot Tube 011926F 011926F 011926F 011926F 5-P Hi Tension Wire IID 010349F 010349F 010349F 010349F 6-P Adapter Nut (Metric) 011927F 011927F 011927F 011927F

R REFRACTORY

1-R Refractory Common (Left & Right) 010079F 010079F 010079F 010079F 2-R Refractory Uncommon (Front and Rear) 010080F 010081F 010082F 010083F 3-R Refractory Retainer Kit 010262F 010263F 010264F 010265F

S SHEETMETAL

1-S Jacket Top (Louvered) 010047F 010048F 010049F 010050F 2-S Flue Collector (Units with Polymer Header) 010063F 010064F 010065F 010066F

Flue Collector (Units with Metal Header) 010067F 010068F 010069F 010070F

3-S Door Assy.

Raypak Green 010267F 010268F 010269F 010270F Cool Dark Gray 013871F 013872F 013873F 013874F Rheem Green 010271F 010272F 010273F 010274F Cool Dark & Warm Dark Gray 013875F 013876F 013877F 013878F Ruud Green 010271F 010272F 010273F 010274F Warm Dark Gray 013879F 013880F 013881F 013882F

4-S Access Panel Set (3 Pcs. Units with Polymer Header) 010311F 010311F 010311F 010311F

Access Panel Set (3 Pcs. Units with Metal Header) 010312F 010312F 010312F 010312F 5-S Jacket Side Panel Right 010313F 010313F 010313F 010313F 6-S Jacket Side Panel Left 010314F 010314F 010314F 010314F 7-S Jacket Rear Panel (2 Pcs.) 010315F 010316F 010317F 010318F 8-S Poolstat Cover/Lock 009505 009505 009505 009505 9-S High Limit Cover 010319F 010319F 010319F 010319F 10-S Base Heat Shield 010320F 010320F 010320F 010320F 11-S Up Front Control Panel

Green 010321F 010322F 010323F 010324F

Cool Dark Gray 013887F 013888F 013889F 013890F

Warm Dark Gray 013891F 013892F 013893F 013894F 12-S High Limit Shield 010342F 010342F 010342F 010342F 13-S Weather Shield 010325F 010326F 010327F 010328F

V VENTING

1-V Indoor Stack Kit (Includes inner adapter panel) 009838 009839 009840 009841

Outdoor Stack Kit (Includes inner adapter panel) 009834 009835 009836 009837 2-V Stack Adapter 010330F 010331F 010332F 010333F 4-V Outer Stack Adapter 011461F 011462F 011463F 011464F 3-V "Pagoda" Top

Green 010334 010335 010336 010337

Cool Dark Gray 013883F 013884F 013885F 013886F

LO NOx HEATERS

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Rheem P-M206, P-M207, P-M406, P-M407, P-M267 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual