CATALOGNO.6100.52-K
Effective: 3-01-00
Replaces: 3-15-99
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models
055B
VERSA
SPA
and
HOT TUB HEATER
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
•
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier'sinstructions.
•
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.
Thismanualshouldbemaintainedinlegibleconditionandkeptadjacenttothe
heater or kept in a safe place for future reference.
®
Part No. 240428
Download from Www.Somanuals.com. All Manuals Search And Download.
PART ONE - OWNER'S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE
INSTRUCTIONS EXACTLY, A FIRE OR EXPLO-
SION MAY RESULT, CAUSING PROPERTY DAM-
AGE, PERSONAL INJURY OR LOSS OF LIFE.
SECTION 1 / START-UP PROCEDURES
BEFORE START-UP
BURNERS
Cleanmainburnersandairlouversofdust, lintand
WATER
First thing, insure that system is filled with water
debris. Keep heater area clear and free from com-
bustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
and have pump operating. Water must be flowing
through the heater during operation.
2
Download from Www.Somanuals.com. All Manuals Search And Download.
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
( MILLIVOLT SYSTEM)
A. This appliance has a pilot that must be lighted by
*If you cannot reach your gas supplier, call the
hand. When lighting the pilot, follow these
fire department.
instructions exactly.
C. Use only your hand to push in or turn the gas
B. BEFORE LIGHTING smell all around the appli-
control knob. Never use tools. If the knob will not
ance area for gas. Be sure to smell next to the
push in or turn by hand, do not try to repair it. Call
floor because some gas is heavier than air and
will settle on the floor.
a qualified service technician. Force or attempted
repair may result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
D. Do not use this appliance if any part has been
underwater. Immediately call a qualified service
*Do not touch any electric switch; do not use any
technician to inspect the appliance and to re-
phone in your building.
place any part of the control system and any gas
control which has been under water.
*Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instruc-
tions.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On/Off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn clock-
wise
to "Off".
NOTE: Knob cannot be turned from "Pilot" to
"Off" unless knob is pushed in slightly. Do not
force.
ROBERTSHAW PILOT
HONEYWELL PILOT
Fig. #8084.0
Fig. #8083.0
6. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to
the next step .
7. Locate pilot mounted on the left side of the
burner drawer. For burner drawer location,
see location of control section, page 18.
8. Turn knob on gas control counter-clockwise
to "Pilot".
9. Push in control knob all the way and hold in.
Immediately place flame to pilot to light.
Continue to hold control knob in for about 1
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
*If knob does not pop up when released, stop
and immediately call your service technician
or gas supplier.
Gas control knobs shown in "Off" position
*If the pilot does not stay lit after several tries,
turn the gas control knob to "Off" and call your
service technician or gas supplier.
10. Stand to the side of the heater and turn the gas
control knob counter clockwise to
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
"On".
HONEYWELL
ROBERTSHAW
GAS VALVE
GAS VALVE
MILLIVOLT
MILLIVOLT
Fig. # 8199
Fig. #8081.0
TO TURN OFF GAS TO APPLIANCE
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
(ELECTRONIC IGNITION SYSTEMS)
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the
gas control knob. Never use tools. If the
knob will not push in or turn by hand, do not try
to repair it; call a qualified service technician.
Force or attempted repair may result in fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to re-
place any part of the control system and any gas
control which has been under water.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
OPERATING INSTRUCTIONS
Gas control knob shown in "ON" position.
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
5. Remove heater door panel.
6. Push in gas control knob slightly and turn clock-
wise
to "Off".
Knob cannot be turned to "Off" unless it is
pushed in slightly. Do not force.
7. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety infor-
mation previously stated. If you don't smell gas,
go to the next step.
Gas control lever shown in the "On" position.
8. Turn gas control knob counterclockwise
to "On".
GAS VALVE-IID
Fig. # 8112
9. Replace heater door panel.
10. Turn on all electrical power to appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance" and
call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat at the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
4. Push in gas control knob slightly and turn
clockwise
to "Off".
5. Replace heater door panel.
3. Remove heater door panel.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
AFTER START-UP
SECTION 2 / CAUTION
Elevated water temperature can be hazardous,
and the U.S. Consumer Product Safety Commission
recommends the following guidelines:
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
WARNING: Should overheating occur or the gas sup-
ply failtoshutoff, turnoffthemanualgascontrol valve
to the appliance.
1. Spa or hot tub water temperatures should never
exceed 104°F (40°C). A temperature of 100°F
(38°C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subse-
quently result in drowning.
3. Pregnant women beware! Soaking in water over
102° F (39°C) can cause fetal damage during
the first three months of pregnancy, (resulting in
the birth of a brain damaged or deformed child).
Pregnant women should stick to the 100°F
(38°C) maximum rule.
VISUAL INSPECTION
With the heater on, remove the door and make a
visual check of the pilot and burner.
The flame should be blue with a well-defined
pattern.
MAX
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err
in regulating water temperatures by as much as
four degrees Fahrenheit (2.2°C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pres
sure problems should obtain a physician's
advice before using pools or hot tubs.
MAIN BURNER FLAME
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihista
mines, or anticoagulants, should not use spas or
hot tubs.
SECTION 3 / MAINTENANCE
AND CARE PROCEDURES
To be followed one month after start-up and then
semi-annually.
PILOT BURNER FLAME
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact your installer or gas
supplier.
1. Inspect top of heater and draft hood for soot, (a
sticky black substance around finned tubes,
baffle and open flue gas passageways).
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to
shutofftheburnersin theeventthatwatersupplytothe
heater is interrupted. It is very important to verify that
the switch electrically opens and shuts off the gas
valve when water flow to the heater is interrupted.
Otherwise, rapidandseveredamagewilllikelyoccurto
the heater. (The water pressure switch should be
checked and adjusted for proper operation by a quali-
fied service person at the time of installation and
periodically checked thereafter. Refer to pressure
switchservicinginstructioninSection4ofthismanual.)
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
2. Clean main burners and pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is
indicated in the previous illustration. Yellow
flame means restriction of the air openings.
Lifting or blowing flame indicates high gas
pressure. Low flame means low gas pressure.
Should this occur, shut the heater off and
contact your gas supplier or qualified service
agency.
POOL & SPA WATER CHEMISTRY
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water pH between 7.4 and 7.8 and total alkalinity
between 100 and 150 p.p.m. If the mineral content and
dissolved solids in the water become too high, scale
forms inside the heat exchanger tubes, reducing
heater efficiency and also damaging the heater. If the
pH drops below 7.2, the heater will be severely dam-
aged. This will result in corrosion of the heat ex-
changer. Heat exchanger damage resulting from
chemical imbalance is not covered by the war-
ranty.
