S430/Kaowool Insulation
Contents
1. handling 150 Lbs Safety Precautions A WARNING Risk of electrical shock fire or explosion Disconnect all power to the heater and close the external manual gas valve at start of this procedure Check for gas leaks with a soapy water solution after reassembly A WARNING Risk of carbon monoxide poisoning from indoor units if exhaust vent joints are not sealed Check all vent joints for leakage after reassembly A WARNING Heavy parts can cause personal injury When lifting use all proper precautions for the weights involved A CAUTION Uncured RTV sealants can cause eye irrita tion Follow manufacturer s instructions when using RTV sealants Location The Insulation is located inside the Combustion Chamber Function The insulation increases the thermal efficiency of the heater and prevents overheating of parts outside the com bustion chamber Servicing Procedure See Figure 1 A WARNING Heavy parts can cause personal injury When lifting use all proper precautions for the weights involved Combination Gas Control Valve OFF Turn Clockwise and press down to turn off gas Drain Inlet Outlet N N Manifold a KK vA Ta eN cr Drain Cock s and Plugs OPEN Close Isolation Valves Figure 1 Isolate and Drain Heater Disconnect Power 1 Turn off the filter pump and all electrical power to the heater Close the external Manual Gas Val2. 00 Short Bolt Placement Hand tighten all long bolts then tighten indicated bolts enough to allow short bolts to engage e Install O rings on tube ends install manifold e SR SRC200 and SR SRC400 Tighten all long bolts HAND TIGHT then tighten the bolts next to the short bolts a little more with a wrench e Insert and start the two short bolts until they engage three or four threads then tighten all bolts according to the normal torque pattern shown on Page 5 e SR SRC333 These models use long bolts only Tighten all bolts HAND TIGHT then tighten according to the normal torque pattern shown on Page 5 Figure 6 Install bolts as shown 29 Tighten the bolts to the torque spec as shown in Figure 7 33 Reinstall the Combustion Chamber top and fasten with Figure 7 Torque Specs 30 Turn on the water and check for leaks between the Manifold Adapter and the Tube Sheet 31 a the coil so that an equal number of heater coil fins nuts on studs from Combustion Chamber body Torque Pattern All Models 34 Reinstall the Combustion Chamber in the Lower Enclosure and fasten with hold down nuts 35 Reinstall the Flameholder and Flameholder Cone if used and then the Combustion Air Blower the Igniter the Combination Gas Valve and associated piping and the Blower Adapter Plate as a unit use new gaskets Be sure to reinstall the Insulation Cap on the bottom of the Flameholder Tighten Adapter Plate nuts to 70 80 in lbs
3. P and Spa On Keys Disabled E Y O OFF Key on Membrane BK w Pad Remains Functional 120VAC IGNITER BLOWER 0 0 YW 120VAC GND BK G ES 0 W Ww amp mua WW GND 2 GROUND GND gt E 120VAC HOT gt BK If cable from Membrane Pad NEUTRAL NEU Ee gt w is a 6 Conductor Cable connect ad en NOTICE If while there is 120VAC connected to the heater you touch EE TER EET j either 120VAC terminal with any 24VAC wire that is connected to the Fireman s Switch field installed L control board including the Fireman s Switch jumper you will immediately destroy the control board and void the warranty 3661 0200 REPAIR PARTS LIST Key Part Part No Description Qty No Flameholder Insulation Cap 1 42001 0075 1 2 Blanket 1 42001 0071 1 Top Insulation 42001 0070 Condensate Evaporator 42001 0065 1 M Insulation 42001 0072 1 2 Blanket 42001 0073 Model SR SRC200 heaters built before 1 1 98 use 2 of Part No 42001 0073
4. STA RITE Heater Insulation Kit K Z FO Ka 7 5 Lo t RS 2 N ST NS lt gt 2 gt Y Sm _7 47 A VS SS DE t Sa z ol Ke ee 0 ZE A Y K NN EE ee ee Ee d N A t 3 S beleeft w Ww gt ze 1 gt Al VOS Ere Y el d TS ze CA A Wes gt i A A 8 E 2 lo SR Ss A NDA low 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 www sta ritepool com Union City TN e Delavan WI e Mississauga Ont Murrieta CA 2003 Sta Rite Industries Inc Printed in U S A 5430 Rev 2 14 03 1 2 Insulation gt Blanket ES 1 Insulation lt Flameholder Insulation Cap Condensate Evaporator 1 Insulation A 1 2 Insulation a Blanket Tools Parts Required Flat Screwdriver Phillips Screwdriver 1 4 and 3 8 Socket Sets with Extenders Sockets needed 1 4 5 16 11 32 7 16 1 2 9 16 7 8 Rubber Mallet Torque Wrench calibrated in Inch Lbs High Temperature RTV 600 F Cont 700 F Intermittent Flame Holder Adapter Plate Gaskets 2 Part No 42001 0065 14 amp 12 Pipe Wrenchs 1 Each or 2 Channel Lock Pliers Optional Lifting Gear capable of
