Raypak Swimming Pool Heater 207A User Guide

INSTALLATION AND OPERATING

INSTRUCTIONS

GAS-FIRED POOL AND SPA HEATER

Atmospheric Models

206A, 266A, 336A and 406A

Low NOx Models

207A, 267A, 337A and 407A

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.

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

reference.

CATALOG NO. 6000.59E

Effective: 02-01-06

Replaces: 12-16-05

P/N 241236

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CONTENTS

PART ONE

OWNER'S OPERATING INSTRUCTIONS

Wiring Diagram - Digital Models, Low NOx

SECTION 4

SERVICING INSTRUCTIONS

General Location of Controls

Control Panel Removal

Control Adjustments - Digital Models

Control Adjustments - Millivolt Models

Digital Thermostat Controls

Thermostat Control Operation

Diagnostics

SECTION 1

START-UP PROCEDURES

Before Start-Up

Lighting Instructions & Shut-Off Procedures -

Manually Lighted Pilots MV

Operating Instruction & Shut-Off Procedures - 33

Automatically Lighted Pilots IID

After Start-Up

Codes

SECTION 2

CAUTION

SECTION 3

Reading a Fault

Remote Control Installation and Operation

Remote Operation

MAINTENANCE & CARE PROCEDURES

Pool & Spa Water Chemistry

Automatic Chlorinators & Chemical Feeders

Cold Weather Operation

Winterizing the Pool & Spa Heater

PART TWO

INSTALLATION & SERVICE INSTRUCTIONS

SECTION 1

RECEIVING EQUIPMENT

SECTION 2

Activating the Remote

Remote Control Wiring

2-Wire Remote Control

3-Wire Remote Control

Water Pressure Switch

Flame Roll-Out Safety Switch

High Limits

Pilot Safety

Burner Tray Removal (ATM)

Gas Valve Removal (ATM)

Main Burner and Orifice Removal (ATM)

Pilot Removal and Cleaning

Heat Exchanger Removal

Tube Cleaning Procedure

Desooting Procedure

GENERAL SPECIFICATIONS

SECTION 3

INSTALLATION INSTRUCTIONS

Code Requirements

Clearances

Outdoor Heater Installation

Florida Building Code 2001

Indoor Heater Installation

Outdoor Stack/Indoor Stack

Atmospheric Specifications and Dimensions

Low NOx Specifications and Dimensions

Combustion and Ventilation Air

Vent Piping

Combustion Chamber Removal

Immersion Well Replacement

Unitherm Governor (U.G.) Replacement

Low NOx Pool Heaters

Operation

Start-Up Procedures

Visual Inspection

Electrical

Gas Supply Connections

Gas Pressure Regulator

Gas Pressure Adjustment Locations

Pipe Sizing For Gas Connections

Plumbing For Water Connections

Flow Rates

Flame Roll-Out Safety Switch

Burner Tray Removal

Gas Valve Removal

Main Burner and Orifice Removal

Pilot Removal

Combustion Blower Removal

Polymer Headers

SECTION 5

Cast Iron Headers

TROUBLESHOOTING

Electrical - Standing Pilot Millivolt

Electrical - Electronic Ignition (IID)

Digital Control Logic - Flow Chart

SECTION 6

REPLACEMENT PARTS

Illustrated Parts List

Part Numbers

Unitherm Governor Operation

Internal Automatic Bypass Valve

External Auxiliary Bypass Valve

Auxiliary Bypass Valve Adjustment

Pressure Relief Valve Installation

Heat Exchanger Pressure Drop Tables

Heat Exchanger Reversal Procedure

Electrical Wiring

Millivolt Models

Digital Models

Transformer Wiring

Wiring Diagram - Millivolt (Mechanical Therm.)

Wiring Diagram - Digital Models, Atmospheric

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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

Fig. # 9472

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 set-

tings 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 31).

BEFORE START-UP

BURNERS

WATER

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 must be flowing through the heater during oper-

ation. Ensure that system is filled with water and have

pump operating.

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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

fire department.

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

hand. When lighting the pilot, follow these

instructions exactly.

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 explo-

sion.

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.

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

under water. Immediately call a qualified serv-

ice technician to inspect the appliance and to

replace any part of the control system and any

gas control which has been under water.

*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.

ROBERTSHAW PILOT

HONEYWELL PILOT

Fig.# 8083.0

Fig.# 8084.1

8. Turn gas control knob counter-clockwise

to "Pilot"

7. Locate pilot mounted on the right side panel of

the burner tray.

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.

HONEYWELL

MILLIVOLT

GAS VALVE

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

Fig.# 9265

gas

control

knob

counter-clockwise

to "On".

INVENSYS/

ROBERTSHAW

MILLIVOLT

11. Replace heater door panel.

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

13. Set thermostat to the desired setting.

GAS VALVE

Fig.# 9263

SHUT-OFF PROCEDURE

1. Set the thermostat to the lowest setting.

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

3. Remove heater door panel.

4. Push the gas control knob slightly and turn

clockwise to "Off". Do not force.

5. Replace heater door panel.

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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)

*If you cannot reach your gas supplier, call the

fire department.

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do

not try to light the pilot by hand.

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.

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.

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.

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.

*Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical 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.

HONEYWELL

VR 8300 GAS

VALVE IID

GAS

INLET

Fig.# 8300

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

ROBERTSHAW 7000

GAS VALVE IID

"Off". Model 206: Push in and move gas con-

trol lever counter-clockwise

position.

to "Off"

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.

Fig.# 8080.0

ROBERTSHAW 7200

GAS CONTROL

LEVER SHOWN

IN “OFF”

8. Turn gas control knob counter-clockwise

to "On". (Honeywell VR 8300 and

Robertshaw 7000)

POSITION

9. Replace heater door panel.

10. Turn on all electrical power to the 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.

GAS

INLET

Fig.# 8934.1

SHUT-OFF PROCEDURES

1. Set the thermostat at the lowest setting.

2. Turn off all the electrical power to the appli-

ance if service is to be performed.

3. Remove heater door panel.

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

For Robertshaw 7200 gas valve.

Push in and move gas control lever counter-

clockwise

to "Off" position.

4. For Honeywell VR 8300 and Robertshaw

5. Replace heater door panel.

7000 gas valve.

Turn gas control knob clockwise

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AFTER START-UP

Feel the inlet and outlet pipes. Outlet pipe should be

only slightly warmer than the inlet. It should not be hot.

WARNING: Should overheating occur or the gas

supply fail to shut off, turn off the manual gas control

to the appliance.

VISUAL INSPECTION - ATMOSPHERIC HEATERS

With the heater on, remove the door and make a visu-

al check of the pilot and burner. The flame should be

blue with a well-defined pattern.

Fig. # 9438

WARNING: Operation of the heater without water

circulation will cause rapid and severe damage to

the heater.

4" MAX

SECTION 2 - CAUTION

Fig. # 8205.2

Elevated water temperature can be hazardous. The

U.S. Consumer Product Safety Commission has these

guidelines:

MAIN BURNER FLAME

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.

Fig.# 8964.1

MILLIVOLT PILOT BURNER FLAME

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.

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

4. Before entering the spa or hot tub, users should

check the water temperature with an accurate ther-

mometer; spa or hot tub thermostats may err in reg-

ulating water temperatures by as much as 4°F

(2.2°C).

5. Persons with a medical history of heart disease, cir-

culatory problems, diabetes, or blood pressure

problems should obtain a physician's advice before

using pools or hot tubs.

checked thereafter.

Refer to Pressure Switch

Adjustment on pg. 37 of this manual).

6. Persons taking medications which induce drowsi-

ness, such as tranquilizers, antihistamines, or anti-

coagulants, should not use spas or hot tubs.

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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).

SECTION 3 - MAINTENANCE AND

CARE PROCEDURES

To be followed one month after start-up and then semi-

annually.

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.

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 opera-

tion.

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 exchang-

er tubes, reducing heater efficiency and damaging the

heater. If the pH drops below 7.2, this will cause cor-

rosion of the heat exchanger and severely damage the

heater. Heat exchanger damage resulting from chem-

ical imbalance is not covered by the warranty.

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 illus-

trated on page 7. Yellow flame means restriction

of the air openings. Lifting or blowing flame indi-

cates high gas pressure. Low flame means low

gas pressure. Should the latter occur, shut the

heater off and contact your gas supplier or quali-

fied service agency.

AUTOMATIC CHLORINATORS AND

CHEMICAL FEEDERS

All chemicals must be introduced and completely dilut-

ed 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).

5. On indoor heaters, clean room intake openings to

ensure adequate flow of combustion and ventila-

tion air.

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.

CAUTION: Combustion air must not be contaminat-

ed by corrosive chemical fumes which can damage

the heater and void the warranty.

See plumbing diagram page 21.

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.

6. Keep area around heater clear and free from com-

bustible 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.

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

remove debris.

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COLD WEATHER OPERATION

IMPORTANT FREEZE INFORMATION

MODERATE CLIMATE: Heater operation can contin-

ue during short-term cold spells. When temperatures

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 protec-

tion. 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 cov-

ered by the warranty.

For cold climate areas, please follow the winterizing

procedures listed.

WINTERIZING THE POOL & SPA HEATER

Heaters installed outdoors in freezing climate areas

may be shut down for the winter. Observe the follow-

ing procedure for winterizing the heater:

1. Turn off gas valve, manual gas valve, and electri-

cal supply to the heater.

2. 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 head-

er. Open drain plug on return header.

Return Header

Drain Plug

Fig. No# 2001

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.

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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 represen-

tative.