5. On indoor heaters, clean room intake openings
to assure adequate flow of combustion and
ventilation air.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
COLD WEATHER OPERATION
MODERATE CLIMATE: Heater operation can con-
tinue during short term cold spells. When tempera-
tures are below freezing, flow (continuous pump op-
eration) must be maintained.
6. Keep area around heater clear and free from
combustible materials and other flammable and
corrosive vapors and liquids.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze protec-
tion. When heaters are used during freezing weather
care must be taken to avoid freeze ups. Continuous
pump operation is a must. Additional protection may
be required. The heater is not warranted against
freeze ups.
BASIC TIPS IF HEATER WILL NOT FIRE:
1. If you have no electrical power; it may be your
"circuit breakers" have tripped. Try re-setting
them.
2. If you have electrical power but the heater will
not fire
COLD CLIMATE: Prolonged operation with water
temperatures below 50°F is not recommended. When
starting the heater with pool temperatures below 50°F,
operate the heater continuously until higher tempera-
tures are reached. Operating the heater for prolonged
periods with pool water below 50° can seriously dam-
age the heater, and is not covered by the warranty.
check the following:
3. The time clock must be moved to the "ON"
position.
4. Your pump strainer basket may be full. If so
remove debris.
For cold climate areas please follow the winterizing
procedures listed below.
5. Your filter may be dirty. If so, backwash or
clean filter.
WINTERIZING THE SPA HEATER
(To tell if your filter is dirty, the gauge pressure
will be higher than usual).
When heaters installed outdoors in freezing cli-
mate areas are to be shut down for the winter, observe
the following step-by-step procedure:
6. The pump may have lost it's prime. It may be
running dry, check the pressure gauge on the
filter. If there is no pressure; then you are not
moving water (or your gauge is broken). Try to
get the pump to run at it's normal flow rate.
1. Turn off gas valve, manual gas valve, and electri-
cal supply to the heater.
2. Open drain cock located on the return header.
3. Disconnectcompressionfittingsfromthepressure
switch and header that connect to the 1/4"
copper tube and allow the tube to drain.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
PART 2 - INSTALLATION / SERVICE INSTRUCTIONS
SECTION 1 / RECEIVING EQUIPMENT
SECTION 3 / INSTALLATION
INSTRUCTIONS
Onreceiptofyourequipmentitissuggestedthatyou
visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill of
Ladingwhensigningforequipment. Removetheheater
from the carton and if it is damaged, report the damage
to the carrier immediately.
Onoccasion,weshipsomeitemsloose.Besurethat
youreceivethenumberofpackagesindicatedontheBill
of Lading.
When ordering parts, you must specify model and
serialnumberofheater. Whenorderingunderwarranty
conditions, you must also specify date of installation.
Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak pool/spa
heater. If there are any questions that this manual does
not answer, please contact the factory or your local
IMPORTANTNOTICE
These instructions are intended for the use of
qualified personnel only, specifically trained and expe-
rienced in the installation of this type of heating equip-
ment and related system components. Installation and
servicepersonnelmayberequiredbysomestatestobe
licensed. If your state is such, be sure your contractor
bears the appropriate license. Persons not qualified
shall not attempt to fix this equipment nor attempt
repairs according to these instructions.
WARNING: Improper installation, adjustment, altera-
tion, service or maintenance may damage the equip-
ment, create a hazard resulting in asphyxiation, explo-
sion or fire, and will void the warranty.
Raypakrepresentative.
CODE REQUIREMENTS
NOTE: The heater should not be located in an area
where possible water leakage will result in damage to
SECTION2/GENERALSPECIFICATION
Theseheatersaredesigncertifiedandtestedunder the area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard / CSA standards for gas-fired pool
heaters
Theheaterisinterchangeableandcanbeusedeither
indoor or outdoors. The appropriate top designated for
that type of use is required. If desired, the top can be
changedatalaterdatetochangefromoutdoortoindoor
orviceversa. Millivoltheaterscontainaself-generating
electrical system operating between .25 and .75 volts.
Installationmustbeinaccordancewithlocalcodes,
or, in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70. For Canada,
the latest edition of CAN/CGA B-149.1 and B-149.2
AMBIENTTEMPERATURERATINGOFHEATERCOM-
PONENTS
BASE INSTALLATION
Heater must be mounted on a level surface. It can
be installed on combustible flooring. Heaters may not
be installed on carpeting.
MillivoltHeaterwithHoneywellGasValve
+32°F to+175°F
MillivoltHeaterwithRobertshawGasValve
0°F to +175°F
CLEARANCES
Electronic Ignition Heaters*
-32°F to +175°F
*Requires 120V or 240V power supply
WARNING: The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet louvers and into the
heater. This could cause heavy internal rusting or
damagesomeelectricalcomponentsandthiswouldvoid
the warranty.
Ratedinputssuitableforupto2000feetelevation.For
elevations above 2000 feet, reduce input 4% for each
1000 feet above sea level, as high elevation reduces
combustion performance. For Canada, reduce input
10% when installed at 2000-4500 foot elevation.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
ALLHEATERS
For clearances from combustible surfaces, see
chart below.
OUTDOOR HEATERS
These heaters are design certified for outdoor
installation, when equipped with the approved top des-
ignated for outdoor use.
Clearances from Combustible construction.
Indoor Installation:
Heater with
outdoorTop
Top* (Drafthood) - 35"; Vent - 6";
Back - 2"; Right Side - 6";
Left Side - 6"; Floor - 0.
Outdoor Installation:
Top* (Stackless Top) -
unobstructed; Back - 2"; Sides - 6".
* Clearance from Top of Vent Terminal
Fig. # 8139
WARNING: Do not install within 3 feet of a Heat Pump
or an outdoor condensing unit. Strong air intake from
these equipment can disturb the combustion process
and cause damage or personal injury.
For servicing, provide at least 24" in front of the
heater for burner tray removal, and at least 18" on the
left side of the heater to inspect and delime the heat
exchanger.
Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three
(3)sidesmustbeopenintheareaundertheoverhang. Roofwaterdrainagemustbedivertedawayfromtheheaters
installed under overhangs with the use of gutters:
For U.S. installations, the point from where the flue products exit the heater must be a minimum of four (4) feet
below, four (4) feet horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top
surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10)
feethorizontally.
For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 feet
below,ortoeitherside,ofanyopeningintothebuilding. RefertothelatestrevisionofCAN/CGA-B149.1andB149.2.
4
foot
Minimum
4
foot
Minimum
4
foot
Minimum
3
foot
Minimum
1
foot
10 foot
Minimum
Minimum
Forced Air Inlet
Fig # 8245.1
U.S. Installation Only
8
Download from Www.Somanuals.com. All Manuals Search And Download.
