Five Star Swimming Pool Heater Sr200na Sr200lp Sr333na Sr333lp Sr400na Sr400lp User Manual

SR POOL AND SPA HEATER  
NATURAL GAS / LP GAS  
AUX  
2
LOW SPEED  
STER PUMP  
BOO  
H
SPEED  
AUX  
1
HIG  
ER  
T
FIL  
PUMP  
O W N E R ’ S M A N U A L  
INSTALLATION, OPERATION & PARTS  
MODELS  
200K BTU/HR  
333K BTU/HR  
400K BTU/HR  
SR200NA  
SR333NA  
SR400NA  
SR200LP  
SR333LP  
SR400LP  
SPECIAL INSTRUCTIONS TO OWNER  
Retain this manual for future reference.  
This manual supplies information for the installation, operation,  
and servicing of the appliance. It is strongly recommended that  
this manual be reviewed completely before proceeding with an  
installation. Its use will reduce service calls and chance of injury  
and will lengthen product life.  
9  
If the information in these instructions is 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.  
Sta-Rite Pool/Spa Group  
293 Wright Street, Delavan, WI 53115  
North America: 800-752-0183, FAX 800-582-2217  
International: 262-728-5551, FAX: 262-728-4461, TELEX: ITT 4970245  
Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA  
© 2003, Sta-Rite Industries, Inc. Printed in U.S.A.  
S396 (Rev. 1/17/03)  
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SAFETY INSTRUCTIONS (Continued)  
Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause improper and  
dangerous operation.  
Connect heater to 120 Volt, 60 Hz., 1 Phase power only.  
Verify proper operation after servicing.  
Do not allow children to play on or around heater or asso-  
ciated equipment.  
Never allow children to use the pool or spa without adult  
supervision.  
Do not attempt to adjust the gas flow by adjusting the reg-  
ulator setting.  
Risk of fire or explosion from incorrect fuel  
use or faulty fuel conversion. Do not try to run a heater set  
up for natural gas on LP gas (Propane) or vice versa. Only  
qualified service technicians should attempt to convert  
heater from one fuel to the other.  
Do not attempt to alter the rated input or type of gas by  
changing the orifice. If it is necessary to convert to a differ-  
ent type of gas, consult your Sta-Rite dealer. Serious mal-  
function of the burner can occur which may result in loss  
of life. Any additions, changes, or conversions required in  
order for the appliance to satisfactorily meet the applica-  
tion needs must be made by a Sta-Rite dealer or other  
qualified agency using factory specified and approved  
parts.  
Read and follow other safety information contained in this  
manual prior to operating this pool heater.  
GENERAL SPECIFICATIONS/  
REQUIREMENTS  
NOTICE: Combustion air contaminated by corrosive chemi-  
cal fumes can damage the heater and will void the warranty.  
The heater is available for use with natural gas or LP  
(propane) gas. Refer to the nameplate for the type of gas  
the heater is equipped to use.  
• Use heater only with the fuel for which it is designed.  
Do not attempt to convert from one type of gas to  
another.  
• If heater design does not match available fuel, have a  
qualified service technician convert the heater to the  
correct fuel before putting heater into operation.  
NOTICE: The Combination Gas Control Valve on this  
appliance differs from most appliance gas controls. If it  
must be replaced, for safety reasons replace it only with an  
identical gas control.  
NOTICE: The jacket covers must be in place to provide  
proper ventilation. Do not operate the heater for more than  
five (5) minutes with the jacket covers removed.  
This heater is design certified by CSA International as com-  
plying with the Standard for Gas-Fired Pool heaters, ANSI  
Z21.56*CSA 4.7, and is intended for use in heating fresh-  
water swimming pools or spas.  
NOTICE: Do not use this heater as a heating boiler, water  
heater, or for heating salt-water pools. This heater is  
intended for use in heating fresh water swimming pools or  
spas only.  
Risk of fire or explosion from flammable  
vapors. Do not store gasoline, cleaning fluids, varnishes,  
paints, or other volatile flammable liquids near heater or in  
the same room with heater.  
Risk of fire, carbon monoxide poisoning, or  
asphyxiation if exhaust venting system leaks. Only quali-  
fied service technicians should attempt to service the  
heater, as leakage of exhaust products or flammable gas  
may result from incorrect servicing.  
The heater requires an external 120 VAC single-phase elec-  
tric power source.  
For indoor installation, the heater must be located as close  
as practical to a chimney or gas vent.  
Risk of explosion if an LP (propane) gas unit  
is installed in a pit or other low spot. LP gas is heavier  
than air. Do not install an LP gas fired heater in pits or  
other locations where gas might collect. Consult local  
codes and fire protection authorities about specific installa-  
tion requirements and restrictions. Locate the heater away  
from LP gas storage and filling equipment as specified by  
the Standard for the Storage and Handling of Liquified  
Petroleum Gases, ANSI/NFPA 58 (latest edition).  
The heater is design certified by CSA International for  
installation on combustible flooring. Specified minimum  
clearances must be maintained to combustible surfaces  
(see “Installation Instructions”, Pages 9 - 11).  
The heater should be located in an area where leakage of  
the heater or connections will not 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 suit-  
able drain pan, adequately drained, be installed under the  
heater. The pan must not restrict air flow.  
The heater may not be installed within five feet of the  
inside surface of a pool or spa unless it is separated by a  
solid fence, wall or other permanent barrier.  
LPG (Propane) fired heaters must not be installed in  
garages in Massachusetts, by order of the Massachusetts  
State Fire Marshall. For more information, call the Fire  
Marshall’s office.  
Risk of asphyxiation if exhaust is not correct-  
ly vented. Follow venting instructions exactly when  
installing heater. Do not use a draft hood with this heater,  
as the exhaust is under pressure from the burner blower  
and a draft hood will allow exhaust fumes to blow into the  
room housing the heater.  
The heater is supplied with an integral venting system for  
outdoor installation. A vent conversion kit (See Page 14 for  
Part Numbers for Conversion Kits) is available for indoor  
installations. Use the specified venting, and only the speci-  
fied venting, when heater is installed indoors.  
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SEQUENCE OF OPERATION  
DESCRIPTION OF THE HEATER  
An electronic temperature sensing thermistor in the mani-  
fold adapter inlet controls the heater operation. When the  
inlet water temperature drops below the temperature set on  
the operating control, the burner controller supplies  
power to the combustion air blower through a series of  
safety interlocks. The interlocks consist of  
Air  
Blower  
• the pressure switch (PS), which senses that the pump is  
running,  
• the high limit switch (HLS), which opens if the heat  
exchanger outlet temperature goes above 135°F, and  
• the automatic gas shutoff (AGS) switch, which opens if  
the heat exchanger outlet temperature goes above  
140°F.  
Mixer  
Inlet  
(Cold  
Water)  
• the stack flue sensor (SFS), which shuts down the heater  
if the flue gas temperature reaches 500°F.  
The air flow switch (AFS) senses the pressure drop across  
the air metering orifice. As soon as there is sufficient air  
flow, the AFS closes, closing the circuit to the hot surface  
ignition (HSI), which ignites the fuel mixture.  
Outlet  
(Mixed  
Water)  
Burner  
Heating Coils  
On a call for heat, the blower and HSI are energized. In  
about 20 seconds, the gas valve opens and ignition occurs.  
The HSI then switches to a sensing mode and monitors the  
flame.  
FIGURE 2  
The heater is equipped with a digital operating control that  
enables the user to pre-set the desired pool and spa water  
temperatures. The control enables the user to select  
between pool and spa heating, and features a digital dis-  
play that indicates the water temperature.  
Figure 2 is a diagram of the heater showing how it operates.  
Precisely matched orifice plates meter the air and gas into  
the mixer. The blower draws the air and gas through the  
mixer and forces it into the burner’s flameholder. A sealed  
heat exchanger surrounds the flameholder, discharging  
exhaust gases out the flue.  
Two inch PVC water piping connects directly to the mani-  
fold/header on the heat exchanger using 2” PVC slip unions  
provided with the heater. The outer manifold remains cool;  
no heat sinks are required. A thermal regulator and an inter-  
nal bypass regulate the water flow through the heat  
OWNER’S OPERATING  
INSTRUCTIONS  
FOR YOUR SAFETY READ BEFORE OPERATING  
IF YOU DO NOT FOLLOW THESE  
INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION  
MAY RESULT, CAUSING PROPERTY DAMAGE,  
PERSONAL INJURY OR LOSS OF LIFE.  
exchanger to maintain the correct outlet temperature.  
A plastic jacket with the top half split for access surrounds  
the assembly. The heater control board assembly, set into  
the top of the jacket, contains the operating controls.  
START-UP AND OPERATION  
START-UP AND SHUTDOWN INSTRUCTIONS ARE ON  
THE LABEL ATTACHED TO THE COVER OF THE APPLI-  
ANCE CONTROL BOX.  
BEFORE START-UP  
A. This appliance does not have a pilot. It is equipped  
with an ignition device which automatically lights the  
burner. Do not try to light the burner by hand.  
B. BEFORE OPERATING check for odor. Sniff all around  
the appliance area for gas. Be sure to sniff next to the  
floor, because some gas (such as propane) is heavier  
than air and will settle on the floor.  
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3. Pregnant women beware! Soaking in water above  
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 follow the 100°F (38°C) maximum rule.  
4. Before entering the spa or hot tub, users should check  
the water temperature with an accurate thermometer;  
spa or hot tub thermostats may err in regulating water  
temperature.  
5. Persons with medical history of heart disease, circula-  
tory problems, diabetes or blood pressure problems  
should obtain their physician’s advice before using  
spas or hot tubs.  
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.  
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, don’t try to repair it, call a qualified ser-  
vice technician. Force or attempted repair may result  
in fire or explosion.  
D. Do not use this heater if any part has been under  
water. Immediately call a qualified service technician  
to inspect the heater and to replace any part of the  
control system and any gas control which has been  
under water.  
E. Do not operate the pool heater unless the pool or spa  
is properly filled with water.  
F. Before operating the appliance for the first time or after  
it has been off for an extended time, perform the fol-  
lowing checklist:  
6. Persons taking medications which induce drowsiness,  
such as tranquilizers, antihistamines or anticoagulants,  
should not use spas or hot tubs.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information to the left.  
2. Set both pool and spa thermostats to the lowest settings.  
3. Turn off all electric power to the appliance.  
4. This appliance does not have a pilot. It is equipped  
with an ignition device which automatically lights the  
burner. Do not try to light the burner by hand.  
1. Remove debris or other articles from inside the  
heater and the area around the heater and its  
exhaust vent. Make sure the ventilation openings are  
clear of debris or obstruction. For installations in an  
enclosed space, make sure openings for combustion  
and ventilation air are unobstructed.  
5. Remove the jacket cover(s) by unfastening the screws  
connecting both halves of the top jacket. See Figure 3.  
2. Keep heater area clear and free from combustibles,  
flammable liquids and chemicals.  
3. Check that all water connections are tight.  
4. Water must be flowing through the heater during  
operation. Make sure that the pool/spa is filled with  
water and have the pump operating. Check that  
water flow is unobstructed from the appliance.  
When operating for the first time or after an extend-  
ed shut-down, run filter pump for several minutes  
to clear all air from the system.  
SPA TEMPERATURE CAUTION  
All safety rules recommended by the U.S. Consumer  
Product Safety Commission should be observed when  
using a spa or hot tub, including:  
1. Spa or hot tub water temperatures should never exceed  
104°F (40°C). A temperature of 100°F (38°C) is consid-  
ered safe for a healthy adult. Special caution is sug-  
gested for young children.  
FIGURE 3: Removal of jacket covers  
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.  
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11. Turn on all electric power to the appliance.  
12. Press either the POOL ON or SPA ON button switches  
on the operating control.  
6. Turn the knob on the gas control clockwise (  
) to  
the black line, depress slightly, and turn to “OFF”  
position. See Figure 4.  
13. Set the thermostat to desired setting (NOTICE: Set  
point must be above actual water temperature or burn-  
er will not fire). See OPERATING CONTROL below.  
14. The blower should come on immediately, and after  
about 20 seconds, the burner should fire. When oper-  
ating for the first time, the burner may not fire on the  
first try because of air in the gas line. If it does not fire  
at first, push the OFF switch, wait five minutes, and  
again push the POOL or SPA ON switch. The burner  
should fire after about 20 seconds. You may have to  
repeat this until all of the air has cleared the gas line.  
15. The burner should fire until the pool/spa temperature  
reaches the desired temperature set on the thermostat.  
The blower will continue to run for about 45 seconds  
after the burner shuts off. If any of the safety interlocks  
should open during burner operation, the burner shuts  
off immediately, but the blower continues to run for  
about 45 seconds.  
Indexing Point  
Gas control is shown ON.  
Turn Clockwise and press  
down to turn gas off.  
Gas is now OFF  
You are  
here  
You are here  
Should overheating occur or the gas supply fail to  
shut off, turn off the manual gas control valve to the  
appliance.  
2671 1096  
FIGURE 4: Turning gas control OFF  
16. If the appliance will not operate, follow the instruc-  
tions “TO TURN OFF GAS TO THE APPLIANCE”, and  
call your service technician or gas supplier.  