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)

1. "Pagoda" top

ASME UNIT (CAST IRON HEADERS)

1. "Pagoda" top

2. 2" CPVC union with "O" rings (2)

3. Plastic pipe finish flange for gas line

4. Bonding lug with mounting screw

(Digital models only)

2. In/Out flanges (2)

3. 1-1/2" flange gaskets (2)

4. 2" flange gaskets (2)

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.

(Digital 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.

MODEL & SERIAL NO.

LOCATED ON

RATING PLATE

(ALTERNATE

LOCATION)

LABEL ON CARTON

Serial No.

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SECTION 2 - GENERAL SPECIFICATIONS

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

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

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

Millivolt Heater with Honeywell Gas Valve

+32°F to +175°F

Millivolt Heater with Robertshaw Gas Valve 0°F to +175°F

Digital 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.

Low 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.

IMPORTANT NOTICE

These instructions are intended only for the use of qualified personnel, specifically trained and experienced in

the installation of this type of heating equipment and related system components. Installation and service per-

sonnel may be required by some states to be licensed. If your state is such, be sure your contractor bears the

appropriate license. Persons not qualified shall not attempt to fix this equipment nor attempt repairs according

to these instructions.

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

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

CODE REQUIREMENTS

NOTE: The heater should not be located in an area where possible water leakage will result in damage to the

area adjacent to the 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 com-

bustion air flow.

Installation must be in accordance with local codes, or, in the absence of local codes, with the latest edition of

the the National Fuel Gas Code, ANSI Z223.1/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for

Canada, the latest edition of CAN/CGA-B149.1 and B149.2 Installation Codes, and Canadian Electrical Code,

CSA C22.1 Part 1 and Part 2.

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CLEARANCES

ALL HEATERS

For clearances from combustible surfaces, see the

chart below.

When installed according to the listed minimum clear-

ances from combustible construction, the pool heater

can still be serviced without removing permanent

construction around the heater.

CLEARANCE FROM

COMBUSTIBLE CONSTRUCTION

However for ease of servicing, we recommend a clear-

ance 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.

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)

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 struc-

ture around the heater.

OUTDOOR INSTALLATION:

Top* - Unobstructed (Outdoor Stack)

Top*** - 36” (Stackless Top)

Floor - 0”

Back - 6”

Right Side - 12” (Water Side)

Left Side - 6”

(Opposite Water Side)

FLOORING: This heater can be installed on com-

*Clearance from top of vent terminal.

**Do not install on carpeting.

bustible 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 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.

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

must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters

installed under overhangs with the use of gutters.

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.

For 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/CGA-B149.1 and

B149.2.

4 ft

Minimum

4 ft

Minimum

4 ft

Minimum

3 ft

Minimum

1 ft

10 ft

Minimum

Forced Air Inlet

For installations in Florida, that must comply with the Florida Building Code 2001, follow the directions on p14

for the installation of hurricane tie-down brackets for all models.

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FLORIDA BUILDING CODE 2001

WIND SPEED = 150 MPH, 3 SECOND GUST

EXPOSURE = C

206/266/336/406 Atmospheric

MODEL #

206

20”

23”

26”

29”

266

336

406

40”

28”

2” x 8” x 1/8” Raypak Pallet

Anchor Bracket (4 Total)

3” Min. Conc.

Pad by others

1/4” x 1-3/4” S.S. Tapcon Bolt & Washer

NOTE: Use hole closest to unit with

washer overlapping edge of unit.

Min. Edge

Distance

6”

Min. Edge

Distance

HOT

6”

(1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer

Ea. Raypak Pallet Anchor Bracket

Use hole closest to unit (4 total)

(1)–1/4” x 1-3/4” S.S. Tapcon Bolt & Washer

Ea. Raypak Pallet Anchor Bracket

Use hole closest to unit (4 total)

3” Min. Conc.

Pad by others

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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-

nicate with an occupied area. Refer to the latest edition of CAN/CGA-B149.1 and B149.2 for specific require-

ments. Locate heater as close as is practical to a chimney or gas vent. Heater must always be vented to the out-

side. See Vent Piping section (pg. 17-18) 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.

INDOOR STACK KIT INCLUDES:

(1) Drafthood, unpainted

(1) Adapter plate

OUTDOOR STACK KIT INCLUDES:

(1) Drafthood, painted

(1) Adapter plate

(3) Mounting brackets (clips)

(3) Screws

(3) Mounting brackets (clips)

(1) Top panel cover

(1) Instructions

(2) 1-foot sections of metal tape

(3) Screws

Clips

(1) Instructions

Clips

OUTDOOR STACK INDOOR STACK

**REFER TO INSTALLATION INSTRUCTIONS

INSIDE BOX FOR INSTRUCTIONS ON HOW TO

INSTALL OUTDOOR/INDOOR STACK.

Model

Part No.

206A/207A

266A/267A

336A/337A

406A/407A

009834

009835

009836

009837

009838

009839

009840

009841

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SPECIFICATIONS AND DIMENSIONS

ATMOSPHERIC UNITS

8-7/8"

4-3/8"

(3-3/8" ASME)

(6-5/8" ASME)

INDOOR

DRAFTHOOD

32-11/16"

ELECTRICAL

CONNECTION

40"

STACKLESS

OUTDOOR TOP

38"

26-5/8"

(28-5/8" ASME)

13-1/4"

GAS

CONNECTION

28"

Shipping Weights (lbs)

Standard

Heater

ASME

Heater

BTUH

Input

(000)

(A)

Cabinet

Width

(B)

Flue

Dia.

(C)

Indoor

Drafthood

(J)

Min.

Indoor

Heater

Model

Gas

Conn. Conn.

Water w/Stackless w/Stackless Draft-

Top

hood

R206A

R266A

R336A

R406A

199.5

266.0

332.5

399.0

20”

23”

26”

29”

6”

7”

8”

9”

61-5/8”

62”

11-3/4”

11”

3/4”

2”

187

206

210

230

249

229

249

268

63”

10-5/8”

12-1/8”

64-9/16”

Designation for a Digital heater using propane gas is “EP”; a Digital 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, digital, 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.

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SPECIFICATIONS AND DIMENSIONS

Low NOx UNITS

8-7/8"

4-3/8"

(3-3/8" ASME)

(6-5/8" ASME)

INDOOR

DRAFTHOOD

34"

26-1/2"

ELECTRICAL

CONNECTION

STACKLESS

OUTDOOR TOP

31-13/16"

20-1/2"

(22-1/2" ASME)

7-3/4"

GAS

CONNECTION

28"

Shipping Weights (lbs)

Standard

Heater

ASME

Heater

BTUH

Input

(000)

(A)

Cabinet

Width

(B)

Flue

Dia.

(C)

Indoor

Drafthood

(J)

Min.

Indoor

Heater

Model

Gas

Conn. Conn.

Water w/Stackless w/Stackless Draft-

Top

hood

R207A

R267A

R337A

R407A

199.5

266.0

332.5

399.0

20”

23”

26”

29”

6”

7”

8”

9”

55-5/8”

11-3/4”

11”

3/4”

2”

174

193

56”

57”

197

219

237

216

238

256

10-5/8”

12-1/8”

58-1/2”

Designation for a Digital 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, digital, 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.

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COMBUSTION AND VENTILATION AIR

(Indoor Units Only)

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply open-

ings 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(Canada-

CAN/CGA-B149.1 and B149.2) and any local codes that may have jurisdiction.

B. All Air From Outdoors:

A. All Air From Inside The Building:

Each opening shall have a minimum net free area

as noted:

When air is supplied directly from outside of build-

ing, each opening shall have a minimum net free

area as noted:

Model Square Inches

Model Square Inches Model Square Inches

206/207

266/267

336/337

406/407

206/207

266/267

200

266

336/337

406/407

333

399

100

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/CGA-B149.1 and B149.2). As much as pos-

sible, 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 inter-

vals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents support-

ed 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 Part No.

206/207 009832

266/267 009832

336/337 009833

406/407 009833

Optional Raypak D-2

Power Vent

Fig.# 9469

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 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/CGA-B149.1 and B149.2).

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The discharge opening must be a minimum of 2 ft ver-

tically from the roof surface and at least 2 ft higher than

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

at least 5 ft in vertical height above the drafthood out-

let. The vent cap location shall have a minimum clear-

ance 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.

GAS SUPPLY CONNECTIONS

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 sup-

ported to maintain proper clearances from combustible

construction.

Type "B" double-wall or equivalent vent pipe is recom-

mended. 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/CGA-

B149.1 and B149.2).

Fig.# 8090.1

Gas piping must have a sediment trap ahead of the

heater gas controls, and a manual shut-off valve locat-

ed outside the heater jacket. All gas piping should be

tested after installation in accordance with local codes.

10' OR LESS

VENT CAP

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 psig (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. FAIL-

URE TO FOLLOW THIS PROCEDURE MAY DAM-

AGE 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.

2' MIN

5' MIN

VENT PIPE

DRAFT HOOD

NOTE: Do not use Teflon tape on gas line pipe thread.

flexible sealant suitable for LP gases is

recommended.

A minimum of 7 in. WC and a maximum of 14 in. WC

upstream pressure under load, and no-load conditions

must be provided for natural gas or a minimum of

12 in. WC and a maximum of 14 in. WC for propane

gas.

HEATER

Fig.# 8119.2

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GAS PRESSURE REGULATOR

ELECTRONIC IGNITION GAS VALVES-CONTINUED

The gas pressure regulator is preset at 4.0 in. WC

throughout for natural gas, 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 (3.0 in. WC for Low NOx) and 10.5 in. WC

propane gas. If an adjustment is needed, remove seal

and turn adjustment screw clockwise

pressure or counter-clockwise

sure.

to increase

to decrease pres-

Gas Pressure

Adjustment

NOTE: Low NOx gas valves are non-adjustable; set-

ting was made at the manufacturer

(Invensys/Robertshaw).