HIGHWINDCONDITIONS(OUTDOORUNITSONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 3' from
high vertical walls, or install a wind break so the heater
is not in direct wind current.
VENTING CONNECTIONS
VENT TERMINAL (Outdoor)
STEP 1: Remove the (4) screws which fasten
jacket top to heater.
STEP 2: Lower outdoor top onto unit lining up
slots in outdoor top with screw holes in
jacket top.
INDOOR HEATERS
The design is also certified for indoor installation
when equipped with the approved draft hood. For
Canada, indoor installation is restricted to an enclosure
that is not occupied and does not directly communicate
with occupied area. Refer to the latest edition of CAN/
STEP 3: Reinstall (4) screws to secure jacket top
and outdoor top to unit.
CGA-B149.1
and
B149.2
for
specific
requirements.Locate heater as close as practical to a
chimney or gas vent. Heater must always be vented to
theoutside. SeeVentPipingSectionforventingdetails.
Minimum allowable space is shown on the nameplate.
Outdoor Top
Jacket Top
Heater with
Indoor Top
Fig. # 8138
Fig. # 8137
COMBUSTION AIR (INDOOR UNITS ONLY)
Air For combustion And Ventilation
(Indoor Units Only)
VENT TERMINAL (Indoor)
Locate and assemble as shown. Secure with
screws supplied in envelope inside carton.
The heater must have both combustion and venti-
lation air. Minimum requirements for net free air supply
openings, one 12 inches from ceiling for ventilation and
one 12 inches from the floor for combustion air as
outlinedinthelatesteditionoftheNationalFuelGasCode,
Z223.1(Canada-CAN/CGA-B149.1 and B149.2) and
any local codes that may have jurisdiction.
Draft Hood
Mounting
Screws
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
a. All Air From Inside The Building:
Each opening shall have a minimum of 50 net free
square inches.
b. All Air From Outdoors:
When air is supplied directly from outside of
building, each opening shall have a minimum of 13
net free square inches.
Fig. # 8143
9
Download from Www.Somanuals.com. All Manuals Search And Download.
VENT PIPING
WARNING: Indoor boilers require a draft hood that
must be connected to a vent pipe and properly vented
to the outside. Failure to follow this procedure can
cause fire or fatal carbon monoxide poisoning.
10' OR LESS
2' MIN
VENT CAP
2' MIN
Vent piping the same size or larger than the draft
hoodoutletisrecommended,however,whenthetotalvent
height is at least ten (10) feet (draft hood relief opening
to vent terminal), the vent pipe size may be reduced as
specifiedinChapter10ofthelatesteditionoftheNational
Fuel Gas Code, ANSI Z 223. (Canada-CAN/CGA-
B149.1 and B149.2). As much as possible avoid long
horizontal runs of vent pipe and too many elbows. If
installationrequireshorizontalorornon-verticalruns,the
vent pipe must have a minimum of 1/4 inch per foot rise
andshouldbesupportedatnotlessthanfivefootintervals.
Plumbers tape, criss-crossed, will serve to space both
horizontalandverticalpiping. Gasventssupportedonly
by the flashing and extending above the roof more than
fivefeetshouldbesecurelyguyedorbracedtowithstand
snow and wind loads. We recommend use of insulated
vent pipe spacer through the roofs and walls.
5' MIN
VENT PIPE
DRAFT HOOD
Forprotectionagainstrainorblockagebysnow,the
ventpipemustterminatewithaventcapwhichcomplies
with the local codes or, in the absence of such codes, to
the latest edition of the National Fuel Gas Code, ANSI
Z223.1-1988 (Canada-CAN/CGA-B149.1 and
B149.2).
HEATER
The discharge opening must be a minimum of two
feet vertically from the roof surface and at least two feet
higher than any part of the building within ten feet. Vent
stackshallbeatleastfivefeetinverticalheightabovethe
draft hood outlet. The vent cap location shall have a
minimumclearanceof4feethorizontallyfrom,and inno
caseaboveorbelow,unlessa4-foothorizontaldistance
is maintained, from electric meters, gas meters regula-
tors and relief equipment.
Theweightoftheventstackorchimneymustnotrest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from supported to
maintainproperclearancesfromcombustibleconstruc-
tion.
Type "B" double wall or equivalent vent pipe is
recommended. Howeversinglewallmetalventpipemay
be used as specified in the latest edition of the National
FlueGasCodeANSIZ223.1-1988(Canada-CAN/CGA-
B149.1 and B149.2).
10
Download from Www.Somanuals.com. All Manuals Search And Download.
GAS SUPPLY CONNECTIONS
Gas piping must have a sediment trap ahead
Gas Pr
of the heater gas controls, and a manual shut-off valve
located outside the heater jacket. All gas piping should
be tested after installation in accordance with local
codes.
Manual Shut
Gas
f Valve
Fig. # 8156
Sediment Trap
CAUTION: The heater and its manual shut off valve
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in
excess of 1/2 psig (3.45 KPA). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
at Heater
Fig. # 8149.0s
ROBERTSHAW MV
W.C Adjustment
W.C Adjustment
DAMAGE THE GAS
VALVE. OVER PRES-
SURED GAS VALVES ARE NOT COVERED BY
WARRANTY. The heater and its gas connections
shall be leak tested before placing the appliance in
operation. Use soapy water for leak test. Do NOT
use open flame.
NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant is recommended.
A minimum of 7" W.C. and a maximum of 14" W.C.
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 12"
W. C. and a maximum of 14" for propane gas.
Fig. # 8199
HONEYWELL VALVE MV & IID W. C. Adjustment
W.C Adjustment
PIPE SIZING FOR GAS CONNECTIONS
MAXIMUM EQUIVALENT PIPE LENGTH
Natural Gas 1000 BTU/ FT 3 . 60 Specific Gravity
@ 0.5" WC Pressure Drop
Propane Gas 2500 BTU/ FT 3 l.53 Specific Gravity
@ 0.5" WC Pressure Drop
1/2"
3/4"
MODEL
055B
N
P
N
P
90
200
200
250
GAS PRESSURE REGULATOR
The gas pressure regulator is preset and sealed at
4" W.C. for natural gas, and ll" W. C. for propane gas.
Between the gas valve and the burners is a l/8" pipe
plug. The pressure at this point, taken with a manome-
ter, should be about 3.7" W. C. natural gas and l0.5"
W.C. propane gas. If an adjustment is needed, remove
Fig. # 8081.0
seal and turn adjustment screw clockwise
increase pressure or counter-clockwise
decrease pressure.
to
to
11
Download from Www.Somanuals.com. All Manuals Search And Download.
PLUMBING FOR WATER CONNECTIONS
LOCATION
CAUTION:NeverinstallPVCdirectlyinheaderflanges.