7. Wait five (5) minutes to clear out any gas. If you then  
smell gas, STOP! Follow “B” in the “Before Startup”  
instructions (Page 4). If you don’t smell gas, go to the  
next step.  
TO TURN OFF GAS TO THE APPLIANCE  
8. Turn the knob on the gas control counter-clockwise  
1. Depress OFF button on operating control.  
2. Turn off all electric power to the unit.  
3. Remove jacket cover(s). See Figure 3.  
(
) to the “ON” position. See Figure 5.  
Indexing Point  
HEATER PARTS MAY BE HOT.  
Gas control is shown OFF.  
Turn Counter-clockwise  
and release to turn gas on.  
4. Turn the knob on the gas control clockwise (  
) to  
the black line, depress slightly, and turn to “OFF”  
position. See Figure 4.  
5. Replace jacket cover(s).  
OPERATING CONTROL  
Digital Temperature  
Display  
LOW SPEED  
BOOSTER PUMP  
HIGH SPEED  
Gas is now ON.  
You are here  
TemperatureUp/Down  
System Operation  
Indicator Lights  
AUX  
2
FILTER  
PUMP  
AUX  
1
You are  
here  
2672 1096  
Dual Temperature  
Controls  
FIGURE 5: Turning gas control ON  
9. Replace jacket cover(s). All jacket covers must be in  
place when operating the appliance.  
FIGURE 6: Operating Control. See Page 36 for External  
Control Interface.  
10. Set 3-way valves on inlet and outlet to pool or spa, as  
appropriate.  
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The five operating switches are:  
After start-up, the outlet water pipe should feel slightly  
warmer than the inlet pipe. If it feels hot, or if you hear the  
water in the heater boiling, there may not be enough water  
flow to the appliance. Make sure that the filter is not  
plugged. If water temperature remains high but the unit  
continues to operate, turn off the appliance and call your  
service technician.  
POOL ON Press this button to govern heater operation by  
the pool temperature setting.  
SPA ON Press this button to govern heater operation by the  
spa temperature setting.  
OFF Press this button to switch off the heater.  
TEMP Press this button to raise the temperature setting.  
SPRING AND FALL OPERATION  
TEMP Press this button to lower the temperature setting.  
If the pool is only used occasionally, lower the pool ther-  
mostat to 65°F. and leave the heater on. This will keep the  
pool and the surrounding ground warm enough so that the  
heater should restore the pool to a comfortable tempera-  
ture within about one day.  
To toggle the display between degrees Centigrade (°C) and  
degrees Fairenheit (°F):  
1. Turn the Operating Control OFF.  
2. Press TEMP or TEMP for 5 seconds. The display  
will flash once and change modes (°C to °F or vice  
versa).  
COLD WEATHER OPERATION  
When either the TEMP or TEMP buttons are depressed,  
the digital display will indicate the temperature setting.  
After five seconds, the display will return to the actual  
pool/spa temperature.  
In addition to the digital temperature display, there are five  
indicator lights:  
The POOL ON light indicates that the pool water tempera-  
ture is governing operation of the heater.  
The SPA ON light indicates that the spa water temperature  
is governing operation of the heater.  
The heater may be operated in the wintertime, provided air  
temperatures remain above freezing and the water tempera-  
ture is not permitted to drop below 65°F. Extended heater  
operation with water temperatures below 65°F can result in  
serious damage to the heater and is not covered by warranty.  
NOTICE: When starting the heater for the swimming sea-  
son with a water temperature below 50°F, the heater may  
be used to heat the water; however, make sure that the  
heater operates continuously until the water temperature  
reaches the heater’s minimum setting of 65°F.  
During cold weather, if there is no danger of freezing,  
operate the filter pump continuously even if the heater is  
not operating. If air temperatures are expected to drop  
below freezing (32°F), shut down the heater and winterize  
it (See ”WINTERIZING”, Page 8). Allowing the heater to  
freeze will void the warranty.  
The HEATING light comes on and stays on when the burn-  
er is firing. This light should be on whenever the burner is  
on. It blinks when the heater is calling for heat but not fir-  
ing. If this light is on but the burner fails to come on, one  
of the “service” lights should come on, indicating a fault in  
the system.  
The SERVICE SYSTEM light indicates that there is insufficient  
water flow to the heater. If the pump is operating, this usual-  
ly indicates that the filter and/or skimmers should be cleaned  
(some filters may require backwashing). If the light remains  
on after the filter/skimmers have been serviced, the system  
should be checked by a qualified service technician.  
The SERVICE HEATER light indicates a fault in the heater  
or its controls. If this light comes on, shut down the heater  
(See TO TURN OFF GAS TO THE APPLIANCE, at left), and  
have a qualified service technician check the system.  
MAINTAINING POOL TEMPERATURE  
To maintain pool temperature, make sure that the heater  
switch and valving are reset to pool settings after using the  
spa.  
ENERGY SAVING TIPS  
1. Keep the pool or spa covered when not in use. This  
will reduce heating costs, reduce water evaporation,  
conserve chemicals and reduce load on the filtering  
system.  
Risk of explosion or fire causing burns or  
death if safety interlocks are disabled. DO NOT attempt to  
operate heater when SERVICE HEATER light is on or if  
blower or burner will not start. Instead, follow instructions  
under “To Turn Off Gas to the Appliance”, at left, and call  
a qualified service technician to repair unit.  
2. Reduce pool thermostat to 78°F or lower; reduce spa  
temperature to 100°F.  
3. Use a time clock to start the filter pump at 6 a.m. or  
later. The swimming pool loses less heat after day-  
break.  
4. For pools used only on weekends, lower the thermostat  
setting by 10°F to 15°F during the week to reduce heat  
loss. A properly sized heater will restore normal tem-  
perature within one day.  
5. Turn the heater off when the pool will not be used for  
an extended period.  
AFTER START-UP  
CHECKING WATER FLOW  
Fire or flooding hazard. If the unit overheats  
and the burner fails to shut off, follow instructions under  
To Turn Off Gas to the Appliance”, Page 6, and call a  
qualified service technician to repair unit.  
6. Follow a regular program of preventive maintenance  
for the heater each new swimming season. Check  
operation of the heater and its controls.  
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CARE AND MAINTENANCE  
MAINTENANCE INSTRUCTIONS  
Explosion hazard. Purging the system with  
compressed air can cause components to explode, with  
risk of severe injury or death to anyone nearby. Use only  
a low pressure (below 5 PSI), high volume blower when air  
purging the heater, pump, filter, or piping.  
4. Remove the Water Pressure Switch. Plug the port in the  
manifold to prevent bugs and dirt from getting into the  
manifold.  
5. Drain the plastic inlet/outlet manifold through the out-  
let pipe. If the pipe does not drain naturally to the  
pool, install a drain cock in the outlet pipe to drain the  
manifold.  
6. Cover air inlet grate with a plastic bag to prevent bugs,  
leaves, etc., from getting into the heater.  
Risk of fire or explosion from flammable  
vapors. Do not store gasoline, cleaning fluids, varnishes,  
paints, or other volatile flammable liquids near heater or in  
the same room with heater.  
The following maintenance is recommended every six  
months and at the start of every swimming season:  
1. Inspect the jacket and venting system to make sure that  
there are no obstructions to the flow of ventilating air  
or burner exhaust. On indoor heaters, check that room  
air intakes are open and clear of obstructions.  
2. Keep the area in and around the heater clear and free  
from combustible materials, gasoline and other flam-  
mable vapors and corrosive liquids.  
Combination Gas Control Valve OFF  
O N  
Turn Clockwise  
and press down  
to turn off gas.  
3. On heaters equipped with a pressure relief valve, test  
the operation of the valve by lifting the valve lever.  
4. Test for proper operation of the pressure switch. (See  
“SWITCH SETTINGS” for testing instructions).  
VENT  
Manual/Gas Valve OFF  
PILOT  
Power  
5. On indoor installations with high-temperature Special  
Gas Vent systems, repeat the Final Installation Check,  
Page 15. Check for evidence of joint leakage. Make  
sure that joints have not slipped partially or completely  
apart. Check pipe and fittings for cracks or breaks.  
The combustion air blower is permanently lubricated,  
and does not require periodic lubrication. The burner does  
not require maintenance or adjustment by the user. Call a  
qualified service technician if you suspect that the burner  
may require maintenance.  
O N  
FF  
OFF  
Remove Water Pressure  
Switch to help Manifold  
Drain  
Drain Inlet/Outlet  
Manifold  
WINTERIZING (See Figure 7)  
Inlet  
2704 1196  
For outdoor heaters in freezing climates, shut the heater  
down and drain it for winter as follows:  
Outlet  
Open  
1. Turn off electrical supply to the heater and pump.  
2. Close main gas control valve and manual gas valve  
(located outside the heater).  
Drain Cock(s) and Plugs  
OPEN  
3. Open drain cock located on the bottom of the mani-  
fold adapter, and drain the heat exchanger and mani-  
fold adapter completely. If heater is below pool water  
level, be sure to close isolation valves to prevent drain-  
ing the pool (isolation valves are not required and  
should not be used on heaters installed above pool  
water level). Assist the draining by blowing out the  
heat exchanger through the pressure switch fitting with  
low pressure compressed air (less than 5 PSI or  
35 kPa).  
Close Isolation Valves  
FIGURE 7: Winterizing  
NOTICE: Water trapped in the heater can cause freeze  
damage. Allowing the heater to freeze voids the warranty.  
To return the heater to service after winterizing:  
1. Close drain cock and fittings.  
2. Before starting the heater, circulate water through the  
heater for several minutes until all air noises stop.  
See also “BEFORE STARTUP” (Page 4) and  
“CARE AND MAINTENANCE” (above).  
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HEATER CLEARANCES – OUTDOOR  
INSTALLATION INSTRUCTIONS  
Risk of fire, explosion, or asphyxiation if heater  
is improperly installed, adjusted, serviced or maintained.  
These instructions are for licensed, certified, trained and  
experienced installers only. Be sure your installer or service  
technician holds all required licenses or certification for  
your area. Attempts by unqualified persons to service or  
repair this heater are dangerous and could be fatal.  
If the heater is located under a roof or deck overhang,  
there must be at least three feet (3’) clear space between  
the bottom of the overhang and the top of the heater  
exhaust vent. The heater must be at least six inches (6”)  
from the nearest wall (clearance for service access will  
depend on the installation). If the heater is under a roof or  
deck overhang, the space around the heater must be open  
on three sides.  
The heater is certified for installation on combustible flooring.  
The following clearances must be maintained from com-  
bustible surfaces:  
TOP ............................................3 FEET  
ALL SIDES..............................6 INCHES  
Orient the heater for convenient access to the water con-  
nections and the gas and electrical connections.  
PUTTING THE HEATER INTO SERVICE  
If the heater is installed below the level of the pool, or  
more than two feet above pool level, the pressure switch  
setting should be adjusted. See PRESSURE SWITCH, in the  
MAINTENANCE section.  
Before putting the heater into service for the first time, fol-  
low the instructions under BEFORE STARTUP in the front  
of this manual. Check for proper operation of the heater by  
following the steps under OPERATING INSTRUCTIONS.  
Damage to equipment caused by improper installation or  
repair will void the warranty.  
3' or more  
Outdoor  
installations  
must have at  
least 3' of  
OUTDOOR INSTALLATION INSTRUCTIONS  
For heaters located outdoors, using the built-in stackless  
venting system.  
clearance  
above vent.  
Risk of explosion if an LP (propane) gas unit is  
installed in a pit or other low spot. LP gas is heavier than  
air. Do not install the heater using LP gas in pits or other  
locations where gas might collect. Consult your local build-  
ing code officials to determine installation requirements of  
heater relative to LP gas storage tanks and filling equipment.  
Installation must meet the requirements of the Standard for  
the Storage and Handling of Liquid Petroleum Gases,  
ANSI/NFPA 58 (latest edition). Consult local codes and fire pro-  
tection authorities about specific installation restrictions.  
Space around unit must be open  
on three sides when under roof  
or overhang.  
leave 6 in.  
of clear space  
between  
unit and  
combustible  
surfaces  
Locate the heater on a level surface in an open area that is  
protected from drainage or run-off. Install the heater in an  
area where leaves or other debris will not collect on or  
around the heater. Do not install the heater where water  
(including sprinklers or runoff) will fall directly onto the  
jacket.  
6"  
TOP VIEW  
FIGURE 8: Combustible Clearances  
9
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CONTROL PANEL INDEXING  
INSTALLATION IN A GARAGE  
OR UTILITY ROOM  
The exhaust discharges vertically from outside the vent  
cover. The heater control panel assembly on top of the  
jacket can be turned to any of six positions for convenient  
access to the panel as follows:  
1. Unbolt and separate the jacket halves.  
2. Pull hair pin clips.  
Risk of fire and explosion if installed at floor  
level in an automotive garage or near gasoline or flamma-  
ble liquid storage. Gasoline fumes are heavier than air and  
will settle to floor level in closed spaces. Gasoline fumes  
and spilled gasoline or other volatile liquids (such as some  
paints and varnishes) will travel across the floor and can be  
ignited by a gas appliance. In a utility room or residential  
garage installation, install the heater with the base at least  
18 inches above the floor. In a garage, install a rail or wall  
to protect the heater from physical damage by a moving  
vehicle.  
3. Depress plastic clips on the control panel assembly.  
4. Lift panel off of support plate.  
5. Turn the assembly to the desired position and snap in  
place.  