Robertshaw 7200

(Heater Model 206)

Robertshaw 7000 BDER

(Heater Models 266-336)

MANOMETER

Gas Pressure

Adjustment

Robertshaw 7000 DERHC

(Heater Model 406)

Non-Adjustable

Gas Valve

MANUAL

SHUT-OFF

VALVE

GAS PRESSURE

TEST AT GAS VALVE

Robertshaw 7000 BDERF

(Heater Models 207-407)

GAS PRESSURE ADJUSTMENT LOCATIONS

MILLIVOLT GAS VALVES

PIPE SIZING FOR GAS CONNECTIONS

Maximum Equivalent Pipe Length

Natural Gas 1000 BTU/FT³0.60

Specific Gravity @ 0.5 in. WC Pressure Drop

Gas Pressure

Adjustment

Propane Gas 2500 BTU/FT³1.53

Fig # 9263

Specific Gravity @ 0.5 in. WC Pressure Drop

Input

3/4”

1”

1-1/4”

1-1/2”

Robertshaw 7000

(Heater Models 206-406)

Model (KBTU)

ELECTRONIC IGNITION GAS VALVES

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

Gas Pressure

Adjustment

406/407 399.0

15 20 55 95 225 215 480

Honeywell VR8304

(Heater Models 206-

406)

Fig # 9263

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PLUMBING FOR WATER CONNECTIONS

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.

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.

CHEMICAL

INSERTION POINT

(IF IN THE PIPING

SYSTEM)

VALVE CLOSED

WHEN SYSTEM

IS HEATING THE POOL

HEATER

WITH INTERNAL

VALVE CLOSED

BYPASS

WHEN SYSTEM

IS HEATING THE SPA

ISOLATION

TO SPA

VALVE

BALL VALVE

PRESSURE

FILTER

RELIEF VALVE

PUMP

COARSE

STRAINER

UNION

CHECK VALVE

TO POOL

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).

FLOW RATES

*When flow rates exceed maximum GPM an external auxil-

iary bypass valve is required. See external bypass valve

section for details.

MODEL

206/207

266/267

336/337

406/407

PIPE SIZE

MIN. GPM MAX. GPM*

1-1/4”–1-1/2” - 2”

125

Fig.# 2012

POLYMER HEADERS

CAST IRON HEADERS (ASME)

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POLYMER HEADERS (STANDARD MODELS)

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

Before attaching the 2-inch unions to the inlet/outlet 1-1/4" galvanized pipe as a slip connection.

header, make sure the O-rings are properly seated in GASKET DESIGN #2: Accepts 2" copper tube as a slip

the grooves. Use AquaLube or equivalent non-petro- connection. The flange is threaded for 2" screw in pipe

leum-based lubricant on the O-ring. Hand tighten the connections. Also used with the 2" CPVC adapters.

unions. Glue PVC piping directly to the unions.

INLET/OUTLET HEADER - POLYMER

O-Ring

Header Flange

(CPVC)

Fig.# 8097.1

Fig.# 8095.1

Header Flange Nut

(CPVC)

INLET/OUTLET HEADER - ASME

Fig.# 2002.1

Flange Gasket

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)

Fig.# 8093.1

Header Flange

Heater must be located so that any water leaks will not

damage the structure of adjacent area. High tempera-

ture 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.

UNITHERM GOVERNOR OPERATION

CAUTION:

The patented Unitherm Governor is a thermostatic

mixing valve specifically designed to maintain con-

stant heater internal temperature between 105° and

115°F despite continually changing flow rates from

the filter and changing pool temperatures. This nar-

row range is needed to prevent damaging condensa-

tion 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 temper-

atures.

Header

Header Flange

(Supplied)

CPVC Connector

(Supplied)

Plumbing

WARNING: NEVER install PVC directly into header

flanges. Use the 2" CPVC adapter supplied loose

with the heater.

U.G. Plug

(Polymer)

DO NOT use petroleum-based assembly fluids (such

as petroleum jelly or lubricating oil). If assembly lube is

required, use a silicon base such as AquaLube etc.

Unitherm

Governor

There are two sets of flange gaskets supplied with

your heater. Use the appropriate gaskets for all your

heater connections. Discard unused set.

Gasket

Fig.# 2011

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INTERNAL AUTOMATIC BYPASS VALVE

PRESSURE RELIEF VALVE INSTALLATION

In addition to the Unitherm Governor, a built-in auto- To conform to local building codes, it may be neces-

matic bypass valve is provided in the in/out header. sary to install a pressure relief valve. A 3/4" pressure

While the Unitherm Governor responds to the changes relief valve, having a capacity equal to the BTUH out-

in water temperature in the heater, the internal bypass put of the model to be installed, is recommended for

valve automatically responds to changes in water this heater. The maximum acceptable pressure relief

pressure in the piping system. Proper amount of water valve setting is 125 psi.

flow is maintained through the heater under varying

pressures dictated by the conditions of the pump and A 3/4" NPT connection is provided in the Polymer

filter.

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.

Bypass Disc

Spring

POLYMER HEADER

(STANDARD MODELS)

Bypass Body

Pressure Relief Valve

PRV Discharge

Connection

Fig.# 2003

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

In/Out Header

Fig. #2004

serves to eliminate needless pressure drop through A 3/4" NPT connection is provided in the header for

the heater and accompanying reduction in the flow installation of a pressure relief valve. The valve shall

rate to the spa jets, etc.

From Heater

be installed in a vertical position.

CAST IRON HEADER

(ASME MODELS)

PRV

To Heater

To Pool/

Spa

From Pool/

Spa

AUXILIARY BYPASS VALVE

(DO NOT USE GATE VALVE)

Fig.# 81.50.0

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 connec-

tion throughout its entire length and must pitch down-

ward 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.

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 comfort-

able to the touch. If pipe is hot, close bypass; if cold,

open bypass.

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HEAT EXCHANGER PRESSURE DROP TABLES

POLYMER HEADER (STANDARD MODELS)

CAST IRON HEADER (ASME MODELS)

PRESSURE DROP (FT OF HEAD)

FLOW

GPM

206/207

266/267

336/337

406/407

206/207

1.8

266/267

3.9

336/337

3.9

406/407

3.9

100

1.5

2.8

4.1

100

1.7

4.6

5.8

2.2

8.0

2.1

5.2

6.5

2.5

9.0

2.4

5.6

7.2

2.7

9.8

2.8

6.1

7.7

3.3

10.5

11.0

11.5

14.0

17.0

10.5

11.0

11.5

14.0

17.0

10.5

11.0

11.5

14.0

17.0

3.7

6.5

8.2

4.3

4.6

7.3

8.7

5.5

5.7

8.8

10.2

13.0

10.2

13.0

6.8

10.0

8.2

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HEAT EXCHANGER REVERSAL PROCEDURE - STANDARD MODELS

1. Remove right and left side access panels

(Figure 1).

2. Disconnect wires at high limit, AGS (automatic gas

shut-off), and pressure switch on the in/out

header (Figure 2).

3. Digital Models: Remove the thermostat tempera-

ture 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 sen-

sor bulb and retainer clip from the sensor well

(Figure 4). Re-route the sensor bulb to the left side

of the heater.

Fig. #1

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-petrole-

um-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. Digital Models: Insert the tempera-ture sensor in

the compression fitting and tighten 1/2 turn past

hand-tight.

Fig. #2

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.

For ASME Models call your factory representative.

Fig. #3

Fig. #5

Fig. #4

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ELECTRICAL WIRING

CONTROL BOX

(FACTORY MOUNTED

LOCATION)

OPTION LOCATION

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.

LEFT SIDE FIELD WIRING

MILLIVOLT MODELS

The Millivolt models are equipped with a self-generat-

ing 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.

SWAY BRACE

DIGITAL MODELS

NOTE:

BONDING LUG

(STANDARD

LOCATION)

BONDING LUG

(OPTIONAL

LOCATION)

Heaters are factory-wired for 240 VAC power supply.

The standard field-wiring connection is on the right

side of the heater.

ATMOSPHERIC

Wiring locations

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 bet-

ter access to wiring.

CONTROL BOX

(FACTORY MOUNTED

LOCATION)

2. Remove the four (4) screws that hold down the

junction box to the sway brace.

OPTION LOCATION

LEFT SIDE FIELD WIRING

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.

SWAY BRACE

9. Re-install P6 connector, ground wires (SPG),

transformer, junction box, front door, and plug right

side with the left side’s grommet plug.

BONDING LUG

(OPTIONAL

LOCATION)

BONDING LUG

(STANDARD

LOCATION)

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.

LOW NOx

Wiring locations

NOTE: 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.

The Electronic Intermittent Ignition Device automati-

cally lights the pilot and main burners upon a call for

heat. The heater is supplied with a dual-voltage trans-

former for 120 VAC or 240 VAC input power hookup.

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TRANSFORMER WIRING

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

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

red wire independently.

120V ATMOSPHERIC HEATER

120V LOW NOx HEATER

BLACK

HOT

BLACK

WHITE

GREEN

BLACK

WHITE

RETURN

SUPPLY

SIDE

SUPPLY

SIDE

NEUTRAL

WHITE

NEUTRAL

HEATER

4 WIRES

HEATER

7 WIRES

GROUND

GREEN

RED

Fig. #9471

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 Low NOx pool heaters attach a wire nut to

each white wire independently.