The VERSA heater requires water flow and posi-
The initial connection must be made with a higher
tive pressure to fire and operate properly. It must temperature material such as CPVC or Copper. PVC
therefore be installed downstream of the discharge
side of the filter pump. A typical installation is plumbed
as follows:
may be utilized immediately after the initial connection.
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
1. The inlet side of the filter is plumbed directly
to the discharge side of the filter pump:
2. The outlet side of the filter is then plumbed
to the inlet of the heater; and
3. The outlet of the heater is plumbed to the
return line to the spa. The pump, filter and
heater are thus plumbed in series.
All chemicals must be introduced and completely
dilutedintothepoolorspawaterbeforebeingcirculated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
trations will result when the pump is not running (i.e.
overnight).
Plumbing from the heater back to the spa must not
have any valves or restriction that could prevent flow
when the pump is operating. To do so will void the
warranty.
Chlorinators must feed downstream of the heater
and have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off.
NOTE: High chemical concentration from feeders and
chlorinators that are out of adjustment will cause very
rapid corrosion to the heat exchanger in the heaters.
Such damage is not covered under the warranty.
Heatermustbelocatedsothatanywaterleakswill
not damage the structure of adjacent area. High
temperature plastic pipe (CPVC) may be connected
directly into the heater if local codes permit.
UNITHERM GOVERNOR OPERATION
FLOW RATES
PIPE SIZE: 1 1/4"-1 1/2" MIN.GPM: 20, MAX.GPM: 60*
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain constant
heater internal temperature between 105° - 115°F de-
spite continually changing flow rates from the filter and
changing pool temperatures. This narrow range is
neededtopreventdamagingcondensationontheburn-
ers which will occur if the heater runs for any length of
time below 100°F. It is also needed to inhibit scale
formationinthetubesbymaintainingtemperatureswell
below accelerated scaling temperatures.
*When flow rates exceed 60 GPM an external auxil-
iary bypass valve is required. See External auxiliary
bypass valve section for details.
COMPANION FLANGE CONNECTIONS
The inlet/outlet header flange accepts a 1 1/2"
copper tube or 1 1/4" galvanized pipe as a slip connec-
tion directly into the manifold. The flange is also
threaded for 1 1/2" pipe thread. 1-1/2" CPVC adapters
(when available) can also be used.
DO NOT use petroleum base assembly fluids
(such as Petroleum Jelly or lubricating oil). If assembly
lube is required, use a silicone base compound, such
as Amoral, etc.
Unitherm
Governor
Inlet/Outlet Header
Fig.#8158.1
Outlet
Inlet
8.0
12
Download from Www.Somanuals.com. All Manuals Search And Download.
EXTERNAL AUXILIARY BYPASS VALVE
(Where required)
throughout its entire length and must pitch downward
from the valve. No shut-off valve shall be installed
between the relief valve and the drain line. Valve lever
should be tripped at least once a year to ensure that
waterways are clear.
An auxiliary bypass valve should be used when
flowratesexceed60GPM(usuallyahighperformance
pump size larger than 1 1/2 HP will exceed this flow
rate).Thisvalveisrequiredtocomplementthe function
of the automatic bypass valve, particularly when start-
ing the heater in winter or early spring when the spa or
pool temperature is down below 55°F. It also serves to
eliminate needless pressure drop through the heater
and accompanying reduction in the flow rate to the spa
jets, etcetera.
ELECTRICAL WIRING
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105 °C wire or its
equivalent, except all black wire must be replaced with
150 °C wire or its equivalent.
From Heater
To Heater
MILLIVOLT SYSTEM
The Millivolt System Residential Heater is
equipped with a self-generating electrical system in
which the electric current is provided by means of a
pilot generator. No external electrical connections are
required.
ELECTRONIC INTERMITTENT IGNITION DEVICE
SYSTEM (IID)
To Pool
rom Pool
Auxiliary Bypass Valve (do not use gate valve)
NOTE: When the electrical hookup to the heater
requires both 24V and 115V or 240V, each input
voltage must be isolated in separate conduit.
Fig. # 8150.0s
AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is
madeby feelingtheinletandoutletpipesattheheater.
Outlet pipes should be slightly warmer than inlet and
comfortable to the touch. If pipe is hot, close bypass; if
cold, open bypass
The Electronic Intermittent Ignition Device auto-
matically lights the pilot and main burners upon a call
for the heat. The heater is supplied with a dual voltage
transformer for 120V or 240V input power hookup.
NOTE: IID Propane Units Only
PRESSURE RELIEF VALVE INSTALLATION
To conform to local building codes, it may be
necessary to install a pressure relief valve. A 3/4"
pressure relief valve having a capacity equal to BTU/
HR output of the model to be installed is recommended
for this appliance.
Heater is equipped with an electronic ignition device
with a 100% safety lockout feature. If the heater fails
to start or lockout. Reset the ignition device by inter-
rupting the power to the heater for 60 seconds.
CAUTION: If service replacement of the electronic
ignition device is required. Replace only with a 100%
safety lockout device with 90 second trial for pilot
ignition.
Drain Pipe
Drain Pipe
Heater Outlet
Heater Outlet
Fig. # 8157.0s
Robertshaw Intermittent
NOTE: To avoid water damage or scalding due to valve
operation, drain pipe must be connected to valve outlet
and run to a safe place of discharge. Drain pipe must be
the same size as the valve discharge connection
Ignition Device
Fig. # 8085
Honeywell Intermittent
Ignition Device
Fig. # 8929.1
13
Download from Www.Somanuals.com. All Manuals Search And Download.
For 120 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the
white wire to the “L2” or neutral leg of the power supply.
Attach the wire nut to the red wire. There should be no
WIRING DIAGRAM KEY
PINK CONNECTOR BLUE CONNECTOR
connection to the red wire for 120V operation.
Fig. #9240
For 240 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the red
wire to the “L2” or second hot leg of the power supply.
Attach the wire nut to the white wire. There should be no
connection to the white wire for 240V operation.
Fig. # 8096
S86
S8600
Fig. # 9241
Heater must be electrically grounded and bonded in
accordance with local codes, or, in the absence of local
codes,withthelatesteditionoftheNationalElectricalcode,
ANSI/NFPA 70 (Canada-Canadian Electrical Code, CSA
C221.1, Part 1 and 2).
NOTE: Input power to the heater (120/240V) should be
suppliedfromtheload(Pump)sideoftimeclockorswitch.
Connecting heater to continuous power source will allow
"Fail"indications(serviceandpressureswitch)whenpump
is not operating.
Fig. # S86/S8600
14
Download from Www.Somanuals.com. All Manuals Search And Download.