6. Make sure that the operating controls can be  
adjusted without having to lean over the  
exhaust vent.  
Provide an adequate ventilation air supply (see Instruc-  
tions, at right). Choose a location that will avoid contami-  
nation by chemical fumes.  
7. Replace hair pin clips.  
8. Replace jacket halves and bolts and tighten.  
NOTICE: LPG fired heaters must not be installed in garages  
in Massachusetts, by order of the State Fire Marshall. For  
more information, call the Massachusetts State Fire  
Marshall’s office.  
5
4
FIL  
TER  
PU  
MP  
NOTICE: Combustion air contaminated by corrosive  
chemical fumes can damage the heater and will void the  
warranty (See Table 1, Page 11).  
3
2
1
6 in. clear  
space above  
2732 1296  
FIGURE 9: Indexing Control Panel  
Raise at least 18"  
above floor to avoid  
flammable vapors  
INDOOR INSTALLATION  
INSTRUCTIONS  
18"  
NOTICE: Local codes may restrict indoor installations.  
Consult local code officials.  
Risk of asphyxiation if exhaust is not correct-  
ly vented. Follow venting instructions exactly when  
installing heater. Do not use a draft hood with this heater,  
as the exhaust is under pressure from the burner blower  
and a draft hood will allow exhaust fumes to blow into the  
room housing the heater. Exhaust venting to the outdoors  
is required for all indoor installations.  
leave 6 in.  
of clear space  
between  
unit and  
combustible  
surfaces  
6"  
Risk of explosion if an LP (propane) gas unit  
is installed in a pit or other low spot. LP gas is heavier  
than air. Do not install the heater using LP gas in pits or  
other locations where gas might collect. Consult your local  
building code officials to determine installation require-  
ments of heater relative to LP gas storage tanks and filling  
equipment. Installation must meet the requirements for the  
Standard for the Storage and Handling of Liquified  
Petroleum Gases, ANSI/NFPA 58 (latest edition). Consult  
local codes and fire protection authorities about specific  
installation restrictions.  
TOP VIEW  
FIGURE 10: Minimum indoor clearances - garage or utility  
room installation  
HEATER CLEARANCES – INDOOR  
The following clearances must be maintained from com-  
bustible surfaces:  
TOP.......................................6 INCHES  
ALL SIDES..............................6 INCHES  
VENT .....................................6 INCHES  
The heater is design certified by CSA International for  
installation on combustible flooring; in alcoves; in base-  
ments; in closets or utility rooms.  
10  
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The heater is design certified by CSA International for  
installation on combustible flooring. For installation on car-  
peting, the heater must be mounted on a metal or wood  
panel that extends at least three (3) inches beyond the base  
of the heater. If the heater is installed in a closet or alcove,  
the entire floor shall be covered by the panel.  
On an indoor installation, the exhaust discharges into a  
vent pipe. Orient the heater so that the vent pipe does not  
interfere with adjustment of the operating controls. The  
operating control panel located on top of the jacket can be  
rotated for convenient access to the control panel.  
The minimum net free area in square inches shall be  
as follows:  
Table 2: Combustion and Ventilation  
Air Requirements  
All Air From  
All Air From  
Inside Building  
Outside Building  
Model Combustion  
Vent  
Combustion  
Vent  
200  
333  
400  
200 Sq. In. 200 Sq. In. 50 Sq. In. 50 Sq. In.  
333 Sq. In. 333 Sq. In. 84 Sq. In. 84 Sq. In.  
400 Sq. In. 400 Sq. In. 100 Sq. In. 100 Sq. In.  
Table 1: Corrosive Vapors and  
Possible Causes  
INDOOR VENT INSTALLATION  
Area  
Likely Contaminants  
Always vent the heater to the outdoors.  
Chlorinated swimming  
pools and spas  
Pool or spa cleaning  
chemicals. Acids, such as  
hydrochloric or muriatic acid  
• Vent it horizontally or vertically using a Special Gas  
Vent, (see Table 5, Page 14), or  
• Vent it vertically using Type “B” double wall vent con-  
nector pipe.  
Locate the heater so as to minimize the length of horizon-  
tal venting and the number of vent elbows required.  
Horizontal vent runs must slope up 1/4” per foot from the  
heater to allow exhaust condensate to drain and must have  
a condensate drain as described in the venting installation  
instructions.  
New construction and  
remodeling areas  
Glues and cements,  
construction adhesives,  
paints, varnishes, and  
paint and varnish strippers.  
Waxes and cleaners  
containing calcium or  
sodium chloride  
Beauty parlors  
Permanent wave solutions,  
bleaches, aerosol cans  
containing chlorocarbons  
or fluorocarbons  
OUTSIDE VENT COVER REMOVAL  
The heater is supplied from the factory with a built-in  
stackless outside vent for outdoor installation. Remove the  
outside vent cover for indoor installation.  
Refrigeration plants or  
various industrial  
finishing and processing  
plants  
Refrigerants, acids, glues  
and cements, construction  
adhesives  
Dry cleaning and  
laundry areas  
Bleaches, detergents, or  
laundry soaps containing  
chlorine.  
Waxes and cleaners  
containing chlorine,  
calcium or sodium chloride  
Clean the Interior Surface  
Vent Body  
4" x 8" Metal  
Flue Collar  
COMBUSTION AND VENTILATION AIR SUPPLY  
Vent Pipe  
For indoor installation, the heater requires air supply open-  
ings for ventilation and combustion. The minimum require-  
ments are for two (2) openings: one 12 inches from the  
ceiling for ventilation air and one 12 inches from the floor  
for combustion air, in accordance with the latest edition of  
the National Fuel Gas Code, ANSI Z223.1., and any local  
codes that may apply.  
Clean and RTV  
This Surface  
Combustion  
Chamber  
2855 0597 RTV  
Flue Collar  
FIGURE 11: Flue collar  
11  
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rior of the 4” end of the metal Flue Collar. Attach the  
metal Flue Collar to the Vent Body using the RTV sup-  
plied with the kit, following the instructions included  
with kit. Do not use a draft hood with this heater.  
3. Attach the vent pipe to the metal Flue Collar with  
sheet-metal screws.  
VERTICAL VENTING - NEGATIVE PRESSURE  
(See Figures 11 and 12)  
Vent the heater vertically in a negative pressure (positive  
draft) system in accordance with the National Fuel Gas  
Code, ANSI Z223.1, and local codes. Type “B” Double-  
wall vent connector is recommended; however single-wall  
pipe is allowed by the National Fuel Gas Code in some  
circumstances. Consult your local code official for detailed  
information. Do not use a draft hood with this heater.  
To connect a negative pressure metal gas vent to the  
heater, order the appropriate Metal Flue Collar from the  
chart below:  
Risk of fire or asphyxiation if vent is not  
assembled according to manufacturer’s instructions or if  
vent parts from different manufacturers are mixed. Vent  
parts from different manufacturers ARE NOT interchange-  
able. Mixing parts from more than one manufacturer may  
cause leaks or damage to vent. When assembling a vent,  
pick one manufacturer and be sure that all vent parts come  
from that manufacturer and are specified by the manufac-  
turer for your system. Follow manufacturer’s instructions  
and local and National Fuel Gas Code requirements care-  
fully during assembly and installation.  
Metal Flue Collar  
Sta-Rite Part No.  
77707-0076  
4x6”  
4x8”  
77707-0077  
4. Install vent pipe so that it can expand and contract  
freely as the temperature changes. Support the vent  
pipe according to applicable codes and the vent manu-  
facturer’s instructions. Pipe support must allow the  
vent pipe free movement out and back, from side to  
side, or up and down as necessary, without putting a  
strain on the heater or vent body. Slope horizontal pipe  
runs up from the heater at least 1/4” per foot. Install  
Listed condensate drains at low points where conden-  
sate might collect. Plumb condensate drains to a drain  
through hard piping or high-temperature tubing such  
as silicone rubber or EPDM rubber – do not use vinyl  
or other low temperature tubing. Follow drain manu-  
facturer’s installation instructions.  
5. Use Listed firestops for floor and ceiling penetrations.  
Use Listed thimble for wall penetrations. Use a Listed  
roof flashing, roof jack, or roof thimble for all roof pen-  
etrations. Do not fill the space around the vent (that is,  
the clear air space in the thimble or firestop) with  
insulation. The roof opening must be located so that  
the vent is vertical.  
1. See Table 3, below, to determine allowable vent sizes  
for your heater.  
NOTICE: Table 3 is for installations in which the total later-  
al vent length (that is, the horizontal distance from the flue  
collar to the main vertical portion of the vent) is less than  
1/2 the total vent height (the vertical distance from the flue  
collar to the vent termination) and which have three or less  
elbows in the system. For venting systems which do not  
meet these conditions, consult the National Fuel Gas  
Code, ANSI Z223.1  
2. Install the metal Flue Collar in the Vent Body of the  
heater (located under the outside vent cover). Fasten  
the metal Flue Collar to the Vent Body with two #10  
®
sheet metal screws. Use UltraCopper silicone RTV to  
seal the metal Flue Collar to the Vent Body. Follow  
instructions supplied with the metal Flue Collar. Before  
connecting the metal Flue Collar to the Vent Body, wet  
a clean cloth or paper towel with isopropyl alcohol  
(rubbing alcohol) and vigorously wipe the socket of the  
Vent Body. Immediately wipe the cleaned surfaces dry  
with a clean cloth or paper towel. Repeat for the exte-  
Table 3: Permitted Minimum and Maximum Vent Heights By Size and Heater Model  
Read “VERTICAL VENTING – NEGATIVE PRESSURE” (above) before using this table.  
Type B Double Wall Vent With Type B Double Wall Connector  
Model 200  
Model 333  
Model 400  
Vent Size  
Min. Height  
Max. Height  
Min. Height  
Max. Height  
Min. Height  
Max. Height  
6 in.  
7 in.  
8 in.  
6 Ft.  
6 Ft.  
6 Ft.  
6 Ft.  
100 Ft.  
100 Ft.  
100 Ft.  
50 Ft.  
30 Ft.  
10 Ft.  
6 Ft.  
100 Ft.  
100 Ft.  
100 Ft.  
100 Ft.  
Not Rec.  
15 Ft.  
8 Ft.  
Not Rec.  
100 Ft.  
100 Ft.  
100 Ft.  
9 and 10 in.  
6 Ft.  
6 Ft.  
Type B Double Wall Vent With Single Wall Connector  
Model 200 Model 333  
Model 400  
Vent Size  
Min. Height  
Max. Height  
Min. Height  
Max. Height  
Min. Height  
Max. Height  
6 in.  
7 in.  
8 in.  
9 in.  
10 in.  
6 Ft.  
6 Ft.  
Not Rec.  
Not Rec.  
Not Rec.  
15 Ft.  
8 Ft.  
Not Rec.  
Not Rec.  
Not Rec.  
Not Rec.  
10 Ft.  
6 Ft.  
Not Rec.  
Not Rec.  
Not Rec.  
20 Ft.  
20 Ft.  
Not Rec.  
Not Rec.  
Not Rec.  
15 Ft.  
8 Ft.  
6 Ft.  
Not Rec.  
Not Rec.  
50 Ft.  
20 Ft.  
6 Ft.  
Not Rec.  
12  
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6. See Table 4 for height of vent termination above the  
HORIZONTAL OR VERTICAL VENTING -  
POSITIVE PRESSURE (SPECIAL GAS VENTING)  
(See Figures 13 and 14)  
roof.  
7. Do not run the heater vent into a common vent with  
any other appliance.  
Vent the heater either horizontally or vertically using one  
of the 4-inch Special Gas Vent Pipes listed on Page 14  
(Table 5). Install the vent pipe in accordance with local  
codes and the provisions of the National Fuel Gas Code,  
ANSI Z223.1, and the vent manufacturer’s instructions.  
Do not use a draft hood with this heater. Use one of the  
special gas vents specified in Table 5 (Page 14) for positive-  
pressure venting of this heater – do not use any other vent  
with it. Install the vent according to the vent manufactur-  
er’s detailed instructions.  
8.  
Fire Hazard. Do not vent the heater  
directly into a masonry chimney. Installation into a  
masonry chimney must use a chimney liner and must  
meet National Fuel Gas Code requirements and all  
local code requirements.  
Table 4: Vent Termination Height vs.  
Roof Pitch  
Minimum Height  
Roof Pitch  
Above Roof*  
Maintain clearance between the vent pipe and combustible  
surfaces according to the vent manufacturer’s instructions  
and code requirements. Do not place any insulating mate-  
rials around the vent or inside the required clear air space  
surrounding the vent. See Table 6 (Page 15) for maximum  
permissable vent lengths. See Table 7 (Page 15) for Listed  
vent components.  
Flat to 6/12  
6/12 to 7/12  
>7/12 to 8/12  
1 Ft.  
1 Ft. 3 in.  
1 Ft. 6 in.  
2 Ft.  
2 Ft. 6 in.  
3 Ft. 4 in.  
4 Ft.  
>8/12 to 9/12  
>9/12 to 10/12  
>10/12 to 11/12  
>11/12 to 12/12  
>12/12 to 14/12  
>14/12 to 16/12  
>16/12 to 18/12  
>18/12 to 20/12  
>20/12 to 21/12  
CONNECTING SPECIAL GAS  
VENT TO THE HEATER  
Metallic:  
5 Ft.  
6 Ft.  
7 Ft.  
1. Order an Appliance Adapter kit:  
7 Ft. 6 in.  
8 Ft.  
®
Sta-Rite Part No. 77707-0086 for Saf-T Vent  
®
or Saf-T Vent CI.  
