Sta-Rite Industries Manifold Bypass Valve User Manual

PRESS

TAB

VENT

PILOT

OFF

ONON

Internal Bypass Valve Kit

2661 1096

Risk of fire, explosion, and electrical shock.

Heater service and repair must be performed by a qualified
installer, service agency, or the gas supplier.

Location

The Manifold Bypass Valve is located inside the
Inlet/Outlet Manifold.

NOTICE: The Inlet/Outlet Manifold must be removed to
service or replace the Manifold Bypass Valve.

Function

The Manifold Bypass Valve maintains a constant flow to
the Heat Exchanger by opening to allow excess flow to
bypass the Heat Exchanger.

Servicing Procedure

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
isolation valves to avoid draining the pool.

3. Disconnect the gas pipe back to the external Manual
Gas Valve to allow the heater to move enough to pro­vide working clearance.

4. Remove Drain Plug under the Inlet/Outlet Manifold to
drain the heater.

5. Loosen the inlet/outlet piping unions.

6. Unscrew the Thermal Regulator Plug.

The Thermal Regulator Spring is behind the

plug and will cause the plug to fly if not restrained.

7. Remove the Thermal Regulator along with the spring
attached to it.

8. Remove the Inlet/Outlet Manifold by removing the 10
bolts holding the Manifold to the tube sheet.

9. Carefully pry the bottom plate off of the Manifold. The
Manifold O-ring and insert will come off with the bot­tom plate.

10.Remove the baffle plate to gain access to the Internal
Bypass Valve chamber.

11. Remove the Bypass Valve Assembly and replace it with
a new one.

12. To Replace the valve, reverse Steps 1 through 10 above.

NOTE: Carefully tap parts together to allow Manifold bolts to
start. When tightening the Inlet/Outlet Manifold bolts, tighten
to 75-115 in-lb. Make sure that O-Rings and sealing surfaces
are clean and that the O-Rings are correctly positioned.
O-ring replacement is recommended.

Safety Precautions:

Fire or explosion hazard. Disconnect all

power to the heater and close the External Manual Gas
Valve before starting this procedure.

Projectile hazard. The Thermal Regulator

plug has a spring behind it. Restrain it when removing it

from the Manifold to prevent it from flying and possibly
injuring persons nearby.

Manifold Bypass Valve

Procedure for Plastic Manifold. See other side of sheet for Cast Iron Manifold with Adapter Procedure.

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

Printed in U.S.A. © 2001, Sta-Rite Industries, Inc. S448 (Rev. 2/27/01)

Manifold Bypass Valve Kit

Torque the Manifold bolts in sequence
as shown, then go once around the
Manifold and re-tighten the bolts to
specified torque.

98

54

12

3 6

710

75-115 in.-lbs./8.4-12.9 nm

3883 0101

PRESS

TAB

VENT

PILOT

OFFOFF

ONON

Internal Bypass Valve Kit P/N 77707-0001

Risk of fire, explosion, and electrical shock.

Heater service and repair must be performed by a qualified
installer, service agency, or the gas supplier.

Location

The Manifold Bypass Valve is located inside the
Inlet/Outlet Manifold.

NOTICE: The Inlet/Outlet Manifold must be removed to
service or replace the Manifold Bypass Valve.

Function

The Manifold Bypass Valve maintains a constant flow to
the Heat Exchanger by opening to allow excess flow to
bypass the Heat Exchanger.

Servicing Procedure

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
isolation valves to avoid draining the pool.

3. Disconnect the gas pipe back to the external Manual
Gas Valve to allow the heater to move enough to pro­vide working clearance.

4. Open the Drain Cock under the Inlet/Outlet Manifold
to drain the heater.

5. Loosen the inlet/outlet piping unions.

6. Unscrew the Thermal Regulator Plug.

The Thermal Regulator Spring is
behind the plug and will cause the plug to fly
if not restrained.

7. Remove the Thermal Regulator along with the spring

attached to it.

8. Remove the Inlet/Outlet Manifold by removing the 8
bolts holding the Manifold to the Manifold Adapter.

9. Remove the baffle plate and O-ring to gain access to
the Internal Bypass Valve chamber.

10.Remove the Bypass Valve Assembly and replace it with
a new one.

11. To Replace the valve, reverse Steps 1 through 10 above.

NOTE: When tightening the Inlet/Outlet Manifold bolts, tight­en to 125-150 in-lb. Make sure that O-Ring and sealing sur­faces are clean and that the O-Ring is correctly positioned.

Safety Precautions:

Fire or explosion hazard. Disconnect all

power to the heater and close the External Manual Gas
Valve before starting this procedure.

Projectile hazard. The Thermal Regulator

plug has a spring behind it. Restrain it when removing it

from the Manifold to prevent it from flying and possibly
injuring persons nearby.

REPAIR PARTS LIST

Manifold Bypass Valve

Procedure for Cast Iron Manifold with Adapter. See other side of sheet for Plastic Manifold Procedure.

Part Part

Description Qty. No.

Internal Bypass Valve Kit 77707-0001
Spring Retainer 1 42001-0088
Spring 1 37607-0012
Separator Plate 1 42001-0011
Bypass Valve Poppet 1 42001-0014

Manifold Bypass Valve Kit