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1. O e BW REPAIR PARTS WATER SYSTEM Part Description Tube Sheet Coil Assembly Kit Includes Key No 2 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 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 Drain Plug Condensate Evaporator Qty NO 2 GA ek X O O SR200NA SR200LP 77707 0232 77707 0117 6 42002 0015 35505 7437 77707 0120 42002 0018 42002 0013 77707 0001 42001 0060S 77707 0205 77707 0206 043 4155 37007 0214 09 226 77707 0017 77707 0010 38000 00075 37607 0011 35505 1313 42001 0097 42001 0016 U178 920P 42001 0031 2691 1196 SR333NA SR333LP 77707 0233 77707 0118 10 42002 0016 35505 7437 77707 0120 42002 0019 42002 0014 77707 0001 42001 0060S 77707 0205 77707 0206 43 4155 37007 0214 9 226 77707 0017 77707 0010 38000 00075 37607 0011 35505 1313 42001 0097 42001 0016 U
2. go to Pages 28 and 29 CONTINUE NO Did burner fire at all YES Go to BURNER TROUBLESHOOTING Page 30 Go to HEATER WILL NOT FIRE D Page 27 Replace Ignition Control Module Check for 24 VAC between VAL and GND terminals on Ignition Control Module SEE NOTE 1 Check for 24 VAC between VAL and GND terminals on Control Board SEE NOTE 1 Fix wiring between VAL and GND terminals of Ignition Control Module and Control Board 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 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 NO Replace Control Board 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 Does heater fire and stay on Did Blower come on 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 ca
3. 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 terminal must be located see Figure 13 e at least 3 and at most 12 out from the wall see Figure 14 following the vent manufacturer s instructions e at least 12 above finished grade or the normally expected snow accumulation level whichever is higher Max 12 Min 3 Vent Vent Termination Termination uz Vent Termination Y 1 Min At least 7 above grade 1 Minimum adjacent above snow or Gas Meter to public 27 Forced Air Ik finished grade Inlet walkways whichever is 3 Minimum clearance if higher horizontal distance to 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 Manufacturer Material Type Sealant Saf T Vent 4 Heat Fab Inc Consult Manufacturer Special Gas Vent 38 Hayward Street Single Wall Greenfield MA 01301 800 772 0739 Saf T Cl Vent Heat Fab Inc Consult Manufacturer Special Gas Vent 38 Hayward Street Double Wall Greenfield MA 01301 800 772 0739 Z Vent 4 Special Z Flex U S Inc G E RTV 106 Gas Vent Type BH 20 Commerce Park North Model SVE Bedrford NH 03110
4. 15 Ft 8 Ft 6 Ft Vent Size 6 in 7 in 8 in 9 and 10 in Type B Double Wall Vent With Single Wall Connector Model 400 Min Height Max Height Not Rec Not Rec 15 Ft 50 Ft 8 Ft 20 Ft 6 Ft 6 Ft Not Rec Not Rec Model 200 Min Height Max Height 6 Ft 15 Ft 6 Ft 8 Ft Not Rec Not Rec Not Rec Not Rec Not Rec Not Rec Model 333 Min Height Max Height Not Rec Not Rec 10 Ft 20 Ft 6 Ft 20 Ft Not Rec Not Rec Not Rec Not Rec Vent Size 12 6 See Table 4 for height of vent termination above the roof Do not run the heater vent into a common vent with any other appliance 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 Above Roof 1 Ft 1 Ft 3 in 1 Ft 6 in 2 Ft 2 Ft 6 in 3 Ft 4 in 4 Ft 5 Ft 6 Ft 7 Ft Roof Pitch Flat to 6 12 6 12 to 7 12 gt 7 12 to 8 12 gt 8 12 to 9 12 gt 9 12 to 10 12 gt 10 12 to 11 12 gt 11 12 to 12 12 gt 12 12 to 14 12 gt 14 12 to 16 12 gt 16 12 to 18 12 gt 18 12 to 20 12 7 Ft 6 in gt 20 12 to 21 12 8 Ft 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 you
5. 9 ES1 m E AFSgw OPERATING CONTROL MEMBRANE PAD AGSYN CONNECTION GAS El VERSION 1 PAD 1 CONTROL CENTER SPA CONTROL External Control Interface Circuit evo Disabled Heater Membrane Pad SENE Ui Enabled Pool Line External Control Interface BK Y BK J 24 DIAGNOSTIC INDICATOR IGNITION CONTROL MODULE Y Y 24VAC SEC BMG R223 PRIM 120VAC FC1 51 External Control Interface Circuit Enabled Pool On 5592 Mies 0 LL 1454 fo and Spa On Keys Disabled Y O OFF Key on Membrane sa BK Pad Remains Functional Y R 120VAC IGNITER BLOWER 2 120VAC 88 GND oe J6 G BK GND E wow W JUNCTION 59 oj y GROUND GND e e 120VAC HOT gt gt If cable from Membrane Pad NEUTRAL NEU gt yl is a 6 Conductor Cable connect NOTICE If while there is 120VAC connected to the heater you touch Replace jumper with leads to Control Board as shown 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 Fireman s Switch field installed r 3661 0200 30 Pool Heater Electrical Schematic Ladder Diagram LADDER DIAGRAM lt gt 120 2 gt N
6. MAINTENANCE INSTRUCTIONS 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 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 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 WINTERIZING See Figure 7
7. RAZ A X 8 Metal Flue Collar ps Vent Pipe E 7 gt M X d S EE E 2 wW PN E 2 He L ER E 4 CA Lo IL Clean and RTV Su Combustion This Surface Chamber Flue Collar 2855 0597 RTV FIGURE 11 Flue collar 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 Metal Flue Collar Sta Rite Part No 4x6 77707 0076 4x8 77707 0077 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 i
8. Saf T Vent Saf T CI Vent Z Vent Vertical Terminal 5400 Cap 5400 Cap 2SVSRCF04 Horizontal Terminal 5490CI Horizontal Term 5490CI Horizontal Term 2SVSTTFOA Tee 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 Do not use a shut off valve to isolate the heater unless it is below the level of the pool or spa Install a check valve if there is a possibility of back siphon ing through the heater when the pump is off 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 NOTICE If the heater is plumbed in backwards it will cycle continuously Make sure piping from filter is not reversed when installing heater WATER PIPING Connect the heater directly to 2 PVC pipe using the inte gral unions provided Heat sinks are not requi
