Rudd 055B Installation Manual
INSTALLATION & OPERATING
INSTRUCTIONS
Versa™
Spa
Heater
Model 055B
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
CATALOG NO. 6100.52U Effective: 04-20-09 Replaces: 02-29-08 P/N 240428 Rev. 22
Rev. 22 reflects the following: Changes to: Fig. 20 and 21 on page 19. The addition of: A caution note to page 19.
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CONTENTS
WARNINGS 4
Pay Attention to These Terms 4
WATER CHEMISTRY 5
OWNER'S OPERATING INSTRUCTIONS 6
Start-Up Procedures 6
Water Temperature Safety 9
MAINTENANCE AND CARE PROCEDURES 9
Basic Tips if Heater Will Not Fire 9
Pool & Spa Water
Chemistry 10
Cold Weather Operation 10
Winterizing the Spa Heater 10
INTRODUCTION 10
Receiving Equipment 10
General Specifications 11
INSTALLATION 11
Code Requirements 11
Base Installation 11
Clearances 11
Outdoor Heaters 13
Indoor Heaters 13
Combustion Air
(Indoor Units Only) 13
Vent Piping 14
Vent Terminal Assembly 14
Gas Supply Connections 15
Plumbing for Water Connections 16
Electrical Wiring 18
Wiring Diagram—Millivolt Units with
Mechanical Thermostat 20
Wiring Diagram—IID Units 21
SERVICE 22
Controls/Adjustments/
Replacements 22
TROUBLESHOOTING 27
REPLACEMENT PARTS LIST 31
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WARNINGS - Pay Attention to These Terms
DANGER:
WARNING:
CAUTION:
NOTE:
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the user's information manual provided with
this heater. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.
WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
Do not handle, use, or store gasoline or other
flammable or combustible materials in the vicinity of
a heater.
Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
WARNING: 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.
CAUTION: Verify proper operation after servicing.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
4
WATER CHEMISTRY
OTE: Corrosive water voids all warranties.
N
Chemical imbalance can cause severe damage to
our heater and associated equipment. Maintain your
y
water chemistry according to Table A. If the mineral
content and dissolved solids in the water become too
high, scale forms inside the heat exchanger tubes,
reducing heater efficiency and damaging the heater. If
the pH drops below 7.2, this will cause corrosion of the
heat exchanger and severely damage the heater. Heat
exchanger damage resulting from chemical imbalance
is not covered by the warranty.
For your health and the protection of your pool equipment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
CAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and void the warranty.
• Occasional chemical shock dosing of the pool or
spa water should not damage the heater providing
the water is balanced.
• Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water,
unless controlled, they can lead to excessive chlorine level which can damage your heater.
• Further advice should be obtained from your pool
or spa builder, accredited pool shop, or chemical
supplier for the correct levels for your water.
Recommended Level(s) Fiberglass Pools Fiberglass Spas
Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)
pH 7.3-7.4 7.3-7.4 7.6-7.8
Total Alkalinity (ppm) 120-150 120-150 80-120
Calcium Hardness (ppm) 200-300 150-200 200-400
Salt (ppm) 6000 Maximum 6000 Maximum 6000 Maximum
Free Chlorine (ppm)* 2-3 2-3 2-3
Total Dissolved Solids
(ppm)
*Free Chlorine MUST NOT EXCEED 5 ppm!
3000 Maximum 3000 Maximum 3000 Maximum
Table A: Water Chemistry
Other Pool and Spa
Types
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OWNER'S OPERATING
4“ MAX
After Start-Up
INSTRUCTIONS
WARNING: If you do not follow these instructions
xactly, a fire or explosion may result, causing
e
property damage, personal injury or loss of life.
Start-Up Procedures
Before Start-Up
Burners
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilation air.
Water
First thing, ensure that system is filled with water and
have pump operating. Water must be flowing through
the heater during operation.
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 appliance.
Visual Inspection
With the heater on, remove the door and make a visual check of the pilot and burner. The flame should be
blue with a well-defined pattern.
Fig. 2: Correct Main Burner Flame Pattern
Fig. 1: Versa Heater
Fig. 3: 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 to
the heater is interrupted. It is very important to verify
that the switch electrically opens and shuts off the gas
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1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On-off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn clockwise to "Off".
NOTE: Knob cannot be turned from "Pilot" to
"Off" unless knob is pushed in slightly. Do not
force.
6. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to
the next step.