240V ATMOSPHERIC HEATER

240V LOW NOx HEATER

BLACK

HOT

BLACK

RED

HOT

RED

HOT

RED

SUPPLY

SIDE

SUPPLY

SIDE

RED

HEATER

4 WIRES

HEATER

7 WIRES

GROUND

GREEN

WHITE

Fig. # 9471.1

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 to make connection to the load/pump side of the time

clock. If using the switched GFCI power source, the heater could display false service indicators on the display

panel if the pump is turned off.

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WIRING DIAGRAM - MILLIVOLT (MECHANICAL THERMOSTAT)

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WIRING DIAGRAM - DIGITAL MODELS - ATMOSPHERIC

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WIRING DIAGRAM - DIGITAL MODELS - LOW NOx

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SECTION 4 - SERVICING INSTRUCTIONS

GENERAL LOCATION OF CONTROLS

ATMOSPHERIC

Drain Plug

(Located in rear header)

Mounted On Top

Of Header

HL1 - High Limit

HL2 - High Limit

Pressure Switch

Temp Sensor/Well

Digital Thermostat

Circuit Board

Unitherm Governor

Draw Plug

Roll-Out

Switch

Transformer

Gas Valve

Pilot

LOW NOx

Mounted On Top

Of Header

HL1 - High Limit

HL2 - High Limit

Pressure Switch

Temp Sensor/Well

Drain Plug

(Located in rear header)

Blower

Relay

Unitherm

Governor

Digital Thermostat

Circuit Board

Blower

Hose

Roll-Out

Switch

Blower

(Manual)

Draw Plug

Gas Valve

Roll-Out

Switch

(Auto)

Air

Switch

Transformer

Pilot

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CONTROL PANEL REMOVAL

CONTROL ADJUSTMENTS - MILLIVOLT MODELS

The water temperature is controlled by the heater ther-

mostat on the upper front panel of the heater. The

control center contains an On/Off switch and one ther-

mostat.

1. Remove (2) screws from front door. Set aside door

for serviceability.

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.

ACCESS

SCREWS

ACCESS

SCREWS

SPA TEMPERATURE

RANGE

POOL TEMPERATURE

RANGE

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.

Fig.# 9473

STAND-BY

TEMPERATURE

SET SCREW

KNOB STOP RING

CONTROL ADJUSTMENTS - DIGITAL MODELS

KNOB STOP SHOWN ABOVE IS

IN THE SPA TEMPERATURE RANGE

Temp Adjust Buttons

Mode Button

OFF

LCD Display

Fig. #9472

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DIGITAL THERMOSTAT CONTROLS

Thermostat operation

Your heater is equipped with a microprocessor-controlled thermostat that controls the pool or spa temperature

by measuring the temperature of the water coming back through the heater. It will then monitor the water tem-

perature and turn the heater back on when it senses that the water temperature is falling below the set point. It

is normal to experience small fluctuations in the return water temperature during the operation of the heater.

The thermostat is calibrated with a very narrow tolerance to ensure accuracy of the set temperature. Thus,

slight fluctuations in water temperature may cause your heater to cycle on and off frequently. This is

not a problem. It will not harm the heater nor interfere with the thermostat’s ability to precisely control the tem-

perature of the pool or spa.

WATER

TEMP

SET

POINT

TEMP

MODE

Fig.# 9480

LCD Display

Temp Buttons

Mode Button

Program button

THERMOSTAT CONTROL OPERATION

The pool heater thermostat, located on the upper front

panel of the heater, controls the pool/spa water tem-

perature. This control center contains a mode button,

up and down temperature adjustment buttons, and an

LCD display.

Mode

Pool or Spa

Actual Water

Temperature

Flame Icon

Mode Button

Setpoint Temperature

DISPLAY CALL FOR HEAT

The MODE button functions as a means to turn the

heater off or on in either the POOL or SPA setting. The

LCD display indicates the mode the heater is in and

the actual water temperature.

Fault History File

To access the Fault History File, press the Mode but-

ton until the display reads OFF. Press both the “UP”

and “DOWN” buttons at the same time (5-7 seconds)

until the display changes and shows a fault code. The

latest fault code will be displayed first. By pressing the

“UP” or “DOWN” buttons, a series of faults will be dis-

played from the last (highest number) to the first (low-

est number). If the buttons are not touched after 5-7

seconds, the display will return to its normal operation.

Temp Buttons

If the heater is in POOL or SPA mode, the desired

water temperature (SETPOINT) will also be displayed

and may be changed using the UP or DOWN buttons.

A manual toggle switch is also provided right below the

MODE button to allow the heater to be turned off.

Operation

In the POOL or SPA modes, the actual water temper-

ature is displayed along with the desired water temper-

ature (SETPOINT). If the heater is firing, a flame icon

will be visible.

To adjust the setpoint temperature, make sure the con-

trol is in the appropriate mode (POOL or SPA) and

push the UP or DOWN buttons.

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Program Button

F/Cfff – Fahrenheit to Celsius

1) To access the program screen, press the Mode

button until the display reads OFF. Remove the

four screws holding the control cover on. Swing

control panel down so the back side of the board

is visible (see page 30). Locate the Program Mode

button as shown in the figure on pg. 32. Press the

program button (5-7 seconds) until SETdef

appears on the digital display. Release the pro-

gram button.

Refer to step one above to access the program

screen. Press the Mode button until F/Cfff 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 “F” or “C” on

the temperature display. Choose the desired tempera-

ture scale. Once this is done, reassemble the control

panel.

SETspa 104 – SPA Set Point Maximum Adjustment

Refer to step one above to access the program

screen. Press the Mode button until SETspa 104

appears on the digital display. Using the “UP” and

“DOWN” buttons will change the Maximum

Temperature Setting to your desired value. The con-

trol can be set for a maximum of 107°F. Once this is

done, reassemble the control panel.

2) Press the Mode button sequentially until the

desired program event is reached. There are 5 dif-

ferent events that can be programmed. They

appear in the sequence listed below:

Resets board to factory default settings.

set

SETpool 104 – POOL Set Point Maximum Adjustment

Refer to step one above access into the program

screen. Press the Mode button until SETpool 104

appears on the digital display. Using the “UP” and

“DOWN” buttons will change the Maximum

Temperature Setting to your desired value. The con-

trol can be set for a maximum of 107°F. Once this is

done, reassemble the control panel.

Resets faults in the History File.

Change from Fahrenheit to Celsius.

SPA setpoint maximum adjustment.

POOL setpoint maximum adjustment.

SETdef – Default Settings

Refer to step one above to access the program

screen. SETdef should appear on the screen. If not,

press the Mode button until SETdef appears on the

digital display. Press and hold both “UP” and “DOWN”

buttons for 5-7 seconds until 3 dashes (---) appear.

This operation resets the operating program to its fac-

tory 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).

Once this is done, reassemble the control panel.

RESfl – Reset Fault History

Refer to step one above to access the program

screen. Press the Mode button until RESfl appears

on the digital display. Press and hold both “UP” and

“DOWN” buttons for 5-7 seconds until 2 dashes (--)

appear.This operation resets the Fault History file to

“0” and clears all the stored faults. Once this is done,

reassemble the control panel.

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NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa ther-

mometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool

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

pool or spa.

DIAGNOSTICS

READING A FAULT

The digital thermostat models are equipped with on-

board diagnostic controls. If there is a safety fault, a The word “SERVICE” will flash on and off if the PC

fault code will be displayed along with a service

indication.

board detects a known fault. The fault will be dis-

played in three big letters on the lower left of the dis-

play.

If the PRS fault code is displayed, it indicates that

there is insufficient water flow through the heater.

Make sure the pool filter and pump strainer are clean

before calling a service representative.

Service Will

3 Letter

Flash

Fault Code

See table

for fault

Fig.# 9485

definition

Fig.# 9482

STATUS CODES

PROGRAM MODES

Display

CFH

CLK

Definition

Display

CCC

F/C

Definition

Celsius setting

Call for heat

Time clock

Change from Fahrenheit to Celsius

Fahrenheit setting

Reset defaults

EOL

End of line test (Factory Use Only)

Low NOx Unit

FFF

LON

LOW

OFF

RES

SET

Caution-low water temperature

Off mode

Set point max adjustment

PRO

REM

SPK

Propane gas configured

Remote control activated

Spark

SPR

Spare fault code indicator

FAULT CODES

Display

Definition

BD1

Board failure

EEP

Microprocessor error

Blower pressure failure

Flame sensing when pilot and gas

valves are closed

FAN

FFL

GVC

GVO

HL1

HL2

IGN

ILO

Gas valve closed

Gas valve open

High limit switch #1 open

High limit switch #2 open

Ignition failure

Ignition lockout

PLT

Pilot failure

PRS

ROL

SNS

VNT

Water pressure switch open

Heat roll-out safety switch open

Sensor failure

Vent switch open

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REMOTE CONTROL INSTALLATION AND OPERATION

CAUTION: Before installing remote controls to the digital 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-

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

controlling the heater by displaying REM in the display. When connecting the heater to a remote system, iden-

tify whether it is a two- or three-wire remote system. Select the appropriate instruction listed below to properly

install the remote to the heater.

REM

OFF Mode

Heating in the SPA Mode

Heating in the POOL Mode

Remote Mode

ACTIVATING THE REMOTE

Pool Common

(BLK/ORN)

The digital thermostat heaters have the ability to dis-

connect from the remote it is wired to. To activate or

deactivate the remote follow these steps:

Spa Common

(ORN/BLK)

Press and hold all three buttons for 5 to 7 seconds.

24VAC HOT

(BLU)

7-PIN Remote

Wiring Connector

WATER

TEMP

SET

POINT

Fig.# 9491

TEMP

REMOTE OPERATION

MODE

The digital model heaters are equipped with the ability

to work with external remote controls. The supplied 7-

pin 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 suppling its own

voltage to the heater, it will not work with this

heater and may damage the digital circuit board.