9. 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 White to White Green Ground to Black to Green Ground Black Conduit from Fireman s Switch Wiring Harness to Control Box Cama View From Above Interior View From Below Exterior mE S Wire into bottom of Junction box in Flexible Conduit FIGURE 23 Field Wiring 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 FIGURE 24 Open Control Box Cover 21 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 t
10. Vertical or Horizontal No of 90 Elbows Maximum Length 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 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 Check that vent is supported at elbows tees and horizon tal and vertical runs according to manufacturer s instruc tions and code requirements 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 Check that all joints are completely together and sealed 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 Wall Thimble Part of Vent term Part of Vent term 2SVSWTF04 Vent Brand
11. 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 ALE SIDES 6 INCHES Orient the heater for convenient access to the water con nections and the gas and electrical connections 3 or more Outdoor installations must have at least 3 of clearance above vent 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 TOP VIEW FIGURE 8 Combustible Clearances CONTROL PANEL INDEXING 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 Unbolt and separate the jacket halves Pull hair pin clips Depress plastic clips on the control panel assembly Lift panel off of support plate 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 7 Replace hair pin clips 8 Replace jacket halves and bolts and tighten N 2732 1296 FIGURE 9 Indexing Control Panel INDOOR INS
12. water level Back of pressure switch has a reference scale FIGURE 19 Pressure Switch Adjustment 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 Verify proper operation of the water pressure switch at the start of every season and every six months thereafter by the following steps 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 CAUTION 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 So
13. 6911 800 654 5600 e at least 4 feet below or horizontally from or 1 foot above any doors or windows or gravity air inlet to a building e At least 3 feet above any forced air inlet located within 10 feet e At least 4 feet horizontally from electric meters gas meters regulators and relief equipment e At least 7 feet above grade adjacent to walkways or sim ilar traffic areas 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 Metal Special Support see Vent weight xcd of pipe Appliance Listed Adapter Terminal Condensate Tee Metal Vent Body Slope at least 1 4 per foot n Condensate down towards drain w Trap condensate drain 9 Minimum 12 Maximum Clearance FIGURE 14 Typical Special Gas Vent Pipe Installation Horizontal Positive Pressure 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 Table 6 Maximum Vent Length 4 Special Gas Vent
14. For outdoor heaters in freezing climates shut the heater down and drain it for winter as follows 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater 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 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 Combination Gas Control Valve OFF Turn Clockwise
15. 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 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 3 5 Combination Gas Control Valve 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 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 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 Turn on the heater and verify the gas supply pres sure Page 20 After the burner ignites ope
16. 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 Heplace Air Flow Switch AFS If problem persists replace Blower Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board Disconnect wires F1 Connect correctly and retry and F2 from Ignition No Does Blower start Control Module and short them together Does Blower come NO Replace Blower Does Blower YES on Start NO Replace Ignition Control YES Module THERMISTOR on Verify Thermistor wiring If OK replace Thermistor CAUTION Do not jumper a safety switch to NOTE ES1 is a spare and should be jumpered remedy a failed switch Diagnostic LED s SFS Replace Heater Membrane Pad Assembly reset power to Heater and retry Heater should fire SFS on Is the Stack Flue Switch or Sensor correctly connected to the wiring harness B Is the Membrane Pad connected to the correct pins on the Control Board See Page 36 DONE Replace Heater Control Board with new style board reset power to Heater and retry Reconnect correctly Heater should fire Change Low Level Board Programming to SF1 See Check the J3 and J6 Page 4 1
17. and press down to turn off gas Manual Gas Valve OFF Power X i 7 f y 5 Drain Inlet Outlet 2 Manifold gt E Drain Cock s and Plugs OPEN 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 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 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
18. as appropriate 11 Turn on all electric power to the appliance 12 Press either the POOL ON or SPA ON button switches on the operating control 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 Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance 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 TO TURN OFF GAS TO THE APPLIANCE Depress OFF button on operating control 2 Turn off all e
