STA-RITE SR, SRC200 User Manual

Heater Insulation Kit

Sta-Rite Pool/Spa Group

293 Wright Street, Delavan, WI 53115

North America: 800-752-0183, FAX [phone]
International: 262-728-5551, FAX: [phone], TELEX: ITT 4970245

www.sta-ritepool.com

Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA

© 2003, Sta-Rite Industries, Inc. Printed in U.S.A. S430 (Rev. 2/14/03)

Tools/Parts Required

Flat Screwdriver, Phillips Screwdriver
1/4” and 3/8” Socket Sets with Extenders

Sockets needed:1/4”, 5/16, 11/32, 7/16, 1/2, 9/16, 7/8

Rubber Mallet
To rque Wrench calibrated in Inch-Lbs.
High Temperature RTV (600° F. Cont.; 700° F. Intermittent)
Flame Holder/Adapter Plate Gaskets

(2 - Part No. 42001-0065)

14” & 12” Pipe Wrenchs (1 Each) or 2 Channel-Lock Pliers

Optional: Lifting Gear capable of handling 150 Lbs.

Safety Precautions:

Risk of electrical shock, fire or explosion.

Disconnect all power to the heater and close the external
manual gas valve at start of this procedure. Check for gas
leaks with a soapy water solution after reassembly.

Risk of carbon monoxide poisoning from

indoor units if exhaust vent joints are not sealed. Check

all vent joints for leakage after reassembly.

Heavy parts; can cause personal injury.
When lifting, use all proper precautions for the weights
involved.

Uncured RTV sealants can cause eye irrita­tion. Follow manufacturer’s instructions when using RTV

sealants.

Location

The Insulation is located inside the Combustion Chamber.

Function

The insulation increases the thermal efficiency of the
heater and prevents overheating of parts outside the com­bustion chamber.

Servicing Procedure (See Figure 1):

Heavy parts; can cause personal injury.
When lifting, use all proper precautions for the weights
involved.

1. Turn off the filter pump and all electrical power to the

heater. Close the external Manual Gas Valve.

2. If the heater is below the water level of the pool, close

the isolation valves to avoid draining the pool.

3. Remove the drain plug under the manifold and drain

the heater.

4. While the heater is draining, remove the upper left and

upper right jacket halves.

5. Remove the switch covers on both sides of the mani-

fold and unplug the wires from the Automatic Gas
Shutoff, the High Limit Thermostat, and the Thermistor
(See Figure 2, Key No. 1). If necessary, disconnect the
Water Pressure Switch and remove it.

6. Disconnect exhaust vent from indoor units.

7. Disconnect the gas pipe at the external union between

the heater and the external manual gas valve.

8. Disconnect the incoming electrical wires at the junction

box and cut the wire tie holding the Wiring Harness to
the Lower Enclosure (See Figure 2, Key No. 2).

9. Disconnect the inlet and outlet unions and move the

heater enough to allow removal of the manifold
adapter and the inlet/outlet manifold as a unit (See
Figure 2, Key No. 3).

1/2" Insulation

OFF

ON

OFF

ON

Figure 1: Isolate and Drain Heater; Disconnect Power

2

Blanket

1" Insulation

Flameholder Insulation
Cap

Condensate
Evaporator

1" Insulation

1/2" Insulation
Blanket

3120 1197

Power

Combination Gas Control Valve OFF

Turn Clockwise
and press down
to turn off gas.

Manual/Gas Valve OFF

O
N

FF
O

VENT

PRESS

TAB

PILOT

O
N

F
F
O

T

N
E
V

S
S

PRE

B

TA

T
O

PIL

Remove Water Pressure
Switch to help Manifold
Drain

Drain Inlet/Outlet
Manifold

Inlet

Open

2704 1196

Drain Cock(s) and Plugs
OPEN

Close Isolation Valves

Outlet

3

10. Unscrew the bolts that attach the manifold adapter to
the tube sheet and remove the manifold adapter and
the inlet/outlet manifold as a unit.

11. Carefully disconnect all three metering tubes from the
Combustion Air Blower Assembly (1 to the Combination
Gas Control Valve, 2 to the Air Flow Switch).

12. Remove the bolt from the Gas Piping Clamp.

13. Unplug all wires to the Control Box. Unscrew three
nuts and remove the Control Box, the Heat Shield, and
the Membrane Pad and Cover as a unit (See Figure 2,
Key No. 4).

14. Unscrew the four nuts holding the Blower Adapter
Plate to the top of the Combustion Chamber and
remove the Combustion Air Blower, the Igniter, the
Combination Gas Valve and associated piping and the
Blower Adapter Plate as a unit (See Figure 2, Key No.

5). Remove the Flameholder and Flameholder Cone (if
used).
NOTICE: BE CAREFUL not to break or crack the igniter
– it is fragile!

15. Unscrew the nuts holding the Combustion Chamber
top to the Combustion Chamber body.

16. Unscrew 4 hold-down nuts from the hangers support­ing the Combustion Chamber.

17. Wrap a shop rag around each hanger, one at a time (be
careful; it’s sharp) and hammer down on the Lower
Enclosure while lifting the hanger by the shop rag. This
will lift the hanger up off of the hold-down bolt.

18. Lift the Combustion Chamber out of the Lower
Enclosure.

Heavy parts; can cause personal injury.
When lifting, use all proper precautions for the weights
involved.

19. Cut the RTV all the way around the top of the

Combustion Chamber with a screwdriver.

20. With a mallet and screwdriver, go around the
Combustion Chamber cover tapping up until the RTV
separates and releases the Combustion Chamber cover.
Be careful not to damage the Combustion Chamber.

21. Remove the Combustion Chamber cover.

California’s Proposition 65 lists
Refractory Ceramic Fibers heated to 1800° F or higher
as a possible human carcinogen. See the warning box

on Page 6 for further information. Call 1-800-752-0183
for a Material Data Safety Sheet (MSDS).

22. Remove the top insulation, the Heat Exchanger Coil,
the Condensate Evaporator, the Bottom Insulation, and
the metal spacer from the Combustion Chamber. Do
not remove the RTV that seals the manifold mounting
plate to the combustion chamber.

23. Clean up the Combustion Chamber, the Combustion
Chamber cover, and the Spacer. Be sure to completely
remove all RTV from the Combustion Chamber and
Combustion Chamber top.

24. Reinstall the clean spacer in the Combustion Chamber.
Install one 1/2” white Insulation Blanket on top of the
spacer and one piece of 1” “M” insulation on top of the
Blanket. Make sure that the insulation is centered in the
Combustion Chamber.

NOTICE: Model SR/SRC200 heaters built before 1/1/98
require two 1/2” Insulation Blankets.

Figure 2: Removal of major sub-assemblies

1/2" Top
Blanket

1" Top
Insulation

1/2" Bottom
Blanket

1" Bottom
"M" Insulation

Flameholder
Insulation
Cap (Tape
to bottom of
Flameholder)

Spacer

Condensate
Evaporator

Flameholder

3122 1197

Figure 3: Correct order for installation of insulation.

5

4

2

3

1