* Vent must be at least eight (8) feet away from nearest vertical  
surface. Vents extending five (5) feet or more above the roof must  
be braced or guyed. Consult your local code officials for detailed  
information.  
Sta-Rite Part No. 77707-0087 for Z-Vent.  
2. Remove the outside vent cover.  
3. Install the Appliance Adapter in the Vent Body of the  
heater (located under the outside Vent Cover). Before  
connecting the Appliance Adapter to the Vent Body,  
wet a clean cloth or paper towel with isopropyl alco-  
hol (rubbing alcohol) and vigorously wipe the socket  
of the Vent Body. Immediately wipe the cleaned sur-  
faces dry with a clean cloth or paper towel. Repeat for  
the exterior of the heater end of the Appliance Adapter.  
Attach the Appliance Adapter to the vent body using  
the adhesive specified by the vent manufacturer, fol-  
lowing the vent manufacturer’s instructions.  
Listed  
Termination  
Cap  
Min. 8 Ft.  
See Table 4  
Storm Collar  
For Min. Hght.  
Flashing  
6" Minimum  
Clearance to  
Combustible  
Materials  
Risk of carbon monoxide poisoning if adapter  
is improperly attached. Mechanical connections (such as  
screws) can cause cracking and leaks in the adapter. Do  
not drill holes or use screws to connect the appliance  
adapter to the heater vent body. Attach with manufacturer’s  
specified adhesive.  
Class B Double Wall  
Firestop  
Metal Vent Pipe  
Risk of fire or asphyxiation if vent is not  
assembled according to manufacturer’s instructions or if  
vent parts from different manufacturers are mixed. Vent  
parts from different manufacturers ARE NOT interchange-  
able. Mixing parts from more than one manufacturer may  
cause leaks or damage to vent. When installing a vent,  
pick one manufacturer and be sure that all vent parts come  
from that manufacturer and are specified by the manufac-  
turer for your system. Follow manufacturer’s instructions  
and local and National Fuel Gas Code requirements care-  
fully during assembly and installation.  
Metal Flue  
Collar  
Vent  
Support Vertical  
Vent Pipe so  
adapter does not  
take weight of  
pipe.  
Body  
FIGURE 12: Typical Metal Vent Pipe Installation  
(Vertical – Negative Pressure)  
13  
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4. Install vent pipe so that it can expand and contract  
freely as the temperature changes. Support the vent  
pipe according to applicable codes and vent manufac-  
turer’s instructions. Pipe support must allow the vent  
pipe free movement out and back, from side to side, or  
up and down as necessary, without putting a strain on  
the heater or vent body. Slope horizontal pipe runs up  
from the heater at least 1/4” per foot. Install Listed con-  
densate drains at low points where condensate might  
collect. Plumb condensate drains to a drain through  
hard piping or high-temperature tubing such as sili-  
cone rubber or EPDM rubber – do not use vinyl or  
other low temperature tubing. Follow drain manufac-  
turer’s installation instructions.  
the clear air space in the thimble or firestop) with  
insulation. The roof opening must be located so that  
the vent is vertical.  
6. Vent Termination – Vertical (See Table 4, Page 13, for  
height of vent termination above the roof. See Table 7,  
Page 15, for Listed terminations.) Use a Listed vent ter-  
minal specified by local and national codes and your  
manufacturer’s instructions. A roof termination must be  
vertical.  
7. Vent Termination – Horizontal (See Table 7). Use a list-  
ed wall thimble and vent terminal from Table 7.  
The terminal must be located (see Figure 13):  
• at least 3” and at most 12” out from the wall (see Figure  
14), following the vent manufacturer’s instructions.  
• at least 12” above finished grade or the normally  
expected snow accumulation level, whichever is higher  
5. Use Listed firestops for floor and ceiling penetrations.  
Use Listed thimble for wall penetrations. Use a Listed  
roof flashing, roof jack, or roof thimble for all roof pen-  
etrations. Do not fill the space around the vent (that is,  
Max 12"  
Min 3"  
4' Min.  
4' Min.  
Vent  
Termination  
Vent  
Termination  
Vent  
Termination  
4' Min.  
1' Min.  
4' Min.  
At least 7'  
above grade  
adjacent  
to public  
1' Minimum  
Gas Meter  
above snow or  
Forced Air  
walkways  
finished grade  
Inlet  
3' Minimum clearance if  
(whichever is  
horizontal distance to  
higher)  
exhaust opening is less  
than 10 feet.  
FIGURE 13: Minimum exhaust vent clearances. Local codes may differ - consult local code officials.  
Table 5: Recommended Special Gas Vents (Positive Pressure)  
Brand  
Manufacturer  
Heat-Fab, Inc.  
38 Hayward Street  
Greenfield, MA 01301  
(800) 772-0739  
Material Type  
Sealant  
Saf-T Vent® 4”  
Special Gas Vent  
(Single Wall)  
Metal  
Consult Manufacturer  
Consult Manufacturer  
G.E. RTV 106  
Saf-T CI Vent®  
Special Gas Vent  
(Double Wall)  
Heat-Fab, Inc.  
Metal  
Metal  
38 Hayward Street  
Greenfield, MA 01301  
(800) 772-0739  
Z-Vent 4” Special  
Gas Vent (Type BH),  
Model SVE  
Z-Flex U.S., Inc.  
20 Commerce Park North  
Bedrford, NH 03110-6911  
(800) 654-5600  
14  
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• at least 4 feet below or horizontally from, or 1 foot  
above, any doors or windows or gravity air inlet to a  
building  
• At least 3 feet above any forced air inlet located within  
10 feet  
8.  
Fire Hazard. Do not run the heater vent  
into a common vent with any other appliance. Do not  
run the Special Gas Vent into, through, or within any  
active vent such as a factory built or masonry chimney.  
• At least 4 feet horizontally from electric meters, gas  
meters, regulators and relief equipment  
• At least 7 feet above grade adjacent to walkways or sim-  
ilar traffic areas.  
Table 6: Maximum Vent Length  
4” Special Gas Vent (Vertical or Horizontal)*  
No. of 90° Elbows  
Maximum Length  
Allow at least 3 feet vertical clearance over vent termina-  
tion when terminating under an overhang or deck.  
Avoid corners or alcoves where snow or wind could have  
an effect. Exhaust may affect shrubbery and some building  
materials. Keep shrubbery away from termination. To pre-  
vent staining or deterioration, sealing or shielding exposed  
surfaces may be required.  
0
2
4
6
50 Ft.  
40 Ft.  
30 Ft.  
20 Ft.  
* Minimum vent length is one (1) foot, or in accordance with vent  
manufacturer’s instructions, and local and national codes.  
Horizontal vents 3’ or less in length do not require a condensate  
tee, but must slope down toward the outlet at 1/4” to the foot to  
allow condensate to drain.  
Metal Special  
Support  
Gas Vent  
weight  
Final Installation Check:  
Check that horizontal vent pipe runs slope uniformly at  
least 1/4” per foot to condensate drain(s). No sags, no dips,  
no high or low spots.  
requires  
of pipe  
Appliance  
Listed  
Adapter  
Terminal  
Condensate  
Tee  
Metal  
Vent  
Check that vent is supported at elbows, tees, and horizon-  
tal and vertical runs according to manufacturer’s instruc-  
tions and code requirements.  
Body  
Slope at least  
1/4" per foot  
Check that vent supports and wall and ceiling penetrations  
allow free movements up, down, and sideways without  
putting any strains on the heater or vent body.  
Check for at least six (6) inch free air clearance between  
the heater vent pipe and combustible materials.  
Condensate  
drain w/Trap  
down towards  
3" Minimum,  
12" Maximum  
Clearance  
condensate drain  
Check that all joints are completely together and sealed.  
FIGURE 14: Typical Special Gas Vent Pipe Installation  
(Horizontal-Positive Pressure)  
WATER CONNECTIONS  
The heater requires proper water flow and pressure for its  
operation. See Figures 15 and 16 for the recommended  
installation. The filter pump discharges to the filter, the fil-  
ter discharges to the heater, and the heater discharges  
directly to the pool or spa.  
Table 7: Listed Thimbles and Vent Terminals (for Special Gas Vents)  
Vent Brand  
Wall Thimble  
Horizontal Terminal  
Vertical Terminal  
Saf-T Vent®  
Saf-T CI Vent®  
Z-Vent  
(Part of Vent term.)  
(Part of Vent term.)  
2SVSWTF04  
5490CI Horizontal Term.  
5490CI Horizontal Term.  
2SVSTTF04 Tee  
5400 Cap  
5400 Cap  
2SVSRCF04 Cap  
15  
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A manual bypass valve should be installed across the  
heater when the pump flow exceeds 120 GPM. See  
instructions below for setting of the manual bypass.  
Make sure that the outlet plumbing from the heater con-  
tains no shut-off valves or other flow restrictions that could  
prevent flow through the heater (except as noted below).  
To switch flow between the pool and spa, use a diverter  
valve. Do not use any valve that can shut off the flow.  
3-Way  
Valve  
Chlorinator  
Heater  
Do not use a shut-off valve to isolate the heater unless it is  
below the level of the pool or spa.  
Main  
Drain  
Filter  
Install a check valve if there is a possibility of back-siphon-  
ing through the heater when the pump is off.  
Pool  
Spa  
Pump  
NOTICE: Improper operation of chemical feeders can cause  
severe damage to the heater which is not covered by the  
warranty. Either equip chemical feeders with an anti-siphon  
device to prevent chemicals from siphoning into the heater  
if the pump shuts off, or install the chemical feeder down-  
stream of the heater (see “Water Chemistry,” Page 17).  
3-Way  
Valve  
3-Way  
From Pool  
Valve  
NOTICE: If the heater is plumbed in backwards, it will  
cycle continuously. Make sure piping from filter is not  
reversed when installing heater.  
FIGURE 16: Typical pool piping layout  
WATER PIPING  
Connect the heater directly to 2” PVC pipe, using the inte-  
gral unions provided. Heat sinks are not required. The low  
thermal mass of the heater will prevent overheating of the  
piping connected to the heater even if the pump shuts  
down unexpectedly.  
From Filter Outlet  
to Heater  
SYSTEM 3™  
Modular Media  
Filter  
Inlet  
Warm Water  
Out to Pool or Spa  
To Pool  
To Filter  
Inlet  
Corrosion Resistant,  
Positive Seal  
To Spa  
Check Valve  
Sanitizer  
2735 1296  
Cool Water  
In From Spa  
FIGURE 15:  
Typical installation  
Cool Water  
In From Pool  
16  
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WATER FLOW RATE  
Maximum and minimum water flow rates required by the  
heater are listed below:  
Table 8: Maximum and Minimum  
Flow Rate in GPM  
Model  
200  
333  
Minimum Flow  
Maximum Flow  
20  
33  
40  
120  
120  
120  
Cool Water In  
400  
If the water flow rate to the heater is above 120 GPM, it  
must be reduced by installing a manual bypass valve (Figure  
17). After installing the valve, adjust the valve to bring the  
flow rate within the acceptable range. Then remove the  
valve handle or lock it in place to prevent tampering.  
Warm Water Out  
Occasionally a two-speed pump will not develop enough  
pressure on the low speed to operate the heater. In this  
case, run the pump at high speed only to operate the  
heater. If this does not solve the problem, do not try to run  
the heater. Instead, correct the installation.  
2680 1096  
1. Set Manual  
Bypass Valve  
2. Remove handle  
Do not operate the heater while an automatic pool cleaner  
is also operating. If the circulation pump suction is plugged  
(for example by leaves), there may not be adequate flow to  
the heater. Do not rely on the pressure switch in this case.  
Outlet to  
Pool  
Inlet from  
Filter  
WATER CHEMISTRY  
Water chemistry should follow good swimming pool water  
chemistry practices. See Table 9 (below) for water chem-  
istry parameters.  
FIGURE 17: Manual bypass valve  
When using a chlorinator, install it downstream from the  
heater and at a lower level than the heater outlet. Install a  
corrosion resistant positive seal check valve (see Figure 15)  
between the heater and the chlorinator to prevent concen-  
trated chemicals from back-siphoning into the heater.  
Back-siphoning is most likely to occur when the pump  
stops, creating a pressure-suction differential.  
Table 9: Water Chemistry Parameters  
Disinfectant levels  
Free Chlorine, ppm  
Combined Chlorine, ppm  
Bromine, ppm  
Minimum  
1.0  
Ideal  
2.0-4.0  
None  
4-6  
Maximum  
10.0  
None  
2.0  
0.2  
10.0  
Other Sanitizers  
Levels not established. Consult local health department before use.  
Chemical Values  
pH  
Total Alklinity (Buffering), ppm  
7.2  
60  
7.4-7.6  
80-100  
7.8  
180  
as CaCO  
3
Total Dissolved Solids, ppm  
Calcium Hardness, ppm, as CaCO  
Heavy Metals  
N/A  
150  
None  
N/A  
200-400  
None  
1,500 ppm > TDS at startup*  
500-1,000  
None  
3
Biological Values  
Algae  
Bacteria  
None  
None  
None  
None  
None  
Refer to Local Code  
NOTICE: Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger  
and will void the warranty.  