19. 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 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 SEQUENCE OF OPERATION 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 e the pressure switch PS which senses that the pump is running e the high limit switch HLS which opens if the heat exchanger outlet temperature goes above 135 F and e the automatic gas shutoff AGS switch which opens if the heat exchanger outlet temperature goes above 140 F e 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 or
20. check valves isolation valves flow nozzles or therapeutic pool valving must have a relief valve installed as described above See Page 16 To High Side of Differential Pressure Gauge To Low Side of Diff Pressure Gauge To Air Flow Switch NOTICE The gas piping and unions are not shown for clarity make this test with all gas piping connected as for normal service FIGURE 21 Connect Gas Valve to End Cap Air Orifice Instructions For Checking the Gas Pressure Through the Combination Gas Control Valve Risk of fire and explosion Improper 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 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
21. 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 Provide an adequate ventilation air supply see Instruc tions at right Choose a location that will avoid contami nation by chemical fumes 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 NOTICE Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty See Table 1 Page 11 6 in clear space above Raise at least 18 above floor to avoid 16 flammable vapors leave 6 in of clear space between unit and combustible surfaces 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 6 INCHES ALE SIDES crs eset 6 INCHES VENTS a 6 INCHES 10 The heater is design certified by CSA International for installation on combustible flooring For installation o
22. plugged for example by leaves there may not be adequate flow to the heater Do not rely on the pressure switch in this case WATER CHEMISTRY Water chemistry should follow good swimming pool water chemistry practices See Table 9 below for water chem istry parameters 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 Minimum Free Chlorine ppm Combined Chlorine ppm Bromine ppm 2 0 Other Sanitizers Chemical Values pH 7 2 Total Alklinity Buffering ppm 60 as Total Dissolved Solids ppm N A Calcium Hardness ppm as 150 Heavy Metals None Biological Values Algae Bacteria None None Warm Water Out ex 1 Set Manual 7 f E Bypass Valve 2680 1096 2 Remove handle Outlet to Pool 522 Inlet from Filter FIGURE 17 Manual bypass valve Ideal Maximum 2 0 4 0 10 0 None 0 2 4 6 10 0 Levels not established Consult local health department before use 7 4 7 6 7 8 80 100 180 N A 1 500 ppm gt TDS at startup 200 400 500 1 000 None None None Refer to
23. spas or hot tubs OPERATING INSTRUCTIONS A U STOP Read the safety information to the left Set both pool and spa thermostats to the lowest settings Turn off all electric power to the appliance 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 Remove the jacket cover s by unfastening the screws connecting both halves of the top jacket See Figure 3 S BS 25 Tp Mi MS xc FIGURE 3 Removal of jacket covers 6 Turn the knob on the gas control clockwise V to the black line depress slightly and turn to OFF position See Figure 4 Indexing Point Gas control is shown ON Turn Clockwise and press down to turn gas off You are here 2671 1096 FIGURE 4 Turning gas control OFF 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 8 Turn the knob on the gas control counter clockwise X to the ON position See Figure 5 Indexing Point Gas control is shown OFF Turn Counter clockwise and release to turn gas on You are here 2672 1096 FIGURE 5 Turning gas control ON 9 Replace jacket cover s All jacket covers must be in place when operating the appliance 10 Set 3 way valves on inlet and outlet to pool or spa
24. 0255 WC78 38AT 42001 00635 42001 00535 42001 00565 32850 0099 42001 00525 42001 00575 42001 00595 42001 00965 37337 0092 42001 00585 77707 0022 42001 0022 32165 4081 77707 0004 42001 0004 42001 0055 42002 00245 SR333NA SR333LP 77707 0009 42001 0009 32165 4084 42001 00085 42001 00305 77707 0054 42001 0054 42001 00665 42001 00075 42002 00255 WC78 38AT 42001 00635 42001 00535 42001 00565 32850 0099 42001 00525 42001 00578 42001 00595 42001 00965 37337 0092 42001 00585 77707 0022 42001 0022 32165 4081 77707 0004 42001 0004 42001 0055 42002 00245 SR400NA SR400LP 77707 0009 42001 0009 32165 4084 42001 00085 42001 00305 77707 0054 42001 0054 42001 00665 42001 00075 42002 00255 WC78 38AT 42001 00635 42001 00535 42001 00565 32850 0099 42001 00525 42001 00578 42001 00595 42001 00965 37337 0092 42001 00585 77707 0022 42001 0022 32165 4081 77707 0004 42001 0004 42001 0055 42002 00245 TS Available separately Not illustrated Kit parts not available separately 2 Not available separately 35 Pool Heater Wiring Connection Diagram CONNECTION DIAGRAM AGS Switch Air Flow Switch Y R Y BL Extra Switch 1 Y O Stack Flue Sensor lt Gas Valve Hi Limit Switch Pressure Switch Y y L y 1101 M 10 BL 0 w a 1 RE BRR Y R i 6999 oo y de 48 25222 gf 42 E HLS 2 6