7. Locate pilot mounted on the left side of the
burner tray. For burner tray location,
see General Location of Controls section,
page 17.
HONEYWELL
GASVALVE
MILLIVOLT
ROBERTSHAW
GAS VALVE
MILLIVOLT
A. This appliance has a pilot that must be lighted by
hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTING smell all around the appli-
ance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use any
phone in your building.
*Immediately call your gas supplier from a neigh bor's phone. Follow the gas supplier's instruc-
tions.
LIGHTING INSTRUCTIONS
Gas control knobs shown in "Off" position
ROBERTSHAW PILOT
HONEYWELL PILOT
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
(MILLIVOLT SYSTEM)
8. Turn knob on gas control counter-clockwise
to "Pilot".
9. Push in control knob all the way and hold in.
Immediately place flame to pilot to light.
Continue to hold control knob in for about 1
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
*If knob does not pop up when released, stop
and immediately call your service technician
or gas supplier.
*If the pilot does not stay lit after several tries,
turn the gas control knob to "Off" and call your
service technician or gas supplier.
10. Stand to the side of the heater and turn the gas
control knob counter-clockwise to "On".
11. Replace heater door panel.
12. Turn On-off switch to the "On" position.
13. Set thermostat to the desired setting.
TO TURN OFF GAS TO APPLIANCE
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will not
push in or turn by hand, do not try to repair it. Call
a qualified service technician. Force or attempted
repair may result in a fire or explosion.
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.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
1. Set the thermostat to the lowest setting.
2. Turn On-off switch to the "Off" position.
3. Remove heaterdoor panel.
CAUTION: Propane is heavier than air and will settle on the ground. Since propane can accumulate in
onfined areas, extra care should be exercised when lighting propane heaters.
c
7
CAUTION: Propane is heavier than air and will settle on the ground. Since propane can accumulate in
TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
5. Remove heater door panel.
6. Push in gas control knob slightly and turn clockwise to "Off".
Knob cannot be turned to "Off" unless it is
pushed in slightly. Do not force.
7. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety infor-
mation previously stated. If you don't smell gas,
go to the next step.
Gas control lever shown in the "On" position.
8. Turn gas control knob counter-clockwise
to "On".
Gas control knob shown in "ON" position.
OPERATING INSTRUCTIONS
9. Replace heater door panel.
10. Turn on all electrical power to appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance" and
call your service technician or gas supplier.
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the
gas control knob. Never use tools. If the
knob will not push in or turn by hand, do not try
to repair it; call a qualified service technician.
Force or attempted repair may result in fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas
control which has been under water.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
(ELECTRONIC IGNITION SYSTEMS)
4. Push in gas control knob slightly and turn
clockwise to "Off".
5. Replace heater door panel.
1. Set the thermostat at the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
3. Remove heater door panel.
GAS VALVE-IID
onfined areas, extra care should be exercised when lighting propane heaters.
c
8
valve when water flow to the heater is interrupted.
Otherwise, rapid and severe heater damage will likely
occur. (The water pressure switch should be checked
and adjusted for proper operation by a qualified service person at the time of installation and periodically
checked thereafter. Refer to pressure switch servicing
instructions in this manual.)
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the heater.
Water Temperature Safety
MAINTENANCE AND CARE PROCEDURES
o be followed one month after start-up and then semi-
T
annually.
1. Inspect top of heater and drafthood for soot, a
sticky black substance found around finned tubes,
baffle and open flue gas passageways.
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
Elevated water temperature can be hazardous, and
the U.S. Consumer Product Safety Commission recommends the following guidelines:
1. Spa or hot tub water temperatures should never
exceed 104°F (40°C). A temperature of 100°F
(38°C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Use of drugs and/or alcoholic beverages before or
during spa or hot tub use may cause drowsiness
which could lead to unconsciousness and subsequently result in drowning.
3. Pregnant women beware! Soaking in water over
102° F (39°C) may cause fetal damage during the
first three months of pregnancy, including brain
damage or deformity. Pregnant women should
observe 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.
2. Clean main burners and pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve.
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is indicated in the previous illustration. Yellow flame
means restriction of the air openings. Lifting or
blowing flame indicates high gas pressure. Low
flame means low gas pressure. Should this occur,
shut the heater off and contact your gas supplier
or qualified service agency.
5. On indoor heaters, clean room intake openings to
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.
6. Keep area around heater clear and free from combustible materials and other flammable and
corrosive vapors and liquids.