WIRING DIAGRAM MILLIVOLT UNITS
WITH MECHANICAL THERMOSTAT
Fig. # 1934e
WIRING DIAGRAM MILLIVOLT UNITS
WITH SOLID STATE THERMOSTAT
Fig. # 2246e
15
Download from Www.Somanuals.com. All Manuals Search And Download.
WIRING DIAGRAM 152178 Model 055 IID
BL
BL
BL
16
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 4 / SERVICING INSTRUCTIONS
GENERAL LOCATION OF CONTROLS
Drain Valve
HIGH LIMITS
(Located in the
Inlet/Outlet header)
Pressure Switch
Burner & Pilot
Thermal Fuse
Solid State Thermostat &
Ignition Control
Gas Valve
Fig. # 8160.1s
CONTROLS/ADJUSTMENTS/REPLACEMENTS
al
CAUTION: Label all wires prior to disconnection when
ortable
erature
e
servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after Typical
servicing. Comforta
Spa
DANGER - SHOCK HAZARD -make sure electrical Temperat
power to the heater is disconnected to avoid potential Range
serious injury of damage to components.
Knobstop Ring
Set Screw
TEMPERATURE CONTROLS
The water temperature is controlled by the heater
thermostat on the upper front panel of the heater. The PRESSURE SWITCH
control center contains an On/Off toggle switch and a
thermostat. Theswitchfunctionsasameansforturning that the heater operates only when the filter pump is in
the heater on or off. operation. It is factory set at 1.75 PSI for deck level
The pressure switch, or heater actuator, insures
The thermostat is fitted with a means of limiting the installations. Whentheheaterislocatedbelowthelevel
upper temperature limit below the maximum level. The of the spa or pool, it may be necessary to reset the
knob stop adjustment ring illustrated below is adjust- pressure switch to compensate for the no-flow static
able by loosening the set screw, rotating the knobstop head. If it is necessary to reset the pressure switch, we
ring to the desired location and retightening the set recommend that following procedure:
screw.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
PRESSURE SWITCH ADJUSTMENT:
FLAME ROLL-OUT SAFETY SWITCH
1. With pump and heater on, turn adjustment
The heater is equipped with a thermal cutoff device
knob (clockwise) until a click is heard from the topreventflameroll-outintheeventtheheatexchanger
gas valve. becomes blocked. This is a "Single-use" type fusible
2. Turn adjustment knob (counter clockwise) 1/4 link or thermal fuse, that must be replaced when dis-
turn.
abled by an over temperature condition, caused by
excessive restriction in the heat exchanger flue pas-
sage.
3. Turn pump off and on several times. Heater
should shut off immediately. If it does not,
repeat steps above until proper adjustment is
made.
Fig. #9177
HIGH LIMITS
The heater is equipped with two automatic high
limits. Set to operate at 135°F and 140°F.
NOTE: An erratic high limit is often characteristic of
internal heat exchanger problem, i.e. scale buildup,
U.G. operation. Refer to troubleshooting section.
Adjustment Knob
Fig. # 8069.1
5' Max.
Fig. # 8159.0s
5' Max.
HIGH LIMIT REMOVAL
1. Disconnect top portion of unit. (See heat ex-
change removal procedure step 1 thru 7 and
step 10)
2. Remove defective high limit and replace with
new high limit.
3. Reverse above procedure to reinstall.
NOTE: If heater is installed outside of the limits shown,
a flow switch must be used in place of the pressure
switch when mounted and wired adjacent to the heater.
PILOT SAFETY (Millivolt System)
TWO SPEED PUMPS
The heaters equipped with the standing pilot (milli-
voltsystem), havepilotgeneratorswhichactasasafety
devicetoshutofftheflowofgastothemainburnersand
the pilot burner in case the pilot flame is extinguished.
The pilot burner must be manually relighted to place the
heater in operation again. Refer to the lighting instruc-
tions provided on the heater label.
In some cases, the flow on the low-speed is insuf-
ficient to operate the heater. This is apparent when the
pressure switch cannot be further adjusted or if the
heater makes banging noises. In these cases, the
pump must be run at high speed when heating the
water.
CAUTION: Do not operate the heater without the func-
tion of a properly adjusted pressure switch.
PILOT SAFETY (IID Units) ELECTRIC IGNITION
The heater employs a pilot safety which closes the
maingasvalvewithin8/10thsofasecondwheneverthe
pilot flame is interrupted. Pilot flame is automatically lit
when the device is powered. Unit performs its own
safety check and opens the main valve only after the
pilot is proven to be lit.
18
Download from Www.Somanuals.com. All Manuals Search And Download.
BURNER DRAWER REMOVAL
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit.
6. Disconnect wires that terminate at gas valve, and
thermal fuse.
Pilot
Pilot
Air
7. Slide out burner tray.
8. Reverse above procedure to reinstall.
Opening
GAS VALVE REMOVAL
1. Remove burner tray. (See burner tray removal
procedure).
2. Disconnect pilot tubing from gas valve.
3. Remove gas valve with manifold from burner tray.
4. Remove manifold from gas valve.
5. Reverse above procedure to re-install.
Orifice
Orifice
Fig. # 8102.0s
MAIN BURNER AND ORIFICE REMOVAL
1. Remove burner drawer. (See burner drawer re-
moval procedure).
HONEYWELL PILOT
ROBERTSHAW PILOT
2. Remove screws and burner hold down bracket.
HEAT EXCHANGER REMOVAL
1. Shutwater,gas,andelectricityoff,closevalvesand
relieve pressure.
NOTE: If the heat exchanger is sooted badly, the
burner hold down bracket and spacer can become
distorted from direct flame impingement and this usu-
ally necessitates replacement of these parts.
2. Drain heat exchanger.
3. Loosen and remove flange bolts.
4. Remove flange and inlet/outlet pipes from the
header. Remove drain valve from rear header
5. Remove outdoor stackless top or indoor stack top
from unit.
6. Remove jacket top, flue collector, and baffle.
7. Remove upper front jacket panel, and disconnect
wires at toggle switch.
3. Lift burners from slotted spacers and slide from
orifices. Clean with a wire brush.
4. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood toothpick
through orifice. Do not enlarge hole. To remove
orifice, use a socket wrench and remove from
manifold. DO NOT overtighten when reinstalling.
8. Remove capillary bulb from inlet/outlet header.
9. Disconnect press switch tube from inlet/outlet
header.
10. Disconnect hi-limit wire from thermostat, and pres-
sure switch.
11. Lift heat exchanger straight up from combustion
chamber, using caution not to damage refractory.
12. Reverse above procedure to re-install.
PILOT REMOVAL AND CLEANING
1. Remove burner drawer. (See burner drawer re-
moval procedure).