25. 1 in 55066 Sta Rite NO connectors for corrosion Heset power to Heater and Pool Spa Heater Training and on the male pins retry Heater should fire Service Manual Were you Corrosion found able to change the device code SFO to SF1 YES Clean pins Heplace Stack Flue Sensor Heset power to Heater and YES retry Heater should fire Heset power to Heater and retry Heater should fire Does the Digital Temerature NO Display show Error Code E05 or E06 Check Heat Exchange Coil for liming or low flow Verify whether you have a SENSOR Stack Flue Sensor or a Stack Flue Switch 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 SFO See YES Page 4 11 in S5066 Sta Rite YES Pool Spa Heater Training and YES Did Error Code E05 or E06 disappear after change Does the Digital Temerature Display show Error Code E05 or E06 Service Manual Were you able to change the device code SF1 to SFO NO NO Replace Heater Control Board reset power to Heater and retry Heater should fire Reset power to Heater YES Check Heat Exchanger Coil and retry Heater should for liming or low flow fire NO Replace Heater Membrane Pad Assembly reset power to power to Heater and retry Heater and retry Heater should fire
26. 178 920P 42001 0031 SR400NA SR400LP 77707 0234 77707 0119 12 42002 0017 35505 7437 77707 0120 42002 0020 42002 0022 77707 0001 42001 0060S 77707 0205 77707 0206 U43 41SS 37007 0214 U9 226 77707 0017 77707 0010 38000 00075 37607 0011 35505 1313 42001 0097 42001 0016 U178 920P 42001 0031 Not available separately e illustrated 34 o REPAIR PARTS ELECTRICAL SYSTEM Part Description Display Cover Retainer Cap Kit Incl Key No 1 Display Cover Retainer Cap CPSC Warning Label Heater Display Cover Igniter Bracket lt Igniter Igniter Gasket Kit Incl Key Nos 4 and 5 Igniter 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 6 19x5 16 Phil Pan Heater Wiring Harness A Ss Ss Ss SH Junction Box Cover Kit Incl Key 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 Stack Flue Sensor SR200NA SR200LP 77707 0009 42001 0009 32165 4084 42001 0008S 42001 00308 77707 0054 42001 0054 42001 00665 42001 00075 42002 0
27. 29 Burner Troubleshooting SYMPTOM CAUSE Loud high pitched whine Flame is too rich Flame is fluttery Flame is too lean Exhaust may have acrid smell or burner may fail to stay lit Burner pulsates or Exhaust vent is too long surges especially on ignition Combustion appears Flame current is not normal but flame does being sensed not stay lit Heat Exchanger Troubleshooting SYMPTOM CAUSE Boiling in heat exchanger Low water flow to heater May be accompanied by Heat exchanger plugged bumping sounds Bypass valve stuck open Thermal governor stuck closed Sweating Thermal governor failed 30 REMEDY 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 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 Reduce length of exhaust vent and or number of elbows 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 REMEDY Service pump and or filter Service heat exchanger Correct water chemistry Service bypass valve Replace thermal governor Replace thermal governor For complete Electrical Syst
28. 7707 0202 42001 0084 42001 0202 42001 0065 42001 0075 42001 0031 77707 0002 42001 00015 33457 10515 77707 3200 77707 3200L 77707 0007 043 6255 043 1255 U36 38SSW 77707 0008 42001 0073 42001 0072 42001 0070 42001 0071 42001 00745 42002 00055 42001 02095 42001 02145 42001 00515 38404 40975 77707 0321 42001 0321 79 370 7707 0351 42001 0351 79 370 77707 1351 42001 0351 79 370 5402 32165 4082 77707 1321 42001 0321 79 370 5403 32165 4083 31786 40195 42001 02065 77707 0092 42001 00945 77707 0011 42001 0067 42001 0090 77707 0203 42001 0084 42001 0203 42001 0065 42001 0075 42001 0027 42001 0031 77707 0002 42001 00015 33457 10515 77707 3333 77707 3333L 77707 0007 43 6255 043 1255 U36 38SSW 77707 0008 42001 0073 42001 0072 42001 0070 42001 0071 42001 00745 42002 00055 42001 02095 42001 02145 42001 00515 38404 40975 77707 0311 42001 0311 79 370 77707 0341 42001 0341 79 370 77707 1341 42001 0341 U9 370 5402 32165 4082 77707 1311 42001 0311 U9 370 5403 32165 4083 31786 40195 42001 02065 77707 0093 42001 00945 77707 0011 42001 0067 42001 0090 77707 0204 42001 0084 42001 0204 42001 0065 42001 0075 42001 0027 42001 0031 77707 0002 42001 00015 33457 10515 77707 3400 77707 3400L 77707 0007 43 6255 043 1255 U36 38SSW 77707 0008 42001 0073 42001 0072 42001 0070 42001 0071 42001 00745 42002 00055 42001 02095 42001 02145
29. ATER Metallic 1 Order an Appliance Adapter kit Sta Rite Part No 77707 0086 for Saf T Vent or Saf T Vent Cl 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 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 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 tha
30. 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 Flameholder Adapter Plate Gasket Flameholder Assembly Flameholder Combustion Chamber Gasket Flameholder Insulation Cap Flameholder Insert Condensate Evaporator Upper RH Heater Enclosure Kit Lower Enclosure 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 1 Insulation 1 Top Insulation 1 2 Insulation Blanket Lower Enclosure Insulation Metal Vent Cover Metal Exhaust Elbow Kit One Piece Metal Eloow Cover Assembly Not available separately Kit parts not available separately Not illustrated Not included with heater Order separately Model SR200 uses 2 ll KR BR A 3 3 SR200NA SR200LP 42001 00515 38404 40975 77707 0331 42001 0331 U9 370 77707 0361 42001 0361 U9 370 77707 1361 42001 0361 U9 370 5402 32165 4082 77707 1331 42001 0331 9 370 5403 32165 4083 31786 40195 42001 02065 77707 1 42001 00945 77707 0011 42001 0067 42001 0090 7