*Start-up TDS includes source water TDS and any other inorganic salt added at start-up.  
17  
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NOTICE: When the heater is mounted more than five feet  
above or two feet below the deck level, a Pressure Switch  
is no longer adequate. A Flow Switch must be installed  
instead.  
NOTICE: Heater operation with incorrect Pressure Switch  
setting may cause operation with no water flow. Operation  
of the heater without sufficient water flow may severely  
damage it.  
WATER PRESSURE SWITCH  
Hazardous pressure. Do not bypass the Water  
Pressure Switch or render it inoperable.  
Switch Settings  
The water pressure switch turns off the burner if the water  
flow is interrupted. If the water flow is restricted, the water  
pressure switch may prevent the burner from firing and  
cause the “Service System” light to go on. If the light  
remains on after the filter has been serviced, have a quali-  
fied service technician check the system.  
Verify proper operation of the water pressure switch at the  
start of every season and every six months thereafter by the  
following steps:  
For deck-level heater installations, the Pressure Switch is  
factory set at 3 psi. If the pressure switch is one to two feet  
below or one to five feet above the pool water level, reset  
the switch so that it is open when the pump is off and  
closed when the pump is running. Turn the star-wheel on  
1. Lower the thermostat setting to turn off the heater.  
2. Wait at least 15 minutes after the burner is off, and  
then turn off the filter pump.  
3. Turn up the thermostat as though to fire the burner.  
4. Wait one minute. The “Service System” light should go  
on but the burner should not fire and the blower should  
not start. If the blower or burner do start, or if the  
“Service System” light does not go on, there is a pres-  
sure switch malfunction. Immediately press the OFF but-  
ton on the operating control to turn the burner off and  
call a qualified service technician to check the system.  
the switch clockwise (  
the pool) and counterclockwise (  
) to raise setting (heater below  
) to lower the setting  
(heater above the pool - see Figures 18 and 19). Test the  
switch after resetting.  
Live steam hazard. If the Burner and the  
Pump stop at the same time, wait at least 15 minutes  
before starting the filter pump to avoid severe damage to  
the heater.  
PRESSURE RELIEF VALVE  
A pressure relief valve is not supplied with the heater.  
Some local codes may require installation of a pressure  
relief valve. If your local code requires a relief valve, install  
a 3/4” pressure relief valve complying with the ANSI/ASME  
Boiler and Pressure Vessel Code, having a capacity equal  
to the Btu/hr rating of the heater. The relief pressure of the  
valve MUST NOT EXCEED 50 PSI.  
FIGURE 18: Remove cover for access to Switch  
Raise Pressure  
A 3/4” NPT connection is provided in the manifold for  
installing a pressure relief valve. The relief valve must be  
installed vertically. To install the valve, use a 3/4” brass  
nipple and elbow, as illustrated in Figure 20. No valve is  
allowed to be placed between the manifold adapter and  
the relief valve.  
Raise pressure set  
point if pressure  
switch is more  
than 2 feet below  
water level  
2734 1296  
Lower Pressure  
User  
supplied  
pipe  
fittings  
Lower pressure  
set point if pressure  
switch is more  
than 5 feet above  
water level  
2681 1096  
Pipe relief valve discharge  
to a drain or other safe  
disposal site.  
Back of pressure switch  
has a reference scale.  
FIGURE 20: Relief Valve (Check Local Codes)  
FIGURE 19: Pressure Switch Adjustment  
18  
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To High Side of Differential  
Pressure Gauge  
To avoid water damage or scalding from operation of the  
relief valve, install a drain pipe in the outlet of the pressure  
relief valve that will direct water discharging from the  
valve to a safe place for disposal. Do not install any reduc-  
ing couplings or valves in the drain pipe. The drain pipe  
must be installed so as to allow complete drainage from  
the valve and drain line. The relief valve should be tested  
at least once a year by lifting the valve lever.  
O N  
OFF  
Connection for  
Test  
VENT  
PRE
TAP  
To Low Side of Diff.  
Pressure Gauge  
PILOT  
CAUTION  
To Air Flow  
Switch  
Explosion hazard. Any heater installed with  
restrictive devices in the piping system downstream from  
the heater (including check valves, isolation valves, flow  
nozzles, or therapeutic pool valving) must have a relief  
valve installed as described above. See Page 16.  
O N  
N
F
F
OFF  
T
N
VE  
S
S
RE  
P
B
A
NOTICE: The gas  
OT  
IL  
P
piping and unions  
are not shown  
for clarity; make  
this test with all  
gas piping  
Connection for  
Service  
connected (as for  
normal service).  
2788 0397  
FIGURE 21: Connect Gas Valve to End Cap Air Orifice  
Instructions For Checking the Gas Pressure  
Through the Combination Gas Control Valve  
Combination Gas Control Valve.  
Risk of fire and explosion. Improper  
3. Install a 1/8” NPT barbed fitting into the ‘PRESSURE  
TAP’ port. Use a flexible tube to connect it to the low  
side of a differential pressure gauge or a slope  
gauge.  
installation, adjustment, alteration, service, or main-  
tenance of the Combination Gas Control Valve can  
lead to fire or explosion, causing loss of life, per-  
sonal injury, or property damage.  
NOTICE: If you are using a slope gauge or a differ-  
ential pressure gauge of less than 3” capacity, close  
the shutoff valve of the gauge to avoid pulling the liq-  
uid out of the gauge when the blower starts.  
4. Disconnect the tube from the Gas Valve ‘VENT’ port.  
Connect it to a tube with a tee running to the high  
side of a differential pressure gauge and to the blow-  
er’s air orifice grille (See Figure 21, above).  
5. Turn on the heater and verify the gas supply pres-  
sure (Page 20).  
6. After the burner ignites, open the shutoff valve of the  
gauge. The pressure gauge should then read 0.2” wc  
0.1” wc (0.0” to 0.1” wc = rich mixture; 0.3” to 0.5”  
wc = lean mixture). (Since the pressure tap is con-  
nected to the low side of the gauge, the pressure is  
actually negative.)  
These instructions are for the use of qualified  
service technicians only!  
Do not attempt this procedure unless you have  
been trained and certified in the care and repair of  
gas-fired appliances!  
Do not attempt this procedure if the following  
instructions are confusing!  
This appliance is equipped with an unconventional gas  
control valve that is factory set with a manifold pressure  
of –.2” wc. Installation or service must be performed by  
a qualified installer, service agency, or the gas supplier.  
If this control valve is replaced, it must be replaced with  
an identical control.  
The combination gas valve incorporates dual shut-off  
valves and a negative-pressure regulator. For proper  
operation, the regulated pressure at the outlet manifold  
of the valve must be 0.2” wc below the reference pres-  
sure at the blower mixer inlet, and the gas valve ‘VENT’  
tap must be connected to the endcap air orifice as  
shown in Figure 21 (above).  
Do not attempt to adjust the gas input by adjusting the  
regulator setting. The correct gas regulator setting is  
required to maintain proper combustion and must not be  
altered.  
To check that the gas pressure setting is correct,  
use the following procedure:  
Risk of fire or explosion if  
Combination Gas Control Valve is incorrectly  
adjusted. If it is necessary to adjust the gas  
valve, this must be done only by a qualified  
service agency.  
7. Turn off the heater.  
8. Replace the plastic hose between the ‘VENT’ port  
and the inlet of blower mixer. Remove the barbed fit-  
ting and replace the plug in the ‘PRESSURE TAP’  
port of the gas valve, using a thread sealant  
approved for use with natural gas and LPG.  
9. Replace the heater covers and cycle the heater to  
check for proper operation.  
1. Turn off the heater and remove the top covers for  
access to the Combination Gas Control Valve.  
2. Use a 3/16” hex key to remove the plug from the  
‘PRESSURE TAP’ port on the outlet side of the  
19  
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GAS CONNECTIONS  
PRESSURE TESTING  
The heater requires a gas supply of not less than 4” wc and  
not more than 14” wc. Gas supply pressures outside of this  
range may result in improper burner operation. A minimum  
inlet pressure of 4” wc is required to maintain input rating.  
The gas supply must be installed in accordance with the  
National Fuel Gas Code, ANSI Z223.1, and all applicable  
local codes. Install a manual shut-off valve and a sediment  
trap and union located outside the heater jacket (Figure  
22). Do not use a restrictive gas cock.  
The following gas pipe sizes are recommended for natural  
gas supply piping. For low pressure LP gas, pipe size may  
be reduced by 1/4”, with a minimum pipe size of 3/4”.  
Check for compliance with local codes.  
Before operating the heater, the heater and its gas connec-  
tions must be leak tested. Test all gas connections for leaks  
with soapy water.  
Risk of fire or explosion. Do not use an open  
flame to test for leaks.  
The heater and its individual shutoff valve must be discon-  
nected from the gas supply piping system during any pres-  
sure testing of that system at test pressures in excess of 1/2  
psig (3.5 kPa).  
The heater must be isolated from the gas supply system by  
closing its individual manual shutoff valve during any pres-  
sure testing of the gas supply at test pressures equal to or  
less than 1/2 psig (3.5 kPa).  
NOTICE: DO NOT use a corrugated flexible gas line to  
supply heater. It will not deliver enough gas (at nominal  
diameter) to supply heater.  
SUPPLYING POWER TO THE HEATER  
The heater requires a 120V/60Hz/1Ph power supply.  
Enclose the 120 Volt line to the heater in an approved flex-  
ible conduit connected directly to the junction box on the  
inside of the heater jacket.  
Table 10  
Recommended Pipe Size For Natural Gas  
Line voltage field wiring should be 14 gauge, with a circuit  
capacity of 15 amps.  
1,000 BTU/ft3, 0.6 Sp Gr, 0.5” wc Pressure Drop  
Model  
0-25’  
26-50’ 51-100’ 101-200’ 201-300’  
ELECTRICAL WIRING  
1. All wiring must be in accordance with all applicable  
codes.  
200  
333  
400  
3/4”  
1”  
1”  
1”  
1”  
1-1/4”  
1-1/2”  
1-1/2”  
1-1/4”  
1-1/2”  
2”  
1-1/4”  
1-1/4”  
1-1/4”  
1-1/4”  
2. The heater, when installed, must be electrically  
grounded and bonded in accordance with local codes  
or, in the absence of local codes, with the National  
Electrical Code, ANSI/NFPA 70. A bonding lug is pro-  
vided on the outside of the jacket under the vent for  
this purpose.  
3. Electrical power circuits to the pool heater must follow  
local codes and National Electrical Code or Canadian  
Electrical Code (as applicable).  
Manual  
Shut-off  
Valve  
4. All wiring between the heater and devices not attached  
to it, or between separate devices which are field  
installed and located, shall conform to the specifica-  
tions of Type T wire (35°C rise).  
At least 4"  
Union  
5. All line voltage wiring shall be enclosed in approved  
flexible conduit, and shall be securely attached to the  
field wiring box located inside the jacket. The conduit  
or cable connector at the field wiring box should con-  
tain an insulating bushing or its equivalent to prevent  
abrasion of the wires as they enter the box.  
Sediment  
Trap  
FIGURE 22: Gas line and Trap  
6. The filter pump should run continuously when the  
heater is on, and for at least 15 minutes after the  
heater is off. Any switches in the pump circuit (includ-  
ing circuit breakers) that can disconnect the pump  
must also disconnect the heater.  
7. Do not wire single pole switches, including protective  
devices, into a grounded line. Observe hot/neutral  
polarity when connecting power to the heater.  
20  
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Connect the hot lead of the power supply to the black  
wire, the neutral lead to the white wire, and the ground  
wire to the green wire (See Figure 23).  
A time clock controlling the filter pump should have a low-  
voltage Fireman’s Switch that switches off the heater at  
least 15 minutes before shutting off the pump.  
NOTICE: When using a timer and Fireman’s Switch, the  
heater’s power supply should come from the load side of  
the timer. The Fireman’s Switch completes the circuit for  
the low voltage safety switches. It DOES NOT get any  
power from the 115 volt power supply.  
Connect the Fireman’s switch to the heater as follows:  
1. Turn off power to heater at main circuit breaker panel.  
2. Unbolt and remove the upper jacket halves (see Figure  
3, Page 5).  
3. Open control box cover (see Figure 24).  
4. Remove the factory-installed jumper between the  
Fireman’s Switch terminals (see Figure 25).  
5. Connect the wires between the Fireman’s Switch termi-  
nals on the heater and those on the time clock using  
18 gauge wire with a minimum 3/64” thick insulation  
rated for a temperature rise of at least 105°C. Route the  
wires out through the knockout on the bottom of the  
Control Box. Use a 90° conduit el and conduit run out  
through the cutout on the Lower Enclosure, next to the  
Junction Box (see Figure 23).  