2. Disconnect pilot tubing, disconnect wires from gas
valve.
3. Disconnect pilot bracket from burner shield.
4. Remove pilot from bracket.
5. Remove pilot orifice and air opening (Honeywell
MV unit only), and clean with wire or small brush.
CAUTION! DO NOT enlarge hole in pilot orifice.
6. Reverse above procedure to re-install.
19
Download from Www.Somanuals.com. All Manuals Search And Download.
DESOOTING PROCEDURE
CONTROL IMMERSION WELL REPLACE
1. Remove plumbing and top portion of unit (See
heat exchange removal procedure steps 1
through 6).
CAUTION: SOOT IS COMBUSTIBLE. EXERCISE
EXTREME CARE. NEVER USE A WIRE BRUSH.
2. Remove U.G. spring, U.G. and copper shield.
3. Collapse well tube at open end with chisel.
4. Push well up through header.
5. Insert new well and roll in place. If a roller is not
available, solder the well in place with silver solder.
Soot can clog areas between fins and cause even-
tual tube failure. Any sign of soot at the base of the
burners or around the outer jacket indicates a need for
cleaning.
1. Disconnect top portion of unit. (See heat ex-
changer
removal procedure steps 1 through 6).
2. Remove burner tray (See burner tray removal
procedure.)
3. Take a garden hose and wash heat exchanger,
making sure soot is removed completely from be-
tween fins. Avoid excessive water against refrac-
tory.
Immersion Well
Fig . # 8126.0s
NOTE: In extreme cases it may be necessary to re-
move the heat exchanger completely for cleaning. The
simplest method is steam cleaning at the local car
wash. DO NOT WIRE BRUSH.
UNITHERM GOVERNOR (U.G.) REPLACEMENT
1. Shut water, gas and electricity off, close valves and
relieve pressure.
2. Drain heat exchanger.
3. Disconnect inlet & outlet pipes with flange from in/
out header.
COMBUSTION CHAMBER REMOVAL
1. Remove heat exchanger (See heat exchanger
removal procedure).
4. Grasp retainer spring from inlet side of header, and
slide thru inlet hole.
2. Lift up and remove front and rear refractory shield.
3. Remove refractory panels.
5. Remove shield.
4. Reverse above procedure to re-install.
6. Remove U.G. with seating gasket, and stainless
steel baffle (not shown).
7. Reverse above procedure to re-install.
U.G.
U.G.
Fig . # 8155.0s
ainer
ing
Shie
Refactory Panel Top View
Outlet
Inlet
Inlet/Outlet
Header
Fig . # 8158.1
To test the operation of the Unitherm Governor,
placeinhotwater(over110°F)andwatchformovement
against spring. If there is no movement, replace unit.
20
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 5 / TROUBLE SHOOTING GUIDE
IMPORTANT NOTICE
These instructions are primarily intended for the use of qualified personnel specifically trained and experienced
in the installation of this type of heating equipment and related system components. Installation and service
personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this
equipment nor attempt repairs according to these instructions.
MECHANICAL (FOR QUALIFIED SERVICE PERSONNEL ONLY)
PROBLEM
CAUSE
SOLUTION
Harmonics, or whining noise.
U.G. inoperative..........................
Check movement by putting in hot water (110°F
or higher). If no movement, replace.
*Debris or restriction in system........ Locate the restriction and remove. Flush system
and clean.
*Debris in gas line......................... Remove debris or blow out gas line.
Low flow....................................
Scale forming in heat exchanger - clean heat
exchanger and check pool pH and total alkalinity.
Heater going on and off
continously.
Dirty filter..................................
Low water level in pool.................. Raise water level.
External bypass setting out of
Backwash filter.
adjustment................................
*Pressure switch out of
Adjust bypass
adjustment................................
Adjust pressure switch
Liming or scale forming on
7.8 heat exchanger.
Pool water.................................
High flow rates...........................
U.G. Inoperative.........................
Recommended pH should be between 7.4 and
7/8 total alkalinity 100-150 PPM maximum. Hard-
ness 150-400 PPM maximum.
Sooting
Reduce by adding manual bypass valve and
adjust by putting thermometer in header (1/4"
NPT) drain opening. Set bypass so thermometer
reads between 105° and 110°F.
Check movement by putting in hot water (110°F
or higher). If no movement, replace.
*Air starvation..............................
*Improper venting.........................
*Insects or debris clogging
Refer to installation instructions.
Follow recommended installation instructions.
burner intake ports......................
Clean burners.
Pilot outage.
Low gas pressure........................ Adjust gas pressure.
Restricted pilot........................... Clean pilot.
Weak pilot generator.................... Replace pilot.
Yellow lazy flame
Low gas pressure........................ Adjust gas pressure.
*Insects or debris clogging
burner intake ports......................
Clean burners.
Outer jacket very hot
(paint blistered)
*Broken refractory caused by
shipping damage or improper
combustion................................
Excessive sooting of heat
Replace refractory panels.
exchanger.................................
Determine cause of sooting & correct.
Takes long time to heat
pool or spa.
Calculate temperature in °/hr......... Heat rise (°/hr.)= Heater Output
Pool gallonage x 8.33
or refer to heater sizing chart.
This does not take into account heat loss due
to weather.
Filter not running long enough........ Reset time clock.
Dirty filter...................................
Clean filter.
Gas line or meter undersized......... Refer to installation instructions.
(* Usually occurs on initial start-up.)
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Liming
Bypassing too much water............ Inspect bypass for movement, if no movement,
replace.
U.G. not functioning...................... Replace if no movement when heated.
Leaking at well.
Overacid..................................
Overacid..................................
Replace well and maintain water chemistry
properly.
Replace heat exchanger and maintain
chemistry properly.
Leaking at heat exchanger.
Gasket brittle and leaking -
(overheated).
Heater running after pump
shuts off...................................
Refractory damage.....................
Sooted heater............................
See pressure switch adjustment.
Replace refractory.
Determine cause of sooting and correct.
ELECTRICAL ( MILLIVOLT)
RAYPAK POOL OR SPA HEATER ELECTRICAL
CHECK WITH MV GAS VALVE
CAUTION: For qualified service personnel only.
1. Filter must be on with adequate water flow through heater.
2. Gas valve must be "ON" position. Thermostat set higher
than pool water temperature.
3. Jumpers are for temporary check only. If left in place,
they could cause the heater to burn up.
Light pilot
If pilot burner
does not light
If pilot burner goes out
when main burner lights
or when gas valve knob
is released
If pilot burner remains lit.
Jump across both "TH"
wires on gas valves
Check gas supply, gas
line size, gas pressure.
Also check for insects
or debris in pilot output.
Remove both "TH"
wires from gas valve.