31. ES Replace Ignition Control Module 27 Diagnostic LED s AGS AFS HLS PS THERMISTOR an Verify that water flow rate is Service pump and filter to AGS or HLS on above minimum required for restore proper flow After ser heater vicing verify proper operation YES of Pressure Switch PS Replace High Limit Switch HLS or Automatic Gas YES Verify that inlet water temper NO Shutoff AGS i ature is below 104 F Replace thermistor or Control CONTINUE Board to correct overheating 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 CONTINUE Verify that wiring is OK and pressure tap is not blocked Re CONTINUE Adjust Water Pressure Switch to close with pump running and open with place Pressure Switch i pump off AFS on Ea Does Blower operate YES Verify that there is no block age in Blower intake Heat Verify that water flow rate is above minimum required for heater NO Exchanger and exhaust and that exhaust is not too long Replace Blower YES Check for 120 VAC at Blower see Indoor Vent Installation connector on ignition try Page 15 NO Verify correct connection of wiring and that pressure taps to AFS are OK Verify that vinyl tubing to AFS and Blower is not misrouted kinked disconnected or punctured Verify that wires BM
32. EUTRAL IGNITER BLOWER 120 VAC CLASS II TRANSFORMER OPERATING CONTROL 24 VAC 24 VAC GND AIR s 24V oaic LOGIC FLOW SWITCH 9 9 9 WATER HI 9 9 PRESSURE LIMIT SWITCH SWITCH e 4 COM NO 1 6 AGS SWITCH o Lc gt GAS VALVE PX STACK FLUE THERMISTOR SENSOR SENSOR NOTES 1 er ba e Fe s1 24 vac ARE CONNECTED ON THE IGNITION MODULE 2 PIN AND SOCKET CONNECTOR 3 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
33. Local Code None None 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 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 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 the switch clockwise to raise setting heater below the pool and counterclockwise to lower the setting heater above the pool see Figures 18 and 19 Test the switch after resetting FIGURE 18 Remove cover for access to Switch Raise Pressure Raise pressure set point if pressure switch is more than 2 feet below water level Lower pressure set point if pressure switch is more than 5 feet above
34. STA RITE SR POOL AND SPA HEATER NATURAL GAS LP GAS O 5S MA NU AL INSTALLATION OPERATION amp PARTS MODELS 200K BTU HR SR200NA SR200LP 333K BTU HR SR333NA SR333LP 400K BTU HR SR400NA 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 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 e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from neighbor s phone Follow the gas supplier s instructions f 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 2003 Sta Rite Industries Inc Printed in U S A 5396 Rev 1 17 03 INSTALLATION OPERATION AND SERVICE MANUAL Model SR Pool and Spa Heater Natural Gas LP Gas TO INSTALLER Affix these instructions adjacent to the heater TO CONSUMER Retain these instructions for future refe
35. TALLATION INSTRUCTIONS 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 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 The heater is design certified by CSA International for installation on combustible flooring in alcoves in base ments in closets or utility rooms INSTALLATION IN A GARAGE OR UTILITY ROOM 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
36. chart SFS HLS PS or Pages 28 and 29 THERMISTOR on Is red SERVICE HEATER LED on 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 Do any diagnostic LED s on back of board AGS AFS SFS HLS PS or THERMISTOR come on and stay on Does red SERVICE Go to chart HEATER WILL HEATER LED come NOT FIRE C on 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 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 AWARNING Hazardous voltage Can shock burn A WARNING Fire and Explosion hazard Do not or kill Disconnect power before servicing any jumper switch terminals to remedy a failed safety components switch 23 Heater Will Not Fire A Start Is green SPA or Depress POOL or SPA ON YES Heater should fire on demand POOL LED button on Membrane Pad for heat Does POOL or SPA LED come on Check for 120 VAC power to heater YES Check wiring connections between power supply to YES Check for 24 VAC at sec Junction Box and ondary Transformer Junction Box to Terminal Board and restore continuity Restore
37. duced by 1 4 with a minimum pipe size of 3 4 Check for compliance with local codes NOTICE DO NOT use a corrugated flexible gas line to supply heater It will not deliver enough gas at nominal diameter to supply heater Table 10 Recommended Pipe Size For Natural Gas 1 000 BTU ft 0 6 Sp Gr 0 5 wc Pressure Drop Sediment Trap FIGURE 22 Gas line and Trap PRESSURE TESTING Before operating the heater the heater and its gas connec tions must be leak tested Test all gas connections for leaks with soapy water A WARNING 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 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 Line voltage field wiring should be 14 gauge with a circuit capacity of 15 amps ELECTRICAL WIRING 1 All wiring must be in accordance with all applicable codes 2 The heater w
38. em parts breakdown Key Nos 1 through 4 See Page 35 For complete Water System parts breakdown Key Nos 10 through 13 see Page 34 For compete Burner System parts breakdown Key Nos 5 through 9 See Pages 32 and 33 2737 0197 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 LO e o 009 0 0607 00853 lt co gt O e O co For Heater mounting bolts and clamps purchase separately Part No 42001 2692 1196 32 e e O NOO gt AQU 9 9 9 fF We REPAIR PARTS BURNER SYSTEM SR333NA SR400NA SR333LP SR400LP Part Description Combination Gas Control Valve Kit 3 4 Union Gas Orifice Kit NG Incl Key Nos 3 and 4 T Gas Orifice NG Gas Orifice O Ring Gas Orifice Kit LPG Incl Key Nos and 431 Gas Orifice LPG Gas Orifice O Ring NG to LPG Conversion Kit Incl Key Nos 3 and 4 T Gas Orifice NG 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 T Gas Orifice 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
39. fter 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 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 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 fo