5. cause cancer May also cause temporary eye skin or respiratory tract irritation Avoid breathing fiber particulates and dust Wear a NIOSH MSHA approved respirator loose long sleeved clothing eye protection and gloves when working with or around insulation Wash work clothes separately Rinse washing machine after use For first aid Eyes Flush with water Skin Wash with soap and water If swallowed Do not induce vomiting Get medical attention if gastrointestinal symptoms develop If inhaled Get to fresh clean air If any of the irritations above persist seek medical attention immediately For additional product information or for a Material Safety Data Sheet MSDS call 1 800 752 0183 CONNECTION DIAGRAM Y R Y BL Y O Gas Valve Hi Limit Switch YW F Pressure Switch AGS Switch Air Flow Switch Stack Flue Sensor Extra Switch 1 lt Y eo Pa Dal y EA Ir T 0 0 o foe PR BR PR BR A LL a 100660 6 eo Ya de rs e 5 gt 5 TS 5 Ya E 5 J6 m S 2 1 w Quo AFSY OPERATING CONTROL a MEMBRANE PAD 9 CONNECTION SFSYA Es GAS 3 VERSION 1 PAD 1 CONTROL CENTER SPACONTROL External Control Interface Circuit eee Disabled Heater Membrane Pad O e Enabled Pool Line External Control Interface BK Y DIAGNOSTIC INDICATOR IGNITION CONTROL MODULE Y Y 24VAC SEC FC1 SU External Control Interface WOOO Y Circuit Enabled Pool On 4 H E
6. et and O Ring sealing surfaces see Figure 4 27 Reinstall the Heat Exchanger Coil on the Insulation Pull the Heat Exchanger Coil and the Bottom Insulation forward together to align with the mounting plate see Figure 5 1 Clean the tube sheet and O ring sealing surface with a nylon brush then brighten the tube sheet surface with 320 grit emery cloth NOTE When cleaning be careful not to push the tube sheet into the combustion chamber If you do thread a couple of bolts into it and pull it back in place 2 Brush off all dust and debris with a brush and wipe it down with a cloth N SOOS Y G GGG 3 Apply silicone grease supplied to O Rings 4067 0901 Figure 4 Clean the Tube Sheet and O Ring sealing sur faces thoroughly as described above A Center Insulation in lower enclosure Add Evaporator Plate B Center Heating Coil on Insulation Evaporator Insulation Heating Plate y Coil NZ 2 Tube Do not A Sheet disturb RTV in these areas C Slide Coil Insulation and Evaporator Plate into Manifold Mounting Plate D No Gaps between insulation and Tube Sheet Here and Here 4076 1001 Figure 5 Align bottom insulation and Heat Exchanger Coil as shown 28 Install the manifold and manifold bolts See Figure 6 for long and short bolt positions Models SR200 SRC200 Short Bolt Placement Models SR400 SRC4
7. he Combustion Chamber cover Be careful not to damage the Combustion Chamber Remove the Combustion Chamber cover A WARNING California s Proposition 65 lists Refractory Ceramic Fibers heated to 1800 F or higher as a possible human carcinogen See the warning box on Page 6 for further information Call 1 800 752 0183 for a Material Data Safety Sheet MSDS Remove the top insulation the Heat Exchanger Coil the Condensate Evaporator the Bottom Insulation and the metal spacer from the Combustion Chamber Do not remove the RTV that seals the manifold mounting plate to the combustion chamber Clean up the Combustion Chamber the Combustion Chamber cover and the Spacer Be sure to completely remove all RTV from the Combustion Chamber and Combustion Chamber top Reinstall the clean spacer in the Combustion Chamber Install one 1 2 white Insulation Blanket on top of the spacer and one piece of 1 M insulation on top of the Blanket Make sure that the insulation is centered in the Combustion Chamber NOTICE Model SR SRC200 heaters built before 1 1 98 require two 1 2 Insulation Blankets Flameholder Flameholder Insulation Cap Tape to bottom of Flameholder Condensate Evaporator 1 Bottom M Insulation lt 1 2 Bottom Blanket Figure 3 Correct order for installation of insulation 25 Install the new Condensate Evaporator on top of the insulation 26 Clean the tubeshe
8. he Heat Shield and the Membrane Pad and Cover as a unit See Figure 2 Key No 4 14 Unscrew the four nuts holding the Blower Adapter Plate to the top of the Combustion Chamber and remove the Combustion Air Blower the Igniter the Combination Gas Valve and associated piping and the Blower Adapter Plate as a unit See Figure 2 Key No 5 Remove the Flameholder and Flameholder Cone if used NOTICE BE CAREFUL not to break or crack the igniter it is fragile 15 Unscrew the nuts holding the Combustion Chamber top to the Combustion Chamber body 16 Unscrew 4 hold down nuts from the hangers support ing the Combustion Chamber 17 Wrap a shop rag around each hanger one at a time be careful it s sharp and hammer down on the Lower Enclosure while lifting the hanger by the shop rag This will lift the hanger up off of the hold down bolt 18 Lift the Combustion Chamber out of the Lower Enclosure 4 WARNING Heavy parts can cause personal injury When lifting use all proper precautions for the weights involved 19 Cut the RTV all the way around the top of the Combustion Chamber with a screwdriver z S PR SO SIE 5 oO Figure 2 Removal of major sub assemblies 20 21 22 23 24 With a mallet and screwdriver go around the Combustion Chamber cover tapping up until the RTV separates and releases t