Relight pilot
Replace
gas
valve
If main burner fires,
remove jumper
If main burner does not
fire, remove jumper
Jump across pressure
switch terminals
If burner does not remain
lit, attach millivolt meter
and read pilot output.
If pilot burner stays on
If main burner fires,
remove jumper
If main burner does not
fire, remove jumper
Problem is a wire or
component short to
cabinet or low gas
pressure
Ifabove500mV,
replacegasvalve
Clean filter
Jump across thermostat
Check for adequate water
flow from filter
If below 500mV, check
gas pressure. Also check
for insects or debris in
the pilot burner
Replace pressure switch
If output is still low,
replace pilot generator.
If main burner fires,
remove jumper
If main burner does
NOT fire...
Jump across each high
limit and remove jumper
Replace thermostat
Replace high limit that
caused heater to fire
22
Download from Www.Somanuals.com. All Manuals Search And Download.
ELECTRICAL (SOLID STATE THERMOSTAT MILLIVOLT)
If the pool/spa/hot tub water is too cold, troubleshoot the system as follows:
Check voltage at + and - terminals.
VOLTAGE BETWEEN + 0.2 V and 0.75 V.
(Polarity is critical)
VOLTAGE OUTSIDE RANGE + 0.2 V and 0.75 V.
Check pilot generator, correct as necessary.
Set control to max. temperature. After 2-3
cycles, check water temperature.
TEMPERATURE BELOW 105°F
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.
TEMPERATURE 105-108° F.
Control ok.
NOTE: 108°F is the upper control limit.
RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected
sensor resistance from chart below.
RESISTANCE O OHMS (SHORT CIRCUIT) OR
OPEN CIRCUIT GREATER THAN 14 K.
Check system for shorted wires or open circuits.
Replace sensor if necessary.
MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance is:
0-100 ohms at minimum setting:
9k to 11k at maximum setting,
replace circuit board.
MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Replace sensor. Reconnect all leads and check
out system.
Above 11k ohms, replace
potentiometer.
0 ohms (short circuit), replace
potentiometer.
Reconnect all leads and check out system.
If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:
Check voltage at + and - terminals
VOLTAGE BETWEEN + 0.2 V and 0.75 V.
(Polarity is critical)
VOLTAGE OUTSIDE RANGE + 0.2 V and 0.75 V.
Check pilot generator, correct as necessary.
Set control to max. temperature. After 2-3
cycles, check water temperature.
TEMPERATURE ABOVE 108°F
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.
TEMPERATURE 105-108° F.
Control ok.
NOTE: 108°F is the upper control limit.
RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected sen-
sor resistance from chart below.
RESISTANCE ABOVE 15k OHMS (OPEN
CIRCUIT) OR SHORT CIRCUIT.
Fix loose or broken wires. Replace sensor if
necessary.
MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance is:
0-100 ohms at minimum setting;
9k to 11k at maximum setting,
replace circuit board.
MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Replace sensor. Reconnect all leads and check
out system.
Above 11k ohms, replace
potentiometer.
0 ohms (short circuit), replace
potentiometer.
SENSOR RESISTANCE AT VARIOUS TEMPERATURES
Temperature
(deg. F)
61
68
70
77
86
88
95
104
106
Resistance (k ohms)
14.92
12.49 11.88
10.00 8.06
7.69
6.53
5.33
5.10
23
Download from Www.Somanuals.com. All Manuals Search And Download.
WARNING
HIGH VOLTAGE
ELECTRICAL (ELECTRONIC IGNITION IID)
For qualified Technicians ONLY
NOTE: Some heaters may be equipped with
an ignition module that shuts off pilot gas if
pilot fails to light. To reset, interrupt power to
heater.
Intermittent Pilot System
TROUBLESHOOTING HONEYWELL S8600
START
TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT
POWER TO MODULE
(24 V NOMINAL)
YES
NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.
NO
NO
Pull ignition lead and check spark at module.
SPARK ACROSS
IGNITER/SENSOR GAP
YES
Spark Okay?
YES
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
• Check that all manual gas valves are open, supply tubing and pressures are good,
and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.
NO
NO
NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G. models.
SPARK STOPS WHEN
PILOT IS LIT?
YES
• Check continuity of ignition cable and ground wire.
• Clean flame rod.
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
• If problem persists, replace module.
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.
• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.
NO
NO
MAIN BURNER LIGHTS?
YES
NOTE: IF S8600H goes into lockout, reset system.
• Check continuity of ignition cable and ground wire.
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
CALL FOR HEAT ENDS
SYSTEM SHUTS OFF?
YES
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
NO
TROUBLESHOOTING
ENDS
Repeat procedure until trouble free operation is obtained.
24
Download from Www.Somanuals.com. All Manuals Search And Download.
ELECTRICAL (SOLID STATE THERMOSTAT IID)
If the pool/spa/hot tub water is too cold, troubleshoot the system as follows:
Check voltage at 24 V terminals.
VOLTAGE BETWEEN 21.5-28.5 V.
Set control to max. temperature. After 2-3
cycles, check water temperature.
VOLTAGE OUTSIDE RANGE 21.5-28.5 V.
Check transformer, 120 V supply, correct as
necessary
TEMPERATURE BELOW 105°F
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.
TEMPERATURE 105-106° F.
Control ok.
RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected sensor
resistance from chart below.
RESISTANCE O OHMS (SHORT CIRCUIT)
Check system for shorted wires or open circuits.
Replace sensor if necessary.
MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance is:
0-100 ohms at minimum setting;
Replace sensor. Reconnect all leads and check
out system.
9k to 11k at maximum setting,
replace circuit board.
Above 11k ohms but less than
15 k ohms, replace potentiometer.
Above 15k ohms, fix loose or broken wires;
replace potentiometer if necessary.
Reconnect all leads and check out system.
If the pool/spa/hot tub water is too hot, troubleshoot the system as follows:
Check voltage at 24 V terminals.
VOLTAGE BETWEEN 21.5-28.5 V.
Set control to max. temperature. After 2-3
cycles, check water temperature.
VOLTAGE OUTSIDE RANGE 21.5-28.5 V.
Check transformer, 120 V supply, correct as
necessary.
TEMPERATURE ABOVE 108°F
Disconnect sensor leads from circuit board.
Measure sensor resistance with ohmmeter.
TEMPERATURE 105-106° F.
Control ok.
RESISTANCE 1-14k OHMS.
Check water temperature; estimate expected
sensor resistance from chart below.
RESISTANCE ABOVE 15k OHMS (OPEN
CIRCUIT) OR SHORT CIRCUIT.
Fix loose or broken wires. Replace sensor if
necessary.
MEASURED AND ESTIMATED RESISTANCE
MATCH WITHIN 20 PERCENT.