40. he minimum requirement 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 Check that water pressure is within the adjustment range of the Pressure Switch 0 5 psig Verify that switch wiring is OK and sensing tube is not blocked and replace water Pressure Switch Check whether any of the red diagnostic LED s on back of board AGS AFS SFS HLS or PS are on GO TO HEATER WILL NOT FIRE C Page 26 25 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 Service pump filter and elimi nate other flow obstructions Heater should fire on call for heat Re verify that water flow is above minimum requirement Minimum Flow Requirements Model Flow 200 20 GPM 333 30 GPM 400 40 GPM 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 20 GPM 333 30 GPM 400 40 GPM Go to Diagnostic LED s Pages 28 and 29 Heater Will Not Fire C Start Is SERVICE HEATER LED on If any red diagnostic LED s AGS AFS SFS HLS PS or THERMISTOR come
41. he 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 TRANS Y Y THE HE 0000 9069 24VAC 24VAC FUSE FUSE THERMISTOR Jamy OPERATING CONTROL MEMBRANE PAD JMP3 CONNECTION EE ENABLE TOGGLE 1 BK TRANS DISABLE TOGGLE VERSION 1 PAD CONTROL CENTER SPA CONTROL Time Clock or Remote Purchase Separately Supplies Power to Circulator Pump Fireman s Switch x T 1 Completes the gt D i 24 Volt AC Control 5 JJ Board Circuit Z d DO NOT connect this gt E 5 9 circuitto 115 Volt AC 29 24VAC RR Z FIGURE 25 Fireman s Switch Connections 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
42. hen 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 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 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 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 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
43. ifice 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 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 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 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 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 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do
44. ilation 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 The minimum net free area in square inches shall be as follows Table 2 Combustion and Ventilation Air Requirements All Air From Inside Building All Air From Outside Building Combustion Vent Combustion 200 Sq In 200 Sq In 333 Sq In 333 Sq In 400 Sq In 400 Sq In 50 Sq In 84 Sq In 100 Sq In 50 54 In 84 Sq In 100 Sq In INDOOR VENT INSTALLATION Always vent the heater to the outdoors e Vent it horizontally or vertically using a Special Gas Vent see Table 5 Page 14 or e 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 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 Clean the Interior Surface Vent Body
45. iring External Control Interface 20 22 23 30 Repair 31 35 Wiring 36 37 2101111111 PPP 40 SAFETY INSTRUCTIONS FOR YOUR SAFETY This product must be installed and serviced by a professional service technician qualified in pool heater installation Some jurisdictions require that installers be licensed Check with your local building authority about contractor licensing requirements Improper installation and or operation could create carbon monoxide gas and flue gases which could cause serious injury or death Improper installation and or operation will void the warranty Installation must be in accordance with all local codes or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 and the National Electrical Code ANSI NFPA 70 or Canadian Electrical Code as applicable The heater when installed must be electrically grounded and bonded in accordance with local codes or in absence of local codes with the National Electrical Code ANSI NFPA 70 AWARNING This appliance is equipped with an uncon ventional gas control valve that is factory set with a mani fold pressure of 2 inches wc Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Installation or service mus
46. lectric power to the unit Remove jacket cover s See Figure 3 CAUTION HEATER PARTS MAY BE HOT UJ 4 Turn the knob on the gas control clockwise V to the black line depress slightly and turn to OFF position See Figure 4 5 Replace jacket cover s OPERATING CONTROL Digital Temperature Display A LOW SPEED STA RITE Em BOOSTER PUMP SIMPLY SMARTER HIGH SPEED System Operation AUX AUX Indicator Lights PUMP 7 b d 2 e SERVICE HEATER SERVICE HEATING SPA POOL SYSTEM ON ON Dual Temperature Controls FIGURE 6 Operating Control See Page 36 for External Control Interface The five operating switches are 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 ATEMP Press this button to raise the temperature setting W TEMP Press this button to lower the temperature setting To toggle the display between degrees Centigrade C and degrees Fairenheit F 1 Turn the Operating Control OFF 2 Press ATEMP or WTEMP for 5 seconds The display will flash once and change modes C to F or vice versa When either the ATEMP or WTEMP buttons are depressed the digital display will indicate the temperature setting A
47. ll 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 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 Min Height Max Height Min Height Max Height 100 Ft 100 Ft 100 Ft 100 Ft Model 400 Min Height Max Height Not Rec