Fig.# 9480

The digital display format will change and indicate

REMoFF or REMOn.

REMOn = External remote

control active (display will flash

REM)

REMoFF = Remote disabled

(heater thermostat will control

heater - use this mode to test

heater operation)

NOTE: When in remote operation, the keypad

mode and temp buttons are disabled. Remote will

flash even when the unit is off.

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 accumu-

lates on the body. Contact of a finger allows the body to dis-

charge, 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 enclo-

sure for 5 seconds before proceeding.

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REMOTE CONTROL WIRING

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,

cable 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

Wire Nut - BLK/ORN

To Pool (COMM)

its own sensor, push the mode button to the “POOL”

or “SPA” mode and set the desired setpoint (eg. 102

°F for spa).

ORN/BLK - To Spa (COMM)

BLU - 24VAC

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

connect the other side to either the ORANGE/BLACK

wire for "SPA" operation or the BLACK/ORANGE

wire for "POOL" operation.

P8 Connector

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.

See instructions on previous page to activate the

remote control.

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"

BLK/ORN - To Pool (COMM)

ORN/BLK - To Spa (COMM)

BLU - 24VAC

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 connect 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.

See instructions on previous page to activate the

remote control.

P8 Connector

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WATER PRESSURE SWITCH

FLAME ROLL-OUT SAFETY SWITCH

The water pressure switch, or heater actuator, ensures Atmospheric heaters are equipped with a thermal cut-

that the heater operates only when the filter pump is in off device to prevent flame roll-out in the event the

operation. It is located on the inlet/outlet header. It is heat exchanger becomes blocked. This is a "single-

factory set at 1.75 PSI for deck-level installations. use" type fusible link or thermal fuse, that must be

When the heater is located below the level of the spa replaced when disabled by an over-temperature condi-

or pool, it may be necessary to adjust the pressure tion, caused by excessive restriction in the heat

switch to compensate for the no-flow static head. If it exchanger flue passage.

is necessary to adjust the water pressure switch, uti-

lize the following procedure:

WATER PRESSURE SWITCH ADJUSTMENT

1. With pump and heater

on, turn adjustment

Fig.# 9440

knob clockwise until a

click is heard from the

HIGH LIMITS

gas valve.

The heater is equipped with two automatic high limits.

2. Turn adjustment knob

Both are located in the inlet/outlet header. Both are set

counter-clockwise 1/4

to open at 135°F.

turn.

3. Turn pump off and on

NOTE: An erratic high limit is often characteristic of an

several times. Heater

Fig.# 9438

internal heat exchanger problem, e.g. scale build-up,

should shut off immedi-

defective bypass. Refer to Troubleshooting section (on

ately. If it does not,

repeat the above steps.

PRESSURE SWITCH

ADJUSTMENT RANGE

pg. 42).

MAY REQUIRE ADJUSTMENT

FOR LOWER PRESSURE

HIGH LIMIT REMOVAL

1. Shut off main elec-

trical power switch

to heater.

2. Remove inlet/outlet

inspection panel.

3. Remove defective

high limit and

5 FT.

MAX

MAY REQUIRE ADJUSTMENT

FOR HIGHER PRESSURE

5 FT.

MAX

POOL OR SPA

replace with a new

high limit.

Fig.# 9439

4. Replace inspection

panel.

Fig.# 8152.3

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 (pg. 51) for 11 psi

water pressure switch.

PILOT SAFETY - Millivolt Models

Heaters equipped with the standing pilot (millivolt sys-

tem) 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 extin-

guished. 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.

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.

PILOT SAFETY - Digital 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 auto-

matically 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.

CAUTION: Do not operate the heater without the

function of a properly adjusted water pressure switch

or flow switch.

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BURNER TRAY REMOVAL -

PILOT REMOVAL AND CLEANING

ATMOSPHERIC MODELS

1. Disconnect pilot tubing and wires from gas valve.

2. Remove pilot assembly from burner tray.

3. Remove pilot from bracket.

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Remove pilot orifice and air opening (Honeywell

MV unit only), and clean with wire or small brush.

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.

CAUTION! Do not enlarge hole in pilot orifice.

5. Reverse above procedure to reinstall.

9. 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.

Pilot

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

required.

Air

3. Remove burner tray from heater.

4. Turn vertical gas pipe from manifold slightly and

unscrew gas valve.

Opening

5. Reverse above procedure to reinstall.

Orifice

MAIN BURNER AND ORIFICE REMOVAL -

ATMOSPHERIC MODELS

1. Remove burner tray.

2. Remove screws and burner hold-down bracket.

Fig. # 8045.1

Fig. # 8102.0

NOTE: If the heat exchanger is sooted badly, the

burner hold-down bracket and spacer can become dis-

torted from direct-flame impingement and this usually

necessitates replacement of these parts.

HEAT EXCHANGER REMOVAL

1. Shut water, gas and electricity off, close valves

and relieve pressure, then remove relief valve.

Remove side inspection panels.

3. Lift burners from slotted spacers and slide from ori-

fices. Clean with a wire brush.

2. Remove top jacket holding screws.

3. Remove rear top panel.

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.

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.

GAS VALVE

7. Lift heat exchanger straight up using caution not to

damage refractory.

PILOT

8. Reverse above procedure to reinstall. Make sure

the insulation strips are properly replaced on top of

the refractory retainer.

BURNER

GAS

ORIFICE

BURNER

HOLD-DOWN

BRACKET

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Extension Pieces (2)

Auger with Carbide Tip

Wire Brush

Fig.# 8154.0

TUBE CLEANING PROCEDURE

IMMERSION WELL REPLACEMENT

Establish a regular inspection schedule, the frequency (Millivolt and ASME)

depending on the local water conditions and the sever- 1. Shut off water to heater and drain heat exchanger.

ity of service. Do not let the tubes clog up solidly. 2. Remove access panel on water connection side.

Clean out deposits over 1/16" in thickness.

3. Remove old immersion well with bushing and

sleeve.

The heater may be cleaned from the return header 4. Install replacement well in header.

side, without breaking pipe connections. It is prefer-

able, however, to remove both headers for better visi- NOTE: Installation in polymer header should be hand

bility through the tubes and to be sure the ground-up

lime dust does not get into the system.

tight plus 1/2 turn.

Note that you do not remove the top panel or the

heater exchanger, generally.

After reaming, mount the wire brush in place of the

auger and clean out debris remaining in the tubes.

Well Assembly

Another method is to remove the heat exchanger,

ream tubes and immerse heat exchanger in non-inhib-

ited de-scale solvent for severe scale build-up.

DESOOTING PROCEDURE

Fig. #2010

WARNING: SOOT IS COMBUSTIBLE. EXERCISE

EXTREME CARE.

Soot will clog areas between fins and cause eventual

UNITHERM GOVERNOR (U.G.) REPLACEMENT

tube failure. Any sign of soot at the base of the burn- 1. Shut water, gas and electricity off, close valves

ers or around the outer jacket indicates a need for

cleaning.

and relieve pressure.

2. Drain heat exchanger.

1. Remove top and flue collector from cabinet.

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray. (See pg. 38).

4. Remove heat exchanger from the heater and wash

3. Remove retainer plug located next to the outlet

pipe connection.

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

Snap in new U.G.

with a garden hose, making sure soot is removed 5. Reinstall retainer plug, taking care to lubricate

from spaces between fins.

gasket with a non-petroleum based grease such

as AquaLube.

5. Reverse above procedure to reinstall.

NOTE: In extreme cases it may be necessary to do

steam cleaning at the local car wash. DO NOT WIRE

BRUSH.

Retainer Plug

U.G.

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber, you must first have

removed the heat exchanger.

Spring

Gasket

Fig. #2011

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.

Atmospheric Heaters

Low NOx Heaters

REFRACTORY PANELS - TOP VIEW

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LOW NOx POOL HEATERS

The Low NOx pool heaters are certified and tested

under the ANSI Z21.56/CSA 4.7 Standard for Gas-

Fired Pool Heaters.

BLOWER ADJUSTMENT

This Low NOx pool heater is equipped with a combus-

tion air plate (baffle) mounted on the air intake to the

combustion air blower. The baffle has a hole that is uti-

lized to control the air inlet to the blower.

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.

When the combustion air setting is proper, there will be

some lifting of the flames on some areas of the burner

deck under cold-start conditions. After about five min-

utes of operation, the flames should settle down and

blue tips should become visible. Lifting of flames

beyond five minutes would indicate too much combus-

tion air.

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 sat-

isfied the heater will shut down.

VISUAL INSPECTION

Flames can be observed through the slot opening

above 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.

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.

ELECTRICAL

Be sure that electrical service to the heater has prop-

er overload fuse or circuit breaker protection, wire size

and connections which comply with all applicable

codes.

b. Once the blower provides pressure, the main

gas valve will open.

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

FLAME ROLL-OUT SAFETY SWITCH

NOTE: Door must be in place for proper operation.

Low NOx heaters are equipped with (2) thermal cut-off

devices to prevent flame roll-out in the event the heat

exchanger becomes blocked. One is a "manual reset"

type roll-out switch that must be reset by a service

technician after any over-temperature conditions have

been fixed. The second is an “auto reset” type roll-out

switch that resets itself after a few minutes. Excessive

restriction in the heat exchanger flue passage may

cause any of the two switchs to disable the heater.

Manual Reset

Switch

Auto Reset

Switch

Fig.# 9439

Fig.# 9412

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LOW NOx HEATERS (CONTINUED)

MAIN BURNER AND ORIFICE REMOVAL

1. Remove burner tray, following above procedure.

2. Remove pilot. See pilot removal procedure.

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

down brackets, front and rear of tray.