White to White  
Green (Ground)  
to  
Green (Ground)  
Black to  
Black  
Cutout for  
Conduit from  
Fireman's Switch  
Bonding  
Wire  
Bonding Lug  
Bonding Wire  
Wiring Harness  
to Control Box  
View From Above  
(Interior)  
View From Below  
(Exterior)  
Wire into bottom  
of Junction-box  
in Flexible Conduit  
BK  
TRANS  
FIGURE 23: Field Wiring  
Y
Y
FIREMAN’S SWITCH CONNECTION  
NOTICE: If, while there is 120VAC connected to the  
heater, you touch either 120VAC terminal with any 24VAC  
wire that is connected to the control board (including the  
Fireman’s Switch jumper), you will immediately destroy the  
control board and void the warranty.  
OPERATING CONTROL  
MEMBRANE PAD  
CONNECTION  
BK  
JMP3  
ENABLE TOGGLE  
1
DISABLE TOGGLE  
VERSION 1 PAD  
SPA CONTROL  
CONTROL CENTER  
W
Y
Y
O N  
N
TERMINAL BOARD  
W
TRANS  
TRANS  
L1  
F
I
TRANS  
S
W
I
T
C
H
R
E
M
A
N
S
W
L2  
FL  
W
BM  
F1  
Time Clock or Remote  
(Purchase Separately –  
Supplies Power to  
NEUTRAL  
Circulator Pump)  
GND  
JUNCTION BOX  
Fireman's Switch  
Completes the heater  
24 Volt AC Control  
Board Circuit.  
DO NOT connect this  
circuit to 115 Volt AC!  
24VAC  
3
FIGURE 24: Open Control Box Cover  
FIGURE 25: Fireman’s Switch Connections  
21  
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6. Reinstall and bolt up the jacket halves.  
The fuse for the Fireman’s Switch is 1.25 amp 1-1/4x1/4”  
fast blow fuse, available locally.  
MAXIMUM TEMPERATURE SET POINT  
1. Unbolt and remove upper jacket halves (see Figure 3,  
Page 5).  
2. Depress clips and remove control board assembly  
dome (see Figure 9, Page 10).  
3. Push the Max. Temp. Set Point button on the back of  
the control board (see Figure 26). The following  
sequence should happen:  
SET  
MAX  
S1  
SET  
MAX  
S1  
FIGURE 26: Max Temperature Set Point Controls  
A. The unit will come on and the POOL ON light will  
come on.  
B. Press the Temp or Temp pad (on TOP of the  
panel) to set maximum pool temperature.  
C. Wait 30 seconds; the POOL ON light will go off and  
the SPA ON light will come on.  
D.Press the Temp or Temp pad (on TOP of the  
panel) to set maximum spa temperature (set temper-  
ature to 104° F or less).  
E. Wait 30 seconds; the SPA ON light will go off and  
the unit will shut down.  
4. Reinstall and bolt up the jacket halves.  
22  
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Initial Troubleshooting  
Only qualified, trained service technicians with appropriate test equipment should service the heater. Remember  
that all parts of the system affect heater operation. Before starting this troubleshooting procedure, make sure that  
the pump is running correctly, that there are no blockages in the system, that the valves are correctly set and that  
the time clock is correctly set and is running.  
Start here for directions to specific Troubleshooting Chart  
Go to chart “HEATER WILL  
NOT FIRE - A”  
(Page 24)  
NO  
Is green “POOL” or “SPA”  
LED “on”?  
YES  
Go to chart “HEATER WILL  
NOT FIRE - B”  
(Page 25)  
YES  
Is red “SERVICE SYSTEM”  
LED “on”?  
NO  
Are any red diagnos-  
tic LED’s on back of  
board (AGS, AFS,  
SFS, HLS, PS or  
Go to specific safety switch  
troubleshooting chart  
(Pages 28 and 29)  
YES  
YES  
Is red “SERVICE HEATER”  
LED “on”?  
THERMISTOR) “on”  
NO  
NO  
Turn off 120 VAC power to  
heater for about 5 seconds,  
and turn back on. Make sure  
temperature setting is above  
water temperature. Wait one  
minute.  
YES  
NO  
Do any diagnostic LED’s on  
back of board (AGS, AFS,  
SFS, HLS, PS, or  
THERMISTOR) come “on”  
and stay on?  
YES  
Does red “SERVICE  
HEATER” LED come  
“on”  
Go to chart ‘HEATER WILL  
NOT FIRE -C”  
(Page 26)  
NOTICE: Any or all of the diag-  
nostic LED’s may come “on”  
momentarily when you turn on  
the power to the heater.  
NO  
Verify that water temperature setting is  
above water temperature reading. If it is,  
and heater either will not fire or no red  
LED’s come “on”, replace Control Board.  
Hazardous voltage. Can shock, burn  
or kill. Disconnect power before servicing any  
Fire and Explosion hazard. Do not  
jumper switch terminals to remedy a failed safety  
switch.  
components.  
23  
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Heater Will Not Fire - A  
Start  
Depress “POOL” or “SPA” ON  
Heater should fire on demand  
for heat.  
NO  
YES  
Is green “SPA” or  
“POOL” LED “on”  
button on Membrane Pad.  
Does “POOL” or “SPA” LED  
come on?  
Restore power to heater.  
NO  
YES  
NO  
Check for 120 VAC power to  
heater.  
Check wiring connections  
between power supply to  
Junction Box and between  
Junction Box to Terminal  
Board and restore continuity.  
YES  
YES  
Check for 24 VAC at sec-  
ondary of Transformer.  
NO  
Check for 120 VAC between  
“HOT” and “NEUTRAL” termi-  
nals on Terminal Board.  
NO  
NO  
Check wiring connections  
between Terminal Board and  
Transformer primary and  
restore continuity.  
YES  
Check for 120 VAC at primary  
to Transformer.  
YES  
Replace Transformer.  
Jumper Fireman’s Switch at  
Terminal Board and depress  
“POOL” or “SPA” ON button on  
membrane pad. Does “SPA” or  
“POOL” LED come “on”?  
Check Fireman’s Switch circuit  
connections (time clock, wiring,  
external controller relay).  
YES  
NO  
Remove jumper. Check wiring  
between Transformer and J7  
terminals on Control Board  
and between J7 and Fireman’s  
Switch on Terminal Board,  
check fuse, and restore  
continuity.  
Leaving jumper in place,  
check for 24 VAC between  
Fireman’s Switch terminals  
and ground.  
NO  
YES  
Remove jumper. Check rib-  
bon cable connection  
between Membrane Pad and  
J6 on Control Board. Depress  
“POOL” or “SPA” On pad  
again. Does “POOL” or “SPA”  
LED come on?  
YES  
Heater should fire on demand  
for heat.  
Replace Membrane Pad.  
Replace Control Board.  
NO  
YES  
NO  
Jumper pins 9 and 8 on J6 of  
Control Board. Does “SPA”  
LED come on?  
Jumper pins 9 and 7 on J6 of  
Control Board. Does “POOL”  
LED come on?  
GO TO  
“HEATER WILL NOT FIRE - B”  
Page 25  
24  
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Heater Will Not Fire - B  
Start  
Increase POOL/SPA tempera-  
ture setting on Membrane  
Pad above actual water tem-  
perature. Heater should fire  
on demand for heat. If not,  
and no other red LED’s light,  
replace Control Board.  
NO  
NO  
Is red “SERVICE  
HEATER” LED “on”  
Is red “SERVICE SYSTEM”  
LED on?  
YES  
YES  
Verify that pump is on, filter is  
not blocked, and the water  
flow is above the minimum  
requirement.  
NO  
YES  
Service pump/filter and elimi-  
nate other flow obstructions.  
With pump running, adjust  
Water Pressure Switch to  
lower pressure until ‘SER-  
VICE SYSTEM” LED goes  
out. Then verify that “SER-  
VICE SYSTEM” LED goes on  
with pump off.  
YES  
Heater should fire on call for  
heat. Re-verify that water  
flow is above minimum  
requirement.  
NO  
Minimum Flow Requirements  
Check that water pressure is  
within the adjustment range of  
the Pressure Switch (0-5 psig)  
NO  
Model  
Flow  
200  
333  
400  
20 GPM  
30 GPM  
40 GPM  
YES  
Verify that switch wiring is OK  
and sensing tube is not  
blocked, and replace water  
Pressure Switch.  
CONTINUE  
If water pressure is outside of  
adjustment range that will  
open switch with pump off  
and close switch with pump  
on, replace with flow switch  
set above minimum flow  
requirement.  
Minimum Flow Requirements  
Model  
Flow  
200  
333  
400  
20 GPM  
30 GPM  
40 GPM  
Check whether any of the  
red diagnostic LED’s on back  
of board (AGS, AFS, SFS,  
HLS or PS) are “on”  
YES  
Go to “Diagnostic LED’s”,  
(Pages 28 and 29)  
NO  
GO TO  
“HEATER WILL NOT FIRE - C”  
Page 26  
25  
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Heater Will Not Fire - C  
Start  
NO  
Is “SERVICE HEATER” LED  
“on”?  
Go to “INITIAL  
TROUBLESHOOTING”  
Turn off 120 VAC  
power to heater for 5  
seconds, and turn  
back on.  
Make sure tempera-  
ture setting is above  
water temperature.  
Wait one minute.  
YES  
Continue to observe heater  
for several minutes. Cycle  
heater on and off several  
times. Observe for delayed or  
rough ignition, poor combus-  
tion, premature extinction of  
flame, evidence of boiling, or  
operation of any diagnostic  
LED. Go to pertinent trou-  
bleshooting section if any  
malfunction is observed.  
If any red diagnostic LED’s  
NO  
YES  
(AGS, AFS, SFS, HLS, PS, or  
THERMISTOR) come “on”, go  
to Pages 28 and 29.  
Does heater fire and  
stay on?  
CONTINUE  
NO  
NO  
NO  
Did burner fire at all?  
Did Blower come on?  
Replace Control Board.  
YES  
YES  
Verify that gas supply is open  
all the way to Gas Valve, and  
Gas Valve knob is at “on”  
position.  
Check for 24 VAC to Gas  
Valve terminals during ignition  
try. (Voltage appears about 24  
seconds after call for heat).  
SEE NOTE 1.  
Verify that gas is flow-  
ing to burner during  
ignition try. Observe  
gas meter for move-  
ment during ignition  
try (wait for about 30  
seconds after calling  
for heat).  
Go to “BURNER  
TROUBLESHOOTING”  
(Page 30)  
NO  
YES  
Go to “HEATER WILL NOT  
FIRE-D” (Page 27)  
YES  
Check for 24 VAC  
between TH and GND  
terminals on Ignition  
Control Module.  
Replace Ignition Control  
Module.  
YES  
Replace Gas Valve with  
identical part.  
NO  
SEE NOTE 2.  
Check for 24 VAC between  
VAL and GND terminals on  
Ignition Control Module.  
SEE NOTE 1.  
Fix wiring between TH and  
GND terminals of Ignition  
Control Module and Control  
Board.  
NO  
YES  
Check for 24 VAC  
between TH and GND  
terminals on Control  
Board. SEE NOTE 2.  
YES  
NO  
Check for 24 VAC between  
VAL and GND terminals on  
Control Board. SEE NOTE 1.  
YES  
Replace Control Board.  
Check for 24 VAC  
between GAS termi-  
nals on Control  
NO  
Fix wiring between GAS ter-  
minals on Control Board and  
Gas Valve.  
YES  
Fix wiring between VAL and  
GND terminals of Ignition  
Control Module and Control  
Board.  
Board. SEE NOTE 1.  
NO  
NOTE 1: Voltage appears about 24  
seconds after call for heat, and may  
be on for only about 7 seconds.  
Replace Control  
Board.  
NOTE 2: Voltage appears immedi-  
ately after call for heat, and may be  
on for only about 30 seconds.  
26  
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Heater Will Not Fire - D  
Start  
Gas flows during igni-  
tion try, but burner  
does not fire.  
Go back to chart “HEATER  
WILL NOT FIRE-C”  
(Page 26).  
NO  
YES  
YES  
YES  
Check for 120 VAC at  
Igniter leads during  
ignition try.  
YES  
Check gas pressure? OK?  
Replace HSI Igniter.  
NO  
NO  
Replace gas line with larger  
line or replace regulator.  
Check for 120 VAC  
between S1 and S2  
terminals on Ignition  
Control Module during  
ignition try.  
Fix wiring between S1 and S2  
terminals on Ignition Control  
Module and HSI Igniter.  
NO  
Check for 120 VAC  
between L1 and L2  
terminals on Ignition  
Control Module.  
Fix wiring between L1 and L2  
terminals on Ignition Control  
Module and Terminal Board.  
NO  
YES  
Replace Ignition  
Control Module.  
27  
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Diagnostic LED’s: AGS, AFS, HLS, PS, THERMISTOR  
Verify that water flow rate is  
above minimum required for  
heater.  
Service pump and filter to  
restore proper flow. After ser-  
vicing, verify proper operation  
of Pressure Switch (PS).  
NO  
AGS or HLS “on”  
Replace High Limit  
Switch (HLS) or  
Automatic Gas  
Shutoff (AGS)  
YES  
YES  
Verify that inlet water temper-  
ature is below 104° F.  
NO  
Replace thermistor or Control  
Board to correct overheating.  
CONTINUE  
If problem persists, verify proper operation of Internal Bypass Valve  
and Thermal Governor, and check for Heat Exchanger blockage.  
Service pump and filter to  
restore proper flow.  
Verify that water flow rate is  
PS “on”  
NO  
above minimum required for  
heater.  