48. lling for heat Check for 24 VAC between TH and GND terminals on Ignition Control Module SEE NOTE 2 Replace Gas Valve with identical part Fix wiring between TH and GND terminals of Ignition Control Module and Control Board Check for 24 VAC between TH and GND terminals on Control Board SEE NOTE 2 Replace Control Board Check for 24 VAC between GAS termi nals on Control Board SEE NOTE 1 Fix wiring between GAS ter minals on Control Board and Gas Valve 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 Heater Will Not Fire D Start Gas flows during igni NO Go back to chart HEATER tion try but burner WILL NOT FIRE C does not fire Page 26 Check for 120 VAC at YES YES Igniter leads during yg Check gas pressure OK Replace HSI Igniter ignition try NO EI Replace gas line with larger Check for 120 VAC YES Fix wiring between S1 and 92 line Or replace regulator between 51 and 52 gt terminals on Ignition Control terminals on Ignition Module and HSI Igniter Control Module during ignition try Check for 120 VAC NO Fix wiring between L1 and L2 between L1 and L2 gt terminals on Ignition Control terminals on Ignition Module and Terminal Board Control Module Y
49. llow instructions under To Turn Off Gas to the Appliance at left and call a qualified service technician to repair unit 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 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 SPRING AND FALL OPERATION 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 COLD WEATHER OPERATION 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 heate
50. ly the speci fied venting when heater is installed indoors CAUTION abel 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 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 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 spa
51. me 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 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 o D User C j supplied SS pipe fittings Uf 2681 1096 Pipe relief valve discharge to a drain or other safe disposal site FIGURE 20 Relief Valve Check Local Codes 18 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 Explosion hazard Any heater installed with restrictive devices in the piping system downstream from the heater including
52. n 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 Table 1 Corrosive Vapors and Possible Causes area Likely Contaminants Chlorinated swimming pools and spas New construction and remodeling areas Beauty parlors Refrigeration plants or various industrial finishing and processing plants Dry cleaning and laundry areas Pool or spa cleaning chemicals Acids such as hydrochloric or muriatic acid Glues and cements construction adhesives paints varnishes and paint and varnish strippers Waxes and cleaners containing calcium or sodium chloride Permanent wave solutions bleaches aerosol cans containing chlorocarbons or fluorocarbons Refrigerants acids glues and cements construction adhesives Bleaches detergents or laundry soaps containing chlorine Waxes and cleaners containing chlorine calcium or sodium chloride COMBUSTION AND VENTILATION AIR SUPPLY For indoor installation the heater requires air supply open ings for vent
53. n 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 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 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 4 Insta
54. n 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 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 Turn off the heater 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 Replace the heater covers and cycle the heater to check for proper operation GAS CONNECTIONS 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 re
55. not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department 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 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 Do not operate the pool heater unless the pool or spa is properly filled with water Before operating the appliance for the first time or after it has been off for an extended time perform the fol lowing checklist 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 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 o
56. on 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 A WARNING 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 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 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 on
57. perating 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 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 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 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 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 Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use
58. power to heater Check for 120 VAC between HOT and NEUTRAL termi Check wiring connections nals on Terminal Board between Terminal Board and YES Transformer primary and restore continuity Check for 120 VAC at primary NO peony to Transformer Replace Transformer Jumper Fireman s Switch at Check Fireman s Switch circuit Terminal Board and depress connections time clock wiring POOL or SPA ON button on external controller relay membrane pad Does SPA or POOL LED come on Leaving jumper in place Remove jumper Check wiring check for 24 VAC between between Transformer and J7 Fireman s Switch terminals terminals on Control Board and ground and between J7 and Fireman s Switch on Terminal Board check fuse and restore continuity Remove jumper Check rib bon cable connection between Membrane Pad and Heater should fire on demand J6 on Control Board Depress POOL or SPA On pad again Does POOL or SPA LED come on Replace Membrane Pad 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 Heplace Control Board GO TO HEATER WILL NOT FIRE B Page 25 24 Heater Will Not Fire B Start Is red SERVICE HEATER LED on CONTINUE Is red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above t