COMBUSTION

AIR BLOWER

BAFFLE

MOUNTED INLET SIDE

GAS ORIFICE

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.

PILOT

LOW NOx

BURNER

GAS VALVE

BURNER

HOLD-DOWN

BRACKET

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

from the gas manifold.

7. Reverse above procedure to reinstall.

Low NOx Burner Tray

BURNER TRAY REMOVAL

Low NOx Horizontal Pilot

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.

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.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

COMBUSTION BLOWER REMOVAL

GAS VALVE REMOVAL

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

to the burner tray.

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.

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

the base of the heater.

3. Disconnect wire connector from the combustion

blower.

4. Turn vertical gas pipe from manifold slightly and

unscrew gas valve.

4. Carefully remove blower box with combustion

blower.

5. Reverse above procedure to reinstall.

5. Remove (2) screws that secure combustion blow-

er to blower box.

6. Reverse above procedure to reinstall.

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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

CAUSE

SOLUTION

Harmonics, or whining noise U.G. inoperative...................................

Check movement by putting in hot water (110°F or higher).

If no movement, replace.

*Debris or restriction in system............

*Debris in gas line................................

Low flow...............................................

Locate the restriction and remove. Flush system and clean.

Remove debris or blow out gas line.

Scale forming in heat exchanger - clean heat exchanger and

check pool pH and total alkalinity.

Heater going on and off

continuously

Dirty filter..............................................

Low water level in pool........................

External bypass setting out of

Clean or replace filter.

Raise water level.

adjustment............................................

*Pressure switch out of adjustment.....

Adjust bypass.

Adjust pressure switch.

Liming or scale forming in

exchanger

Pool water............................................

Bypassing too much water...................

U.G. not functioning.............................

See Water Chemistry on page 2.

Inspect bypass for movement, if no movement, replace.

Replace if no movement when heated.

Sooting

High flow rates.....................................

Reduce by adding manual bypass valve.

Adjust manual bypass valve until heater outlet water

temperature is between 105°F and 110°F.

Check movement by putting in hot water (110°F or higher).

If no movement, replace.

U.G. Inoperative...................................

*Air starvation.......................................

*Improper venting................................

*Insects or debris clogging

Refer to installation instructions.

Follow recommended installation instructions.

burner intake ports.............................

Clean burners.

Pilot outage

Low gas pressure................................

Restricted pilot.....................................

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

Adjust gas pressure.

Clean pilot.

Replace pilot.

Yellow lazy flame

Low gas pressure................................

*Insects or debris clogging

Adjust gas pressure.

Clean burners.

burner intake ports...............................

Outer jacket very hot

(paint blistered)

*Broken refractory caused by

shipping damage or improper

combustion.........................................

Excessive sooting of heat exchanger..

Replace refractory panels.

Determine cause of sooting & correct.

Takes too long to heat

pool or spa

Under-sized heater...............................

Calculate heating capacity of heater:

Htr. output(BTUH)

Pool gallonage x 8.33 or refer to heater sizing chart.

This does not take into account heat loss due to weather.

Reset time clock.

Filter not running long enough.............

Dirty filter..............................................

Gas line or meter undersized...............

Clean filter.

Refer to installation instructions.

Leaking at well

Overacid...............................................

Replace well and maintain proper water chemistry.

Leaking at heat exchanger

Replace heat exchanger and maintain proper water chemistry.

Gasket brittle and leaking -

(overheated)

Heater running after pump shuts off....

Refractory damage..............................

Sooted heater.......................................

See Pressure Switch Adjustment.

Replace refractory.

Determine cause of sooting and correct.

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

Fan........................................................

Replace fan relay.

Loose connection or failed motor.

Incorrect wiring, replace blower.

Replace air switch.

Burned motor ......................................

Air pressure switch...............................

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

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ELECTRICAL - STANDING PILOT MILLIVOLT

POOL OR SPA HEATER

ELECTRICAL CHECK WITH MILLIVOLT GAS VALVE

CAUTION: 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.

Light pilot

If pilot burner

does not light

If pilot burner goes out

when main burner lights

or when gas valve knob

is released

If pilot burner remains lit

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

Remove both "TH"

wires from gas valve.

Relight pilot

Replace

gas

valve

If main burner fires,

remove jumper

If main burner does not

fire, remove jumper

Jump across pressure

switch terminals

If burner does not remain

lit, attach millivolt meter

and read pilot output

If pilot burner stays on

If main burner fires,

If main burner does not

remove jumper

fire, remove jumper

Problem is a wire or

component short to

cabinet or low gas

pressure

If above 500mV,

replace gas valve

Clean filter

Jump across thermostat

Check for adequate water

flow from filter

If main burner does

NOT fire...

If below 500mV, check

gas pressure. Also check

for insects or debris in

the pilot burner

If main burner fires,

remove jumper

Jump across each

high limit and remove

jumper

Replace pressure switch

Replace thermostat

If output is still low,

Replace high limit that

caused heater to fire

replace pilot generator

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

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ELECTRICAL - ELECTRONIC IGNITION IID

WARNING HIGH VOLTAGE

For qualified technicians ONLY

NOTE: 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

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.

POWER TO PC BOARD?

(24 V NOMINAL)

YES

Pull ignition lead and check spark at PC board.

Spark Okay?

SPARK ACROSS

IGNITER/SENSOR GAP?

YES

Replace the PC board.

• 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.

• Check that all manual gas valves are open, supply tubing and pressures are

good, and pilot burner orifice is not blocked.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

• 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.

MAIN BURNER LIGHTS?

YES

• 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.

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

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.

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

• 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

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DIGITAL CONTROL LOGIC - FLOW CHART

Power On

• 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)

Is the water

temperature displayed?

YES

REM and Water Temperature

displayed and flashing

(a remote control is controlling the heater)

Push MODE

switch to select

"Pool" or "SPA"

Note: Disconnect the remote by turning the

remote function off. See page 35 for instructions.

Push Temp

arrow to scroll to

desired temperature

Water temperature

and set

Is SERVICE displayed and flashing?

temperature

displayed?

YES

Diagnostic Readouts

"SNS" - Temperature sensor out of range (replace sensor)

Sensor Failure

YES

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.

Sensor resistance at various temperatures

CFH

(call for heat) will

display briefly

Temp Degrees F 40

50 60

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

PRS Pressure switch. Verify water flow and pressure

SPK

CLEAN FILTER / STRAINER - backwash if neccessary.

(spark) will display

until pilot is lit

up to 2

HL1 High limit switch. Verify water flow. Inspect internal

HL2 Thermostat (Unitherm Governor) and bypass valve.

ROL Rollout Sensor - Check for blocked heat exchanger and soot.

Atmospheric Units - Replace fusible link.

minutes maximum

Low NOx Units - Press manual reset button.

CLK Fireman or Remote switch connected to safety loop is in the

Flame icon displayed

and flashing?

(pilot lit and rectified)

OFF mode.

VNT Vent switch open. Check connections to the board.

If extractor installed, troubleshoot extractor.

IGN

PLT

Ignition control failure. Check power at PV.

Pilot failure. Check spark (bad ignition circuit or hi-tension wire).

Verify gas to the heater. Verify valve operation (gas present at

tube fitting). Verify clean pilot orifice and clearance from

igniter to ground hood. If pilot is lit, verify that the flame is

rectified (the spark will be off)

YES

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

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

Heater Fired?

YES

END

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SECTION 6 - REPLACEMENT PARTS

NOTE: To supply you with the correct part, it is impor- If determined defective by the Company and within

tant that you supply the heater model number, serial warranty, a like part or equal substitution will be

number and type of gas when applicable.

returned, freight collect. Credit will not be issued.

Any part returned for replacement under standard MANUFACTURER:

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.

2151 EASTMAN AVENUE

OXNARD, CA 93030

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ATMOSPHERIC HEATERS

3-V

1-S

14-M

13-S

2-S

4-V

1-V

6-HP

2-V

5-HP

7-HP

12-HM

3-HP

6-HP

4-HP

12-S

3-R

6-S

14-M

4-S

7-S

17-HM

11-S

8-S

5-C

10-M

9-M

4-C

2-R

4-S

4-M

2-M

11-M

2-J

5-M

2-B

13-M

12-M

3-S

1-G

1-R

16-M

5-S

1-J

3-B

5-B

4-B

1-B

10-S

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LOW NOx HEATERS

3-V

1-S

9-M

4-V

13-S

2-S

1-V

2-V

6-HP

5-HP

7-HP

12-HM

3-HP

6-HP

12-S

3-R

6-S

4-HP

9-M

4-S

17-HM

11-S

7-S

8-S

4-C

6-M

2-J

3-J

2-S

4-S

2-M

7-M

2-B

8-M

3-B

1-G

4-B

3-S

12-M

13-M

1-R

6-C

12-M

10-M

1-J

5-S

7-B

5-B

1-B

10-S

6-B

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3-M

(OPTIONAL)

5-C

14-HM

2-S

16-HM

15-HM

13-HM

2-HM

9-S

1-M

2-C

6-HM

5-HM

3-C

12-HM

7-HM

4-HM

10-HM

11-HM

4-S

3-HM

8-HM

17-HM

9-HM

16-HP

1-M

11-HP

3-M

5-C

19-HP

(OPTIONAL)