CONTINUE  
Verify that wiring is  
YES  
OK and pressure tap  
is not blocked. Re-  
CONTINUE  
Adjust Water Pressure Switch to close with pump running and open with  
pump off.  
place Pressure Switch  
Verify that there is no block-  
age in Blower intake, Heat  
Exchanger, and exhaust and  
that exhaust is not too long  
(see “Indoor Vent Installation”,  
Page 15.  
YES  
Does Blower operate?  
AFS “on”  
NO  
YES  
YES  
Check for 120 VAC at Blower  
connector on ignition try.  
Replace Blower.  
NO  
Verify correct connection of  
wiring and that pressure taps  
to AFS are OK.  
Verify that wires BM  
and F1 are correctly  
connected at the  
terminal strip (see  
Heater Connection  
Diagram, Page 36).  
Check for 24 VAC between  
24 VAC and GND terminals  
on Ignition Control Module on  
ignition try. Check that IND  
wire is correctly connected.  
Verify that vinyl tubing to AFS  
and Blower is not misrouted,  
kinked, disconnected, or  
punctured.  
NO  
NO  
Replace Air Flow Switch  
(AFS).  
Verify correct connection of  
wiring between 24 VAC and  
IND terminals on Ignition  
Control Module and Control  
Board, and replace Control  
Board.  
If problem persists, replace  
Blower.  
YES  
Connect correctly and retry.  
Does Blower start?  
Disconnect wires F1  
and F2 from Ignition  
Control Module and  
short them together.  
Does Blower come  
on?  
NO  
YES  
Replace Blower. Does Blower  
Start?  
NO  
NO  
Replace Ignition Control  
Module.  
YES  
Verify Thermistor wiring. If  
OK, replace Thermistor.  
THERMISTOR “on”  
Do not jumper a safety switch to  
remedy a failed switch.  
NOTE: ES1 is a spare and should be jumpered.  
28  
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Diagnostic LED’s: SFS  
Replace Heater Membrane  
Pad Assembly, reset power to  
Heater and retry. Heater  
should fire.  
SFS “on”  
A) Is the Stack Flue  
Switch or Sensor  
NO  
correctly connected to  
Replace Heater Control Board  
with new style board, reset  
power to Heater and retry.  
Heater should fire.  
the wiring harness?  
B) Is the Membrane Pad  
connected to the  
NO  
NO  
Reconnect correctly.  
correct pins on the  
Control Board?  
(See Page 36)  
NO  
DONE  
Change Low Level Board  
Programming to “SF1” (See  
Page 4-11 in S5066, “Sta-Rite  
Pool/Spa Heater Training and  
Service Manual”). Were you  
able to change the device  
code (SF0 to SF1)?  
YES  
Check the J3 and J6  
connectors for corrosion  
on the male pins.  
NO  
Reset power to Heater and  
retry. Heater should fire.  
Corrosion found?  
YES  
Clean pins  
YES  
Replace Stack Flue Sensor.  
Reset power to Heater and  
retry. Heater should fire.  
DONE  
YES  
Reset power to Heater  
and retry. Heater should  
fire.  
Does the Digital Temerature  
Display show Error Code  
“E05” or “E06”?  
NO  
NO  
Check Heat Exchange Coil  
for liming or low flow.  
NO  
Verify whether you have a  
Stack Flue Sensor or a  
Stack Flue Switch  
SENSOR  
(See Page 4-11 in S5066,  
“Sta-Rite Pool/Spa Heater  
Training and Service  
Manual”).  
Reset power to Heater and  
retry. Heater should fire.  
SWITCH  
Change Low Level Board  
Programming to “SF0” (See  
Page 4-11 in S5066, “Sta-Rite  
Pool/Spa Heater Training and  
Service Manual”). Were you  
able to change the device  
code (SF1 to SF0)?  
YES  
Does the Digital  
Temerature Display  
show Error Code “E05” or  
“E06”?  
YES  
YES  
YES  
NO  
Did Error Code (E05 or E06)  
disappear after change?  
NO  
NO  
Replace Heater Control  
Board, reset power to Heater  
and retry. Heater should fire.  
Reset power to Heater  
and retry. Heater should  
fire.  
Check Heat Exchanger Coil  
for liming or low flow.  
NO  
NO  
Replace Heater Membrane  
Pad Assembly, reset power to  
Heater and retry. Heater  
should fire.  
Replace switch, reset  
power to Heater and retry.  
29  
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Burner Troubleshooting  
SYMPTOM  
CAUSE  
REMEDY  
Loud, high-pitched whine  
Flame is too rich.  
Verify pressure tap between gas valve  
and blower inlet.  
Turn to Page 19 and verify that the gas  
regulator setting is 0.2”wc below the  
blower inlet pressure.  
Replace gas orifice with smaller size.  
Flame is “fluttery.”  
Exhaust may have acrid  
smell or burner may fail  
to stay lit.  
Flame is too lean.  
Turn to Page 19 and verify that the gas  
regulator setting is 0.2”wc below the  
blower inlet pressure.  
Replace gas orifice with larger size.  
Burner pulsates or  
surges, especially on  
ignition.  
Exhaust vent is too long.  
Reduce length of exhaust vent and/or  
number of elbows.  
Combustion appears  
normal, but flame does  
not stay lit.  
Flame current is not  
being sensed.  
Check for wet or damaged igniter with  
low resistance to ground. Replace with  
new igniter.  
Verify burner flameholder is properly  
grounded.  
Replace Ignition Control Module.  
Heat Exchanger Troubleshooting  
SYMPTOM  
CAUSE  
REMEDY  
Boiling in heat exchanger.  
Low water flow to heater.  
Service pump and or filter.  
May be accompanied by  
“bumping” sounds.  
Heat exchanger plugged.  
Service heat exchanger. Correct water  
chemistry.  
Bypass valve stuck open.  
Service bypass valve.  
Thermal governor stuck  
closed.  
Replace thermal governor.  
Sweating.  
Thermal governor failed.  
Replace thermal governor.  
30  
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1
For complete  
Electrical System  
parts breakdown  
2
(Key Nos. 1 through 4),  
See Page 35  
3
5
O N  
N
F
OFF  
F
6
PILO
9
For compete  
Burner System  
parts breakdown  
(Key Nos. 5 through 9),  
See Pages 32 and 33  
7
4
12  
8
11  
4
10  
For complete  
Water System  
parts breakdown  
2737 0197  
(Key Nos. 10 through 13),  
see Page 34  
Repair Parts are available from your Sta-Rite dealer.  
If your dealer cannot supply you, call Sta-Rite Customer Service at 1-800-752-0183.  
31  
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5
1
2
2
3
4
O
N
FF  
O
T
N
E
V
S
S
E
R
For Heater mounting  
bolts and clamps,  
P
A
T
T
O
IL  
P
purchase separately  
Bolt Down Bracket Kit,  
Part No. 42001-0085S.  
9
10  
8
11  
7
6
12  
13  
26  
14  
25  
24  
15  
23  
22  
21  
20  
19  
18  
17  
16  
2692 1196  
32  
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REPAIR PARTS – BURNER SYSTEM  
Model  
Key  
No.  
SR200NA  
SR200LP  
SR333NA  
SR333LP  
SR400NA  
SR400LP  
Part Description  
Qty  
1
2
3
4
3
4
3
4
3
4
Combination Gas Control Valve Kit  
3/4” Union  
Gas Orifice Kit – NG (Incl. Key Nos. 3 and 4)†  
Gas Orifice – NG*  
Gas Orifice O-Ring  
Gas Orifice Kit – LPG (Incl. Key Nos. 3 and 4)†  
Gas Orifice – LPG*  
Gas Orifice O-Ring  
NG to LPG Conversion Kit (Incl. Key Nos. 3 and 4)†  
Gas Orifice – NG*  
1
2
42001-0051S  
38404-4097S  
77707-0331  
42001-0331  
U9-370  
77707-0361  
42001-0361  
U9-370  
42001-0051S  
38404-4097S  
77707-0321  
42001-0321  
U9-370  
7707-0351  
42001-0351  
U9-370  
42001-0051S  
38404-4097S  
77707-0311  
42001-0311  
U9-370  
77707-0341  
42001-0341  
U9-370  
1
1
1
1
77707-1361  
42001-0361  
U9-370  
77707-1351  
42001-0351  
U9-370  
77707-1341  
42001-0341  
U9-370  
1
1
1
1
Gas Orifice O-Ring  
Conversion Instructions, NG to LPG*  
NP to LPG Conversion Decal*  
LPG to NG Conversion Kit (Incl. Key Nos. 3 and 4)†  
Gas Orifice – LPG*  
S402  
S402  
S402  
32165-4082  
77707-1331  
42001-0331  
U9-370  
32165-4082  
77707-1321  
42001-0321  
U9-370  
32165-4082  
77707-1311  
42001-0311  
U9-370  
1
1
1
1
1
1
1
1
Gas Orifice O-Ring  
Conversion Instructions, LPG to NG*  
LPG to NG Conversion Decal*  
Gas Piping Clamp Kit  
Air Blower Kit  
Endcap/Air Orifice – Inlet Mixing Tube  
Endcap Mixing Tube Grill  
Blower/Adapter Plate Gasket Kit  
(Includes Key Nos. 9, 11, 13)  
Blower/Adapter Plate Gasket*  
Blower Adapter Plate  
Flameholder Kit (Includes Key Nos. 11, 12, 13, 14  
and Flameholder Insert)  
S403  
S403  
S403  
32165-4083  
31786-4019S  
42001-0206S  
77707-0091  
42001-0094S  
32165-4083  
31786-4019S  
42001-0206S  
77707-0092  
42001-0094S  
32165-4083  
31786-4019S  
42001-0206S  
77707-0093  
42001-0094S  
5
6
7
8
1
1
1
77707-0011  
42001-0067  
42001-0090  
77707-0011  
42001-0067  
42001-0090  
77707-0011  
42001-0067  
42001-0090  
9
10  
77707-0202  
42001-0084  
42001-0202  
42001-0065  
42001-0075  
42001-0031  
77707-0002  
42001-0001S  
33457-1051S  
77707-3200N  
77707-3200L  
77707-0007  
U43-62SS  
77707-0203  
42001-0084  
42001-0203  
42001-0065  
42001-0075  
42001-0027  
42001-0031  
77707-0002  
42001-0001S  
33457-1051S  
77707-3333N  
77707-3333L  
77707-0007  
U43-62SS  
77707-0204  
42001-0084  
42001-0204  
42001-0065  
42001-0075  
42001-0027  
42001-0031  
77707-0002  
42001-0001S  
33457-1051S  
77707-3400N  
77707-3400L  
77707-0007  
U43-62SS  
11  
12  
13  
14  
Flameholder/Adapter Plate Gasket*  
Flameholder Assembly*  
Flameholder/Combustion Chamber Gasket  
Flameholder Insulation Cap  
Flameholder Insert*  
1
1
1
1
1
1
Condensate Evaporator  
Upper RH Heater Enclosure Kit**  
Lower Enclosure  
15  
16  
17  
17  
18  
19  
20  
21  
1
1
1
1
1
4
4
4
Upper Enclosure Gasket  
Upper LH Heater Enclosure Kit-NG  
Upper LH Heater Enclosure Kit-LPG  
Upper Enclosure Fastener Kit  
3/8” Flat Washer  
3/8” Lock Washer  
3/8” Hex Nut  
Insulation Kit (Includes Key Nos. 22, 23, 24, 25  
and Condensate Evaporator, Page 34)  
1/2” Insulation Blanket*  
U43-12SS  
U36-38SSW  
U43-12SS  
U36-38SSW  
U43-12SS  
U36-38SSW  
1
1#  
1
1
1
1
1
1
1
77707-0008  
42001-0073  
42001-0072  
42001-0070  
42001-0071  
42001-0074S  
42002-0005S  
42001-0209S  
42001-0214S  
77707-0008  
42001-0073  
42001-0072  
42001-0070  
42001-0071  
42001-0074S  
42002-0005S  
42001-0209S  
42001-0214S  
77707-0008  
42001-0073  
42001-0072  
42001-0070  
42001-0071  
42001-0074S  
42002-0005S  
42001-0209S  
42001-0214S  
22  
23  
24  
25  
26  
1” Insulation*  
1” Top Insulation*  
1/2” Insulation Blanket*  
Lower Enclosure Insulation  
Metal Vent Cover  
Metal Exhaust Elbow Kit  
One-Piece Metal Elbow/Cover Assembly  
*
Not available separately.  
** Kit parts not available separately.  
#
Not illustrated.  
Not included with heater. Order separately.  
Model SR200 uses 2.  
33  
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1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
17  
15  
16  
18  
20  
19  
2691 1196  
REPAIR PARTS – WATER SYSTEM  
Model  
Key  
No.  
