Rheem Above Ground Heaters 156 Installation and Operation Manual
Contents
1. Table B Specifications Unpacking On receipt of the heater it is suggested that visual checks are made for external damage to the shipping carton If the carton is damaged make a note to that effect on the Bill of Lading when signing for the ship ment Remove the heater from shipping packaging Report any damage to the carrier immedi ately On occasion items are shipped loose Be sure that the correct number of packages are received as indicated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by consignee Authorization to return goods must be received from the factory prior to shipping Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts specify the model and serial number of the heater When ordering under warranty conditions specify the date of installation Records of the installation must be provided when requested to substantiate a claim Debits for defective replacement parts will not be accepted and will only be replaced in kind per the manufacturer s standard warranties INSTALLATION CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING This unit contains refractory ceramic fiber RCF insulation in the combustion chamber2. 4 On the Remote Interface Harness connect the BLUE wire to one side of the switch and con nect the ORANGE BLACK wire for SPA operation and the BLACK ORANGE wire for the POOL operation 5 Install the Remote Interface Harness to the P8 connector and turn power ON to the heater To activate the remote control see page 23 P8 Connector P8 Connector Wire Nut BLK ORN To Pool COMM BLK ORN To Pool COMM a ORN BLK To Spa COMM p AFT Board AR TEORI ORN BLK To Spa COMM BLU 24VAC 7 BLU 24VAC 2 Wire Remote Control 3 Wire Remote Control 24 Wiring Diagrams MP 120 VAC LP 601944 ID 021 1134 700 WWYYNXXXXXX SNAP OFF PROPANE OPERATION ROLL OUT SWITCH pem Me SENSOR WATER PRESS LIMIT HI LIMIT r R 0 BL W Au GAS VALVE POTENTIOMETER Q R BK MANUAL SWITCH lt BL Y E r Y BL ww GJ V BK GND N m p 6 Y 24V BL IGNITION G 120 240 VAC VOLTAGE W BK TRANS PILOT UL ME _ SWITCH n FIELD INSTALLED OPTIONAL EN LBURNER TRAY Fig 19 Wiring Diagram
3. al E 4 1 Fig 8 Honeywell Gas Valve Electronic Ignition Gas Valves MANUAL SHUT OFF GAS PRESSURE TEST AT GAS VALVE Fig 9 Location of Gas Pressure Adjustment Pipe Sizing for Gas Connections Tubin andi 1 2 in 1 27cm 3 4 in 1 91cm 1 in 2 54cm 9 i 30 8 kW 8m 20m 30m 77m 107 m 272m 150 000 BTU hr 13 ft 34 ft 51 ft 130ft 180ft 4598 i 43 9 kW 4m 10m 16m 40m 55m 140 m Natural Gas 1000 BTU FT 0 60 Specific Gravity 0 5 in WC Pressure Drop Gaz Naturel 3154 5 W m 0 60 Densit 0 124 kPa Pressure Drop Propane Gas 2500 BTU FT 1 53 Specific Gravity 0 5 in WC Pressure Drop Le Gaz Propane 7886 3 W m 1 53 Densit 0 0 124 kPa Pressure Drop Table G Maximum Equivalent Pipe Length Water Connections The heater requires water flow and positive pressure to fire and operate properly It must therefore be installed downstream of the discharge side of the filter pump A typical installation is plumbed as follows 1 The inlet side of the filter is plumbed directly to the discharge side of the filter pump 2 The outlet side of the filter is then plumbed to the inlet of the heater and 3 The outlet of the heater is plumbed to the return line to the pool or spa The pump filter and heater are thus plumbed in series Plumbing from the heater back to the pool or spa must not have
4. 1 S EAS ILLUSTRATED PARTS LIST 39 OPTIONAL OPTIONAL D Lp cs rl M MZ 1 rz ER au gt pee 36 CALL ZE DESCRIPTION BURNER TRAY Burner Tray Sea Level Natural Gas Propane Gas Burner Tray w Gas Valve Sea Level Natural Gas Propane Gas Burner Burner Orifice Sea Level Natural 1 30mm Propane 84mm CONTROLS Thermostat Auto Reset 135 Surface Mount P C Board Control Digital LCD Display Fuse 5 AMP Seal Gasket Thermostat Control Analog PC Board Potentiometer Temperature Sensor Analog 2 Wire Temperature Sensor Digital GAS VALVE Combination Valve Nat Combination Valve Pro HEAT EXCHANGER Heat Exchange Assy Copper Inlet Outlet Header Complete Inlet Outlet Header Includes 6 H Return Header Includes 6 H Tube Bundle Copper Baffle Cupro Nickel Flange Nut Kit O Ring Gasket 2 Sensor Adapter Bypass Kit Bypass Valve Bypass Dam Shaft Bypass Spring Drain Plug Inlet Outlet Header Dam Hose Adapter 1 1 2 MPT x 1 1 2 Hose Optional 2 CPVC Connector amp Nut 2 CONTROL BOX Control Box Analog Includes 7 C Natural Gas Propane Gas Transformer 120 240 24V Analog Digital Ignition Control Natural Gas Analog Ignition Control Propane Gas Analog Rocker Switch 