Disconnect potentiometer leads from circuit board.
Measure resistance with ohmmeter. If resistance
is:
MEASURED AND ESTIMATED RESISTANCE
DON'T MATCH.
Replace sensor. Reconnect all leads and check
out system.
0-100 ohms at minimum setting:
9k to 11k at maximum setting,
replace circuit board.
Above 11k ohms, replace
potentiometer.
0 ohms (short circuit), replace
potentiometer.
Reconnect all leads and check out system.
SENSOR RESISTANCE AT VARIOUS TEMPERATURES
Temperature
(deg. F)
61
68
70
77
86
88
95
104
106
Resistance (k ohms)
14.92
12.49 11.88
10.00 8.06
7.69
6.53
5.33
5.10
25
Download from Www.Somanuals.com. All Manuals Search And Download.
If determined defective by the Company and within
warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
SECTION 6/REPLACEMENT PARTS LIST
NOTE: To supply the correct part it is important that
you state the model number, serial number and type of
gas when applicable.
RAYPAK,INC
31111 AGOURA ROAD
WESTLAKE VILLAGE, CA 91361-4699
Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heater serial number, model number, etc., and shipped
to the Company Freight Prepaid.
For Canada:
RAYPAKCANADALTD.
2805 SLOUGH STREET
MISSISSAUGA,ONTARIO
L4T 1G2
26
Download from Www.Somanuals.com. All Manuals Search And Download.
1-S
2-V
2-S
1-V
7-C
3-H
2-H
8-H
1-C
2-C
4-S
7-H
13-H
12-H
10-H
4-H
6-H
5-H
11-H
1-R
5-M
7-M
4-M
6-C
3-M
6-S
3-S
3-C
1-B
6-M
5-C
2-M
1-M
5-S
4-C
1-G
2-B
11-P
3-B
9-M
MV
9-P
IID
3-P
7-P
14-P
14-P
Fig. #8133.0
Fig. #8132.0
27
Download from Www.Somanuals.com. All Manuals Search And Download.
28
Download from Www.Somanuals.com. All Manuals Search And Download.
29
Download from Www.Somanuals.com. All Manuals Search And Download.
LIMITED WARRANTY
RAYPAK RESIDENTIAL SWIMMING POOL & SPA HEATERS
GENERAL
Raypak,Inc.warrantsthatallpartsofthisproduct willbefreefromdefectsinmaterialsandworkmanshipundernormaluseandservice
for a period of TWO YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR A SINGLE FAMILY RESIDENCE (ONE YEAR
IFOTHERTHANFORSINGLEFAMILYRESIDENCEUSE). Inaccordancewiththetermsofthiswarranty,wewillfurnishaRaypak
replacementforanydefectivepartorrepairthepartatouroption. Thereplacementorrepairwillbewarrantedforonlytheunexpired
portion of the original warranty. Labor costs for removal or reinstallation of parts are not covered by this warranty, nor areshipping
charges to or from Raypak's designated repair center. This warranty does not cover rusting or corrosion on cabinet or burnersthat
does not affect heater's operation.
WARRANTYCONDITIONS
Thiswarrantyappliesonlytotheheateratitsoriginalplaceofinstallation. Thiswarrantywillbevoidiftheheaterisinstalledinviolation
of applicable local codes and ordinances or if the rating plate or serial number is altered or removed.
WARRANTYEXCLUSION
This warranty does not cover defects or malfunctions resulting from:
1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions;
2. Abuse, alteration, accident, fire, flood, freeze and the like:
3. Misuse or neglect, including but not limited to, freeze-ups, operating the heater with the cabinet door off, having flow
restrictions or obstructions between the heater outlet and the spa, or not maintaining a proper chemical balance
(PH level must be between 7.4 and 7.8 and total alkalinity between 100 and 150 PPM. Total dissolved solids (TDS)
must be no greater than 3000 PPM);
4. Use of non-factory authorized accessories or other components in conjunction with the heater.
HOW TO MAKE A CLAIM
Immediatelynotifythedealerfromwhomtheheaterwaspurchased,supplyingmodelandserialnumbersoftheunit,dateofpurchase,
and a description of the problem. The dealer should then promptly contact Raypak about the warranty claim, and for the location of
Raypak'snearestdesignatedrepaircenter. (Ifthedealerforanyreasonisnotavailable, callorwriteRaypakdirectlyattheaddress
shown below, Attention: Warranty Service). After such notification has been given and Raypak has advised the location of its
designatedrepaircenter(whichmaybethedealer),bringorship,transportationprepaid,thedefectivepartforreplacementorrepair
to the designated repair center. However, Raypak reserves the right at all times to inspect the claimed defect and verify warranty
coverage at its factory.
MISCELLANEOUS
Nooneisauthorizedtomakeanyotherwarrantiesonourbehalf,ANYIMPLIEDWARRANTIES,INCLUDINGMERCHANTABILITYOR
FITNESSFORAPARTICULARPURPOSE,SHALLNOTEXTENDBEYONDTHEAPPLICABLEWARRANTYPERIODSSPECI-
FIEDABOVE. RAYPAK'SSOLELIABILITYWITHRESPECTTOANYDEFECTSHALLBEASSETFORTHINTHISWARRANTY
ANDANYCLAIMSFORINCIDENTALORCONSEQUENTIALDAMAGES(INCLUDINGDAMAGEFROMWATERLEAKAGE)ARE
EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
We suggest you immediately complete the information below and retain this Warranty Certificate in the event warranty service is
needed. Reasonableproofoftheeffectivedateofthewarrantymustbepresented;otherwise, theeffectivedatewillbebasedupon
the date of manufacture plus THIRTY (30) Days.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
________________________________________________
Name of Owner
________________________________________________
Name of Dealer
________________________________________________
Address
________________________________________________
Address
________________________________________________
ModelNo.
________________________________________________
SerialNo.
DateofPurchase____________________________________________________________________________________
RAYPAK, INC., 31111 Agoura Road, Westlake Village, CA 91361 (818) 889-1500 FAX (818) 889-4522 Litho in U.S.A.
RAYPAK CANADA LTD., 2805 Slough Street, Mississauga, Ontario L4T 1G2 (905) 677-7999 FAX (905) 677-8036
Download from Www.Somanuals.com. All Manuals Search And Download.
Raypak,Inc.,31111AgouraRoad,WestlakeVillage,CA91361-4699(818)889-1500FAX(818)889-4522
Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036
RaypakAustraliaPty. Ltd, 7GeddesSt., Mulgrave, Victoria, Australia3170(6139)5604944FAX(6139)5604974
LithoinU.S.A.
Download from Www.Somanuals.com. All Manuals Search And Download.
|