1-C

2-P

12-HP

8-HP

10-HP

7-P

9-P

18-HP

2-HP

15-HP

13-HP

14-HP

17-HP

POLYMER IN/OUT HEADER AND ACCESSORIES

HONEYWELL IID ATMOSPHERIC PILOT

1-P

5-P

8-P

2-P

6-P

3-P

4-P

9-P

HONEYWELL MILLIVOLT PILOT

IID LOW NOx PILOT

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ATMOSPHERIC HEATERS

CALL

OUT

DESCRIPTION

206A

266A

336A

406A

BURNER TRAY

1-B

Burner Tray w/Burners (sea level)*

Burner Tray w/o Burners (sea level)*

Burner Tray w/Gas Valve Nat Millivolt

Burner Tray w/Gas Valve Pro Millivolt

Burner Tray w/Gas Valve Nat IID

Burner Tray w/Gas Valve Pro IID

Burner Spacer/Hold Down Kit

Burner

Burner Orifice Nat. #49 (Sea Level)*

Burner Orifice Pro. #57 (Sea Level)*

Burner Tray w/o Manifold w/o burners

CONTROLS

010391F

010395F

010399F

010403F

010407F

010411F

010415F

010392F

010396F

010400F

010404F

010408F

010412F

010416F

010393F

010397F

010401F

010405F

010409F

010413F

010417F

010394F

010398F

010402F

010406F

010410F

010414F

010418F

2-B

3-B

4-B

301210/13 301210/18 301210/22 301210/27

350078F/13 350078F/18 350078F/22 350078F/27

350083F/13 350083F/18 350083F/22 350083F/27

5-B

010421F

010422F

010423F

010424F

1-C

2-C

3-C

4-C

5-C

6-C

Thermostat Auto Reset 135 Deg Surface Mount

AGS 135º (Auto Gas Shut-Off) - Red Epoxy

High Limit 140º - Black Epoxy

P. C. Board/Control IID Units

Thermostat Control MV Units Mechanical

Temperature Sensor IID Units

GAS VALVE

006725F

600892B

600893B

010253F

003346F

009577F

006725F

600892B

600893B

010253F

003346F

009577F

006725F

600892B

600893B

010253F

003346F

009577F

006725F

600892B

600893B

010253F

003346F

009577F

1-G

Combination Valve - Nat. MV

Combination Valve - Pro. MV

Combination Valve - Nat. IID

Combination Valve - Pro. IID

HEAT EXCHANGER - POLYMER

Heat Exchange Assy Copper

Heat Exchange Assy Cupro Nickel

Inlet/Outlet Header Complete

Inlet/Outlet Header (Includes 6-HP)

Return Header (Includes 6-HP)

Tube Bundle Copper **

003898F

003899F

003900F

004306F

003898F

003899F

003900F

004306F

003898F

003899F

003900F

004306F

003898F

003899F

003900F

004306F

1-HP

010043F

010356F

006827F

006706F

006707F

010059F

010364F

010038F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010044F

010357F

006827F

006706F

006707F

010060F

010365F

005261F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010045F

010358F

006827F

006706F

006707F

010061F

010366F

010040F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010046F

010359F

006827F

006706F

006707F

010062F

010367F

010041F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

2-HP

3-HP

4-HP

Tube Bundle Cupro Nickel **

Baffle

5-HP

6-HP

7-HP

Flange Nut Kit

O Ring Gasket (2)

8-HP

Sensor Adapter Digital Electronic

Sensor Well Millivolt

9-HP

Bypass Kit

10-HP

11- HP

12-HP

Bypass Valve

Bypass Dam / Shaft

Bypass Spring (All Sizes Included)

Unitherm Governor

13-HP

14-HP

15-HP

16-HP

Unitherm Governor Plug

Drain Plug

Inlet/Outlet Header Dam

17-HP

18-HP

19-HP

2" PVC Connector & Nut (2)

O Ring (2)

Stainless Steel Baffle

*FOR INSTALLATION AT OVER 2,000 FEET ABOVE 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.

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ATMOSPHERIC HEATERS

CALL

OUT

DESCRIPTION

206A

266A

336A

406A

1-HM

HEAT EXCHANGER - METAL

Heat Exchange Assy.Copper ASME CI

Heat Exchange Assy.Cupro Nickel ASME CI

Inlet/Outlet Header ASME CI

010051F

010360F

006730F

003766F

062236B

800080B

006731F

010055F

010368F

010038F

007870F

800014B

062234B

850254

006727F

010361F

006730F

003766F

062236B

800080B

006731F

006733F

010369F

005261F

007870F

800014B

062234B

850254

010053F

010362F

006730F

003766F

062236B

800080B

006731F

010057F

010370F

010040F

007870F

800014B

062234B

850254

010054F

010363F

006730F

003766F

062236B

800080B

006731F

010058F

010371F

010041F

007870F

800014B

062234B

850254

2-HM

15-HM Inlet & Outlet Flange

16-HM Flange Gasket 1 1/2" Connections

Flange Gasket 2" Connections

3-HM

4-HM

Return Header ASME CI

Tube Bundle Copper ASME *

Tube Bundle Cupro Nickel ASME *

5-HM Baffle

6-HM Stud Bolt Kit

7-HM Header Gasket (9)

8-HM

Unitherm Governor

9-HM U.G. Retainer Spring

10-HM

Bypass Valve

062235B

850252

062235B

850253

062235B

850253

062235B

850253

11-HM Bypass Spring

12-HM

Drain Valve

500719

13-HM

14-HM

17-HM

Sensor Well

003765F

300203

005264F

003765F

300203

005264F

003765F

300203

005264F

003765F

300203

005264F

Well Retaining Clip

Rear Drain Plug & Cover

CONTROL BOX

1-J

2-J

Transformer 120/240/24V

Rocker Switch

006736F

009493F

006736F

009493F

006736F

009493F

006736F

009493F

MISCELLANEOUS COMPONENTS

Pressure Switch 1.75 PSI

1-M

006737F

009133F

009499F

800307

006737F

009133F

009499F

800307

006737F

009133F

009499F

800307

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

2-M

3-M

4-M

5-M

6-M

7-M

8-M

Thermostat Knob

Thermostat Shaft MV

Knobstop

Thermal Fuse

PRV 125 PSI (Optional)

Deliming Kit

Wire/Harness Millivolt

Wire/Harness IID

Control Bezel MV (Includes Dial Decal)

Dial Decal MV

Control Bezel IID (Includes Switch Decal)

Switch/Decal-Membrane

Control Bezel Cover

Gasket Insulation (Swaybrace & Jacket Top)

Touch-up Paint (Green)

009499F

800307

006886F

005899F

008091F

052871F

010386F

009490F

009489F

009858F

009491F

009492F

009487F

010350F

750125

006886F

005899F

007224F

052871F

010386F

009490F

009489F

009858F

009491F

009492F

009487F

010350F

750125

006886F

005899F

007224F

052871F

010386F

009490F

009489F

009858F

009491F

009492F

009487F

010350F

750125

006886F

005899F

007224F

052871F

010386F

009490F

009489F

009858F

009491F

009492F

009487F

010350F

750125

9-M

10-M

11-M

12-M

13-M

14-M

15-M

Touch-up Paint (Dark Gray)

Tie Down Bracket (Optional)

PILOT

Pilot Nat. MV

Pilot Pro. MV

750126

011636

750126

011636

750126

011636

750126

011636

16-M

1-P

600525B

600575B

002003F

003901F

003902F

003903F

004308F

600019B

010352F

306692

600525B

600575B

002003F

003901F

003902F

003903F

004308F

600019B

010352F

306692

600525B

600575B

002003F

003901F

003902F

003903F

004308F

600019B

010352F

306692

600525B

600575B

002003F

003901F

003902F

003903F

004308F

600019B

010352F

306692

2-P

3-P

Pilot Nat & Pro IID

Pilot Orifice Nat. MV

Pilot Orifice Pro. MV

Pilot Orifice Nat. IID .020

Pilot Orifice Pro. IID .012

Pilot Generator MV

Pilot MTG Bracket MV

Pilot Mounting Bracket IID

Lighter Tube (MV Units Only)

Pilot Tube

4-P

5-P

6-P

7-P

8-P

9-P

10-P

11-P

062996

004078F

007864F

010351F

004078F

007864F

010351F

004078F

007864F

010351F

004078F

007864F

010351F

Hi Tension Wire IID with Pilot Electrode

Pilot Shield

REFRACTORY

1-R

2-R

3-R

Refractory Common Lt & Rt

Refractory Uncommon (Front & Rear)

Refractory Retainer Kit

010088F

010089F

010387F

010088F

010090F

010388F

010088F

010091F

010389F

010088F

010092F

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.

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ATMOSPHERIC HEATERS

CALL

OUT

DESCRIPTION

206A

266A

336A

406A

SHEETMETAL

1-S

2-S

Jacket Top (Louvered)

Flue Collector (Units with Polymer Header)

Flue Collector (Units with Metal Header)

Door Assy.