SR200NA  
SR200LP  
SR333NA  
SR333LP  
SR400NA  
SR400LP  
Part Description  
Tube Sheet Coil Assembly Kit  
Qty  
1
77707-0232  
77707-0233  
77707-0234  
(Includes Key No. 2)  
2
3
4
5
6
7
8
9
Coil/Tubesheet Sealing O-Ring Kit  
Manifold Bottom Plate  
Manifold O-Ring*  
O-Ring Kit (Incl. Key Nos. 2, 4)  
Manifold Insert*  
Manifold Baffle Plate*  
Manifold Bypass Valve Kit  
Water Pressure Switch  
Manifold Body with Safeties (Incl. Key Nos. 10, 11)  
Manifold Body Only (Incl. O-Ring Kit)  
5/16 Flat Washer  
5/16-18x2-3/4” Hex Capscrew  
Connector Tube O-Ring  
Connector Tube Kit (Includes O-Ring)  
Thermal Regulator Kit  
( )  
1
1
1
1
1
1
1
1
77707-0117(6)  
42002-0015  
35505-7437  
77707-0120  
42002-0018  
42002-0013  
77707-0001  
42001-0060S  
77707-0205  
77707-0206  
U43-41SS  
77707-0118(10)  
42002-0016  
35505-7437  
77707-0120  
42002-0019  
42002-0014  
77707-0001  
42001-0060S  
77707-0205  
77707-0206  
U43-41SS  
77707-0119(12)  
42002-0017  
35505-7437  
77707-0120  
42002-0020  
42002-0022  
77707-0001  
42001-0060S  
77707-0205  
77707-0206  
U43-41SS  
9
1
10  
11  
12  
13  
14  
10  
10  
2
37007-0214  
U9-226  
77707-0017  
37007-0214  
U9-226  
77707-0017  
37007-0214  
U9-226  
77707-0017  
2
(Incl. Key Nos. 15, 16, 17, 18 and Spring Clip)  
Thermal Regulator (Includes Spring Clip)  
Thermal Regulator Spring*  
Thermal Regulator Cap O-Ring  
Thermal Regulator Spring Clip*  
Thermal Regulator Cap*  
1
1
1
1
1
1
1
1
77707-0010  
38000-0007S  
37607-0011  
35505-1313  
42001-0097  
42001-0016  
U178-920P  
42001-0031  
77707-0010  
38000-0007S  
37607-0011  
35505-1313  
42001-0097  
42001-0016  
U178-920P  
42001-0031  
77707-0010  
38000-0007S  
37607-0011  
35505-1313  
42001-0097  
42001-0016  
U178-920P  
42001-0031  
15  
16  
17  
18  
19  
20  
Drain Plug  
Condensate Evaporator*  
*
Not available separately.  
Not illustrated.  
34  
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1
2
19  
3
4
18  
20  
17  
5
16  
13  
14  
15  
6
7
11  
10  
12  
6
9
8
REPAIR PARTS – ELECTRICAL SYSTEM  
Model  
Key  
No.  
SR200NA  
SR200LP  
SR333NA  
SR333LP  
SR400NA  
SR400LP  
Part Description  
Qty  
1
2
3
4
5
6
Display Cover Retainer Cap Kit (Incl. Key No. 1)*  
Display Cover Retainer Cap  
CPSC Warning Label  
Heater Display Cover  
Igniter Bracket  
Igniter/Igniter Gasket Kit (Incl. Key Nos. 4 and 5)  
Igniter**  
77707-0009  
42001-0009  
32165-4084  
42001-0008S  
42001-0030S  
77707-0054  
42001-0054  
42001-0066S  
42001-0007S  
42002-0025S  
WC78-38AT  
42001-0063S  
42001-0053S  
42001-0056S  
32850-0099  
42001-0052S  
42001-0057S  
42001-0059S  
42001-0096S  
37337-0092  
42001-0058S  
77707-0022  
42001-0022  
32165-4081  
77707-0004  
77707-0009  
42001-0009  
32165-4084  
42001-0008S  
42001-0030S  
77707-0054  
42001-0054  
42001-0066S  
42001-0007S  
42002-0025S  
WC78-38AT  
42001-0063S  
42001-0053S  
42001-0056S  
32850-0099  
42001-0052S  
42001-0057S  
42001-0059S  
42001-0096S  
37337-0092  
42001-0058S  
77707-0022  
42001-0022  
32165-4081  
77707-0004  
77707-0009  
42001-0009  
32165-4084  
42001-0008S  
42001-0030S  
77707-0054  
42001-0054  
42001-0066S  
42001-0007S  
42002-0025S  
WC78-38AT  
42001-0063S  
42001-0053S  
42001-0056S  
32850-0099  
42001-0052S  
42001-0057S  
42001-0059S  
42001-0096S  
37337-0092  
42001-0058S  
77707-0022  
42001-0022  
32165-4081  
77707-0004  
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
4
1
Igniter Gasket  
Manifold Switch Cover  
Automatic Gas Shutoff Switch (AGS)  
3/4” Hex Head Pipe Plug  
High Limit Switch  
Thermistor  
Terminal Board  
Fireman’s Switch Fuse (1.25A, 1-1/4”)  
Ignition Control Module  
Transformer  
Air Flow Switch  
Control Board Kit  
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
#6-19x5/16” Phil Pan  
Heater Wiring Harness  
Junction Box Cover Kit (Incl. Key No. 17)*  
Junction Box Cover  
Junction Box Wiring Decal  
Control Bd Encl/Membrane Panel Kit  
(Incl. Key Nos. 18 and 19)*  
Control Board Enclosure  
Membrane Pad**  
1
1
18  
19  
20  
1
1
1
42001-0004  
42001-0055  
42002-0024S  
42001-0004  
42001-0055  
42002-0024S  
42001-0004  
42001-0055  
42002-0024S  
Stack Flue Sensor  
*
**  
Kit parts not available separately.  
Not available separately.  
***  
Available separately.  
Not illustrated.  
35  
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Pool Heater Wiring Connection Diagram  
CONNECTION DIAGRAM  
Y/R  
AGS Switch  
Air Flow Switch  
Y/BL  
Stack Flue Sensor  
Extra Switch 1  
Y/O  
Y/W  
Gas Valve  
Hi-Limit Switch  
Y
Pressure Switch  
Y
Y
Y
Y
O
O
BL  
O
BL  
W
O
W
BR  
BR  
PR  
PR  
Y/W  
Y
R
R
PS  
HLS  
ES1  
J6  
Y
Y
Y
Y
OPERATING CONTROL  
AFS  
MEMBRANE PAD  
CONNECTION  
AGS  
SFS  
GAS  
JMP3  
VERSION 1 PAD  
SPA CONTROL  
1
CONTROL CENTER  
External Control Interface Circuit  
Disabled, Heater Membrane Pad  
Enabled  
Spa Line  
Common Line  
Pool Line  
External Control Interface  
BK  
BK  
Y
JMP3  
1
24  
VAC  
F1 F2  
DIAGNOSTIC INDICATOR  
IGNITION CONTROL  
MODULE  
JMP3  
Y
Y
24VAC  
SEC  
FC1 S1/  
FC2 120  
VAL GND  
L1 L2 S2 TH IND  
1
External Control Interface  
Circuit Enabled, "Pool On"  
and "Spa On" Keys Disabled.  
"OFF" Key on Membrane  
Pad Remains Functional.  
PRIM  
Y/W  
120VAC  
GY  
GY  
Y/O  
Y/BL  
W
BK  
Y/R  
120VAC  
IGNITER  
BLOWER  
120VAC  
Y/W  
GND  
TRANS  
L2  
TRANS  
L1  
F
I
S
W
I
T
C
H
MOT  
R
E
M
A
N
S
BK  
FL  
BK  
BM  
F1  
G
J6  
GND  
W
W
Y
W
W
GND  
JUNCTION BOX  
GROUND (GND)  
G
BK  
W
120VAC (HOT)  
If cable from Membrane Pad  
is a 6-Conductor Cable, connect  
it to pins 4 - 9 on Operating  
Control Board as shown.  
NEUTRAL (NEU)  
NOTICE: If, while there is 120VAC connected to the heater, you touch  
either 120VAC terminal with any 24VAC wire that is connected to the  
control board (including the Fireman's Switch jumper), you will  
immediately destroy the control board and void the warranty.  
Replace jumper with leads to  
Fireman's Switch (field installed)  
3661 0200  
36  
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Pool Heater Electrical Schematic Ladder Diagram  
LADDER DIAGRAM  
HOT  
120 VAC  
IGNITER  
NEUTRAL  
L1  
F1  
S1  
F2  
S2  
L2  
BLOWER  
GND  
120 VAC  
CLASS II  
TRANSFORMER  
24 VAC  
OPERATING  
CONTROL  
24 VAC  
24 VAC  
GND  
AIR  
FLOW  
SWITCH  
LOGIC  
24V  
TH  
HI  
LIMIT  
SWITCH  
WATER  
PRESSURE  
SWITCH  
IND  
COM NO  
AGS  
SWITCH  
VAL  
GAS VALVE  
STACK FLUE  
SENSOR  
THERMISTOR  
SENSOR  
NOTES:  
1.)  
L1  
L2  
F1 F2  
IND  
S1  
24 VAC  
S2  
GND  
VAL AND TH  
ARE CONNECTED ON THE IGNITION MODULE.  
2. )  
3. )  
PIN AND SOCKET CONNECTOR.  
IF ANY OF THE ORIGINAL WIRES AS SUPPLIED  
WITH THE APPLIANCE MUST BE REPLACED,  
THEY MUST BE REPLACED WITH TYPE 105°C  
OR ITS EQUIVALENT.  
37  
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38  
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39  
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STA-RITE LIMITED WARRANTY  
Pumps, filters, skimmers, underwater lights (except bulbs),  
* Full warranty coverage is in effect for one year after instal-  
lation.The pro-rated warranty covers the tank only during  
the 2nd through 10th year after installation.The amount cov-  
ered decreases by 10% each year.(ie.,2nd year 90% covered,  
3rd year 80% covered, etc.).  
accessories and fittings manufactured by Sta-Rite are war-  
ranted to be free of defects in material and workmanship  
for one (1) year from date of installation.  
Year from date  
Product specific warranties:  
of installation  
The foregoing warranties relate to the original consumer  
purchaser (“Purchaser”) only. Sta-Rite shall have the option  
to repair or replace the defective product, at its sole discre-  
HRPB, DEPB, System 3, and PL – Tanks . . . . . . .10 years  
Internal filter components and valves . . . . . . . . 1 year  
tion. Purchasers must pay all labor and shipping charges  
necessary to replace the product covered by this warranty.  
Requests for warranty service must be made through the  
installing dealer.This warranty shall not apply to any prod-  
uct that has been subject to negligence, misapplication,  
improper installation or maintenance, or other circum-  
stances which are not in Sta-Rite’s direct control.  
Max-E-Therm – Pool/Spa Heaters . . . . . . . . . . . . 2 years  
Heater Enclosure only (Upper RH & LH;  
lower enclosure; and control board enclosure)…10 years  
Automatic Pool Cleaners including Hose . . . . . . 2 years  
Cristal-Flo filters – Tanks . . . . . . . . . . .10 years pro-rated*  
Valve and internal components. . . . . . . . . . . . . . 1 year  
This warranty sets forth Sta-Rite’s sole obligation and  
Purchaser’s exclusive remedy for defective products.  
Posi-Flo II – Tanks . . . . . . . . . . . . . . . . . . . . . . . .10 years  
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year  
STA-RITE SHALL NOT BE LIABLE FORANY CONSEQUENTIAL,  
INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER.  
PRC Cartridge –  
Filter Tanks . . . . . . . . .5 years pro-rated (1st 2 years full)  
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year  
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN  
LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WAR-  
RANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED  
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A  
PARTICULAR PURPOSE,SHALL NOT EXTEND BEYONDTHE  
DURATION OF THE APPLICABLE EXPRESS WARRANTIES  
PROVIDED HEREIN.  
System 3 Above Ground Systems – Tanks . . . . . .10 years  
Pumps / Platform and Internals . . . . . . . . . . . . . 1 year  
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year  
When equipped with A.O. Smith  
2-compartment motors (Does not include  
Some states do not allow the exclusion or limitation of inci-  
dental or consequential damages or limitations on how long  
an implied warranty lasts, so the above limitations or exclu-  
sion may not apply to you.This warranty gives you specific  
legal rights and you may also have other rights which vary  
from state to state.  
pumps sold as part of a systems package) . . . . . 2 years  
Traps / In-Line Strainers . . . . . . . . . . . . . . . . . . . 1 year  
Vertical Commercial Filter – Tanks . . . . . . . . . . .10 years  
Internals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year  
Horizontal Commercial Filter  
Supersedes all previous publications.  
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 years  
(Years 6-9, Prorated declining 20%/year,Yr. 10 - 10%)  
Internals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 year  
Sta-Rite Industries, Inc.,  
293 Wright St., Delavan, WI 53115  
Retain Warranty Certificate (upper portion) in a safe and convenient location for your records.  
DETACH HERE: Fill out bottom portion completely and mail within 10 days of purchase/installation to:  
Sta-Rite, Attn: Warranty Dept., 293 Wright St., Delavan, WI 53115  
Warranty Registration Card  
Name  
Years pool has been in service less than 1 1-3 3-5 5-10  
Purchased from:  
Company name  
Address  
City  
State  
Zip  
Address  
Purchase Date  
Product Purchased  
New installation  
City  
State  
Zip  
Please send me more information on these  
other products from Sta-Rite.  
Replacement  
Type of Pool  
Size of Pool  
Inground  
Vinyl  
Fiberglass  
Gunite  
Pumps Filters Automatic Pool Cleaners  
Maintenance Equipment Test Strips  
Heaters  
S4877PS (Rev. 1/22/01)  
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