9. tering tubes from the Air Flow Switch and the Combination Gas Control Valve to the Combustion Air Blower Assembly see Figure 9 Reconnect exhaust vent pipe and seal with RTV or epoxy according to vent manufacturer s instructions Risk of carbon monoxide poisoning Make sure that entire exhaust vent is sealed after reinstallation 40 41 42 43 44 Reconnect all wiring See Figure 10 for Junction box connections and see Page 7 for complete wiring schematic Before starting the heater test for gas leaks from piping and around Combustion Chamber cover with a soapy water solution Check for water leaks at unions and at manifold flange where it joins the tube sheet Reinstall jacketing and test heater by running it through one complete cycle Test for exhaust leaks from exhaust vent pipe while cycling heater Heater is ready for service White to White H Green Ground to Green Ground Black to Black Wiring Harness to Control Box View From Above Interior Wire into bottom X of Junction box in Flexible Conduit Figure 10 Junction Box Wiring Connections For detailed installation operation maintenace and safety information about the Sta Rite pool heater call customer service at 1 800 752 0183 and request a Sta Rite Pool Spa Heater Training and Service manual publication S5066 Prolonged exposure to the ceramic fiber insulation in 44 WARNING the combustion chamber may
10. torque See Figure 9 75 115 in lbs 8 4 12 9 N m Make sure that all bolts are engaged and hand tight Reinstall Control Box and Heat shield Assembly Torque the bolts in sequence as shown Some noise popping etc is normal as you tighten Flameholder Adapter Go around the manifold and retighten the bolts as Plate Gasket needed to 75 115 in lbs 8 4 12 9 N m you may have to do this several times Flameholder Combustion Chamber Gasket Install one piece of 1 top Insulation on top of the Heat Exchanger and one 1 2 Insulation Blanket over the top Insulation Make sure that the insulation is centered on shows around the insulation Apply fresh High Temperature RTV 600 F Continuous 700 F Intermittent rating all the way around the inside top of the Combustion Chamber and the outside of the Combustion Chamber cover see Figure 8 At reassembly connect tubing as shown 1 From Air Inlet Port to Combination Gas Valve 2 From Air Inlet Port to Air Flow Switch 3 From bottom of Blower to Air Flow Switch Figure 9 Make sure new gaskets are in place when reassembling combustion chamber Apply RTV bead all the way around both Combustion Chamber and Cover 3140 0198 Figure 8 RTV Application For Reassembly 36 37 38 39 Reinstall Control Box and Heat Shield assembly fasten with three nuts Reconnect the water pressure switch if necessary Reconnect the me
11. ve 2 If the heater is below the water level of the pool close the isolation valves to avoid draining the pool 3 Remove the drain plug under the manifold and drain the heater 4 While the heater is draining remove the upper left and upper right jacket halves 5 Remove the switch covers on both sides of the mani fold and unplug the wires from the Automatic Gas Shutoff the High Limit Thermostat and the Thermistor See Figure 2 Key No 1 If necessary disconnect the Water Pressure Switch and remove it 6 Disconnect exhaust vent from indoor units 7 Disconnect the gas pipe at the external union between the heater and the external manual gas valve 8 Disconnect the incoming electrical wires at the junction box and cut the wire tie holding the Wiring Harness to the Lower Enclosure See Figure 2 Key No 2 9 Disconnect the inlet and outlet unions and move the heater enough to allow removal of the manifold adapter and the inlet outlet manifold as a unit See Figure 2 Key No 3 10 Unscrew the bolts that attach the manifold adapter to the tube sheet and remove the manifold adapter and the inlet outlet manifold as a unit 11 Carefully disconnect all three metering tubes from the Combustion Air Blower Assembly 1 to the Combination Gas Control Valve 2 to the Air Flow Switch 12 Remove the bolt from the Gas Piping Clamp 13 Unplug all wires to the Control Box Unscrew three nuts and remove the Control Box t
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