Basic Tips if Heater Will Not Fire
If you have no electrical power:
1. The "circuit breakers" may have tripped. Try resetting them.
9
If you have electrical power, check the following:
1. The time clock must be moved to the "ON" position.
2. Your pump strainer basket may be full. If so
remove debris.
water below 50°F can seriously damage the heater,
and will void the warranty.
For cold climate areas please follow the winterizing
procedures listed below.
Winterizing the Spa Heater
3. Your filter may be dirty. If so, backwash or clean filter. (If your filter is dirty, the gauge pressure will be
higher than usual).
4. The pump may have lost its prime and be running
dry. Check the pressure gauge on the filter. If there
is no pressure; the water is not moving (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 5. If
the mineral content and dissolved solids in the water
become too high, scale forms inside the heat
exchanger tubes, reducing heater efficiency and also
damaging the heater.
If the pH drops below 7.2, the heater will be severely
damaged. This will result in corrosion of the heat
exchanger. Heat exchanger damage resulting from
chemical imbalance is not covered by the warranty.
Cold Weather Operation
When heaters installed outdoors in freezing climate
areas are to be shut down for the winter, observe the
following procedure:
1. Turn off gas valve, manual gas valve, and electrical supply to the heater.
2. Open drain cock located on the return header.
3. Disconnect compression fittings from the pressure
switch and header that connect to the 1/4" copper
tube and allow the tube to drain.
INTRODUCTION
Receiving Equipment
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill
of Lading when signing for the equipment. Remove
the heater from the carton and if it is damaged, report
the damage to the carrier immediately.
On occasion, we ship some items loose. Be sure that
you receive the number of packages indicated on the
Bill of Lading.
Heater operation can continue during short term cold
spells. When temperatures are below freezing, flow
(continuous pump operation) must be maintained.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing, or for freeze
protection. When heaters are used during freezing
weather, care must be taken to avoid freeze-ups.
Continuous pump operation is a must. Additional
protection may be required. The heater is not
warranted against freeze-ups.
Prolonged operation with water temperatures below
50°F is not recommended. When starting the heater
with pool temperatures below 50°F, operate the heater
continuously until higher temperatures are reached.
Operating the heater for prolonged periods with pool
When ordering parts, you must specify model and
serial number of heater. When ordering under warranty conditions, you must also specify the date of
installation.
The manufacturer recommends that this manual be
reviewed thoroughly before installing your pool/spa
heater. If there are any questions that this manual
does not answer, please contact the factory or your
local representative.
10
General Specifications
These heaters are design certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard / CSA standards for gas-fired pool
heaters.
WARNING: Improper installation, adjustment,
lteration, service or maintenance may damage the
a
equipment, create a hazard resulting in
asphyxiation, explosion or fire, and will void the
warranty.
The heater is interchangeable and can be used either
indoors or outdoors. The appropriate top designated
for that type of use is required. If desired, the top can
be changed at a later date to change from outdoor to
indoor or vice versa. Millivolt heaters contain a selfgenerating electrical system operating between .25
and .75 volts.
Ambient Temperature Rating of
Heater Components
Millivolt Heater with Honeywell Gas Valve
+32°F to +175°F
Millivolt Heater with Robertshaw Gas Valve
0°F to +175°F
Electronic Ignition Heaters*
-32°F to +175°F
*Requires 120V or 240V power supply
Rated inputs are suitable for up to 2000 feet elevation.
For elevations above 2000 feet, reduce input 4% for
each 1000 feet above sea level, as high elevation
reduces combustion performance. For Canada,
reduce input 10% when installed at 2000-4500 feet
elevation.
INSTALLATION
NOTE: These instructions are intended for use by
qualified personnel only, specifically trained and
experienced in the installation of this type of heating
equipment and related system components.
Installation and service personnel may be required
by some states to be licensed.
Code Requirements
NOTE: The heater should not be located in an area
where possible water leakage will result in damage
to the area adjacent to the appliance or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable drain pan,
adequately drained, be installed under the
appliance. The pan must not restrict combustion air
flow.
Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70; for Canada,
the latest edition of CAN/CGA B-149.
Base Installation
Heater must be mounted on a level surface. It can be
installed on combustible flooring. Heaters may not be
installed on carpeting.
Clearances
WARNING: The heater shall not be located in an
area where water sprinklers, or other devices, may
cause water to spray through the cabinet louvers
and into the heater. This could cause heavy internal
rusting or damage some electrical components, and
this would void the warranty.
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.
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