010047F

010071F

010075F

010048F

010072F

010076F

010049F

010073F

010077F

010050F

010074F

010078F

3-S

Raypak

Rheem

Ruud

010378F

010382F

010311F

010312F

010376F

010377F

010372F

009505

010379F

010383F

010311F

010312F

010376F

010377F

010373F

009505

010380F

010384F

010311F

010312F

010376F

010377F

010374F

009505

010381F

010385F

010311F

010312F

010376F

010377F

010375F

009505

4-S

Access Panel Set (3 Pcs Units with Polymer Header)

Access Panel Set (3 Pcs. Units with Metal Header)

Jacket Side Panel Right

Jacket Side Panel Left

Jacket Rear Panel

5-S

6-S

7-S

8-S

Poolstat Cover/Lock

9-S

High Limit Cover

Base Heat Shield

Up Front Control Panel

High Limit Shield

Weather Shield

010319F

010320F

010321F

010342F

010325F

010319F

010320F

010322F

010342F

010326F

010319F

010320F

010323F

010342F

010327F

010319F

010320F

010324F

010342F

010328F

10-S

11-S

12-S

13-S

VENTING

1-V

Indoor Stack Kit (Includes inner adapter panel)

Outdoor Stack Kit (Includes inner adapter panel)

Stack Adapter

Outer Stack Adapter

"Pagoda" Top

009838

009834

010330F

011461F

010334

009839

009835

010331F

011462F

010335

009840

009836

010332F

011463F

010336

009841

009837

010333F

011464F

010337

2-V

4-V

3-V

Atmospheric CONVERSION KITS*

Gas Conversions

206A

266A

336A

406A

Nat. to Pro. MV Pilot

Pro. to Nat. MV Pilot

Nat. to Pro. IID Pilot

004690B

010419F

N/A

004690B

010419F

N/A

004692B

010420F

N/A

004692B

010420F

N/A

Pro. to Nat. IID Pilot

N/A

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

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LOW NOx HEATERS

CALL

OUT

DESCRIPTION

207A

267A

337A

407A

BURNER TRAY

Burner Tray w/Burners (0-5000)

1-B

010343F

010084F

010254F

310732/3

351510/3

351523/3

010042F

010871F

010338F

010344F

010085F

010255F

310732/4

351510/4

351523/4

010042F

010871F

010339F

010345F

010086F

010256F

310732/5

351510/5

351523/5

010042F

010871F

010340F

010346F

010087F

010257F

310732/6

351510/6

351523/6

010042F

010871F

010341F

Burner Tray w/o Burner (0-5000)

Burner Hold Down Kit

Burner

Burner Orifice Nat. #26 (0-5000)*

Burner Orifice Nat. #31 (above 5000 ft.)*

Blower

Cooling Fan

Combustion Air Orifice Plate

CONTROLS

2-B

3-B

4-B

5-B

7-B

6-B

1-C

2-C

3-C

4-C

5-C

6-C

Thermostat Auto Reset 135 Deg Surface Mount

AGS 135° (Auto Gas Shut-Off) - Red Epoxy

High Limit 140° - Black Epoxy

P. C. Board/Control

Temperature Sensor

Blower Pressure Switch

006725F

600892B

600893B

010253F

009577F

008062F

006725F

600892B

600893B

010253F

009577F

008135F

006725F

600892B

600893B

010253F

009577F

010354F

006725F

600892B

600893B

010253F

009577F

010355F

GAS VALVE

1-G

Combination Valve - Gas On/Off -Nat

HEAT EXCHANGER - POLYMER

Heat Exchange Assy Copper

Heat Exchange Assy Cupro Nickel

Inlet/Outlet Header Complete

Inlet/Outlet Header (Includes 6-HP)

Return Header (Includes 6-HP)

Tube Bundle Copper **

010329F

1-HP

010043F

010356F

006827F

006706F

006707F

010059F

010364F

010038F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010044F

010357F

006827F

006706F

006707F

010060F

010365F

005261F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010045F

010358F

006827F

006706F

006707F

010061F

010366F

010040F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

010046F

010359F

006827F

006706F

006707F

010062F

010367F

010041F

008259F

006713F

006714F

006805F

006715F

006716F

006717F

006718F

006719F

006720F

006721F

006722F

006723F

006724F

006826F

2-HP

3-HP

4-HP

Tube Bundle Cupro Nickel **

5-HP Baffle

6-HP Flange Nut Kit

7-HP O Ring Gasket (2)

8-HP

Sensor Adapter Digital Electronic

Sensor Well Millivolt

Bypass Kit

9-HP

10-HP Bypass Valve

11-HP Bypass Dam / Shaft

12-HP Bypass Spring (All Sizes Included)

13-HP

Unitherm Governor

Unitherm Governor Plug

Drain Plug

Inlet/Outlet Header Dam

2" PVC Connector & Nut (2)

O Ring (2)

14-HP

15-HP

16-HP

17-HP

18-HP

19-HP

1-HM

Stainless Steel Baffle

HEAT EXCHANGER - METAL

Heat Exchange Assy.Copper ASME CI

Heat Exchange Assy.Cupro Nickel ASME CI

Inlet/Outlet Header ASME CI

010051F

010360F

006730F

003766F

062236B

800080B

006731F

010055F

010368F

010038F

007870F

800014B

062234B

850254

006727F

010361F

006730F

003766F

062236B

800080B

006731F

006733F

010369F

005261F

007870F

800014B

062234B

850254

010053F

010362F

006730F

003766F

062236B

800080B

006731F

010057F

010370F

010040F

007870F

800014B

062234B

850254

010054F

010363F

006730F

003766F

062236B

800080B

006731F

010058F

010371F

010041F

007870F

800014B

062234B

850254

2-HM

15-HM Inlet & Outlet Flange

16-HM Flange Gasket 1 1/2" Connections

Flange Gasket 2" Connections

3-HM

4-HM

Return Header ASME CI

Tube Bundle Copper ASME **

Tube Bundle Cupro Nickel ASME **

5-HM Baffle

6-HM Stud Bolt Kit

7-HM Header Gasket (9)

Unitherm Governor

9-HM U.G. Retainer Spring

8-HM

10-HM

Bypass Valve

062235B

850252

062235B

850253

062235B

850253

062235B

850253

11-HM Bypass Spring

12-HM

Drain Valve

500719

13-HM

14-HM

17-HM

Sensor Well

Well Retaining Clip

Rear Drain Plug & Cover

003765F

300203

005264F

003765F

300203

005264F

003765F

300203

005264F

003765F

300203

005264F

*FOR INSTALLATIONS 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

LOW NOx HEATERS

CALL

OUT

DESCRIPTION

207A

267A

337A

407A

CONTROL BOX

Transformer 120/240/24V

1-J

2-J

3-J

006736F 006736F 006736F 006736F

009493F 009493F 009493F 009493F

008784F 008784F 008784F 008784F

Rocker Switch

Relay Low Nox

MISCELLANEOUS COMPONENTS

Pressure Switch 1.75 PSI

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

Roll-Out Switch 300ºF

Roll-Out Switch 250ºF

PRV 125 PSI (Optional)

Deliming Kit

1-M

006737F 006737F 006737F 006737F

009133F 009133F 009133F 009133F

006035F 006035F 006035F 006035F

011745F 011745F 011745F 011745F

008091F 007224F 007224F 007224F

052871F 052871F 052871F 052871F

010347F 010347F 010347F 010347F

009491F 009491F 009491F 009491F

009492F 009492F 009492F 009492F

009487F 009487F 009487F 009487F

010350F 010350F 010350F 010350F

010348F 010348F 010348F 010348F

2-M

13-M

3-M

4-M

5-M

6-M

7-M

8-M

9-M

Wire/Harness

Control Bezel (Includes Switch Decal)

Switch/Decal-Membrane

Control Bezel Cover

Gasket Insulation (Swaybrace & Jacket Top)

Blower / Air Pressure Switch Sample Tube

Touch-up Paint (Green)

Touch-up Paint (Dark Gray)

Tie Down Bracket (Optional)

PILOT

Pilot Nat. IID Low Nox

Pilot Electrode

10-M

11-M

750125

750126

011636

750125

750126

011636

750125

750126

011636

750125

750126

011636

12-M

1-P

2-P

3-P

010232F 010232F 010232F 010232F

Use 1-P Use 1-P Use 1-P Use 1-P

010233F 010234F 010235F 010236F

004078F 004078F 004078F 004078F

010349F 010349F 010349F 010349F

Pilot Mounting Bracket

Pilot Tube

Hi Tension Wire IID

4-P

5-P

REFRACTORY

1-R

2-R

3-R

Refractory Common Lt & Rt

Refractory Uncommon (Front and Rear)

Refractory Retainer Kit

SHEETMETAL

010079F 010079F 010079F 010079F

010080F 010081F 010082F 010083F

010262F 010263F 010264F 010265F

1-S

2-S

Jacket Top (Louvered)

Flue Collector (Units with Polymer Header)

Flue Collector (Units with Metal Header)

Door Assy.

010047F 010048F 010049F 010050F

010063F 010064F 010065F 010066F

010067F 010068F 010069F 010070F

3-S

Raypak

Rheem

Ruud

010267F 010268F 010269F 010270F

010271F 010272F 010273F 010274F

010311F 010311F 010311F 010311F

010312F 010312F 010312F 010312F

010313F 010313F 010313F 010313F

010314F 010314F 010314F 010314F

010315F 010316F 010317F 010318F

4-S

Access Panel Set (3 Pcs. Units with Polymer Header)

Access Panel Set (3 Pcs. Units with Metal Header)

Jacket Side Panel Right

Jacket Side Panel Left

Jacket Rear Panel

5-S

6-S

7-S

8-S

Poolstat Cover/Lock

009505

9-S

High Limit Cover

Base Heat Shield

Up Front Control Panel

High Limit Shield

Weather Shield

010319F 010319F 010319F 010319F

010320F 010320F 010320F 010320F

010321F 010322F 010323F 010324F

010342F 010342F 010342F 010342F

010325F 010326F 010327F 010328F

10-S

11-S

12-S

13-S

VENTING

1-V

Indoor Stack Kit (Includes inner adapter panel)

Outdoor Stack Kit (Includes inner adapter panel)

Stack Adapter

Outer Stack Adapter

"Pagoda" Top

009838

009834

009839

009835

009840

009836

009841

009837

2-V

4-V

3-V

010330F 010331F 010332F 010333F

011461F 011462F 011463F 011464F

010334

010335

010336

010337

Download from Www.Somanuals.com. All Manuals Search And Download.

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