59. 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 OUTDOOR INSTALLATION INSTRUCTIONS For heaters located outdoors using the built in stackless venting system 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 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 HEATER CLEARANCES OUTDOOR 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
60. r local code officials for detailed information Cap See Table 4 For Min Hght 6 Minimum Clearance to Combustible Materials Class B Double Wall Metal Vent Pipe he a Vent A Support Vertical Body Vent Pipe so adapter does not take weight of pipe FIGURE 12 Typical Metal Vent Pipe Installation Vertical Negative Pressure 13 HORIZONTAL OR VERTICAL VENTING POSITIVE PRESSURE SPECIAL GAS VENTING See Figures 13 and 14 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 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 CONNECTING SPECIAL GAS VENT TO THE HE
61. r 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 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 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 6 Follow a regular program of preventive maintenance for the heater each new swimming season Check operation of the heater and its controls CARE AND MAINTENANCE
62. red The low thermal mass of the heater will prevent overheating of the piping connected to the heater even if the pump shuts down unexpectedly SYSTEM 3 Modular Media FIGURE 15 Cool Water a Mp d Typical installation In From Pool 16 From Pool FIGURE 16 Typical pool piping layout From Filter Outlet to Heater ee Sanitizer Cool Water In From Spa E5 Warm Water Out to Pool or Spa j S Corrosion Resistant CA Positive Seal S Check Valve cm 2 43 A gt 2735 1296 Chlorinator To Pool 6 8 To Spa 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 Maximum Flow Minimum Flow 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 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 Do not operate the heater while an automatic pool cleaner is also operating If the circulation pump suction is
63. rence FOR YOUR SAFETY This product must be installed and serviced by a professional service technician qualified in pool heater installation Improper installation and or oper ation could create carbon monoxide gas and flue gases which could cause serious injury or death Improper installation and or operation will void the warranty FIGURE 1 For instructions on checking the gas pressure through the Combination Gas Control Valve See the sidebar on Page 19 Table of Contents col APT 2 General Specifications Requirements 3 Description of the 4 Sequence of 4 Owner s Operating Instructions 4 B for Olas 4 Spa Temperature Caution 5 Operating 5 0 5 5 To Turn Gas To the Appliance 6 Operating Control gt uae ir ae elut e ees dra oes 6 After 7 Care Maintenance Winterizing 8 Installation Instructions 9 Outdoor Installation 9 Indoor Installation 10 15 Water Connections 15 18 Pressure Relief 18 Gas Connections 5 5652 29 9 PET 19 Checking Combination Gas Control Valve 19 Pressure JESUNE 2 4 444446 der 5 0 Get a 5 20 Electrical W
64. s only 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 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 DESCRIPTION OF THE HEATER Outlet Mixed Burner Water Heating Coils FIGURE 2 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
65. sequence should happen qu m Y Wy 52 D x Q D Ry i 9 yy wh wo FIGURE 26 Max Temperature Set Point Controls A The unit will come on and the POOL ON light will come on B Press the WIemp ATemp 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 WIemp ATemp 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 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 Is green POOL or SPA LED on 1 Go to chart HEATER WILL NOT FIRE B Page 25 Is red SERVICE SYSTEM LED on Are any red diagnos tic LED s on back of Go to specific safety switch board AGS AFS troubleshooting
66. t be performed by a qualified installer service agency or the gas supplier If this control is replaced it must be replaced with an identical control SAFETY INSTRUCTIONS Continued Do not attempt to adjust the gas flow by adjusting the reg ulator setting A WARNING 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 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 e Use heater only with the fuel for which it is designed Do not attempt to convert from one type of gas to another e 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 Risk of fire or explosi
67. t 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 4 Install vent pipe so that it can expand and contract the clear air space in the thimble or firestop with freely as the temperature changes Support the vent insulation The roof opening must be located so that pipe according to applicable codes and vent manufac the vent is vertical turer s instructions Pipe support must allow the vent 6 Vent Termination Vertical See Table 4 Page 13 for pipe free movement out and back from side to side or height of vent termination above the roof See Table 7 up and down as necessary without putting a strain on Page 15 for Listed terminations Use a Listed vent ter the heater or vent body Slope horizontal pipe runs up minal specified by local and national codes and your from the heater at least 1 4 per foot Install Listed con manufacturer s instructions A roof termination must be densate drains at low points where condensate might vertical collect Plumb condensate drains to a drain through 7 Ment Termination Horizontal See Table 7 Use a list hard piping or high temperature tubing such as sili ed wall thimble and vent terminal from Table 7 cone rubber or EPDM rubber do not use vinyl or other low temperature tubing Follow drain manufac turer s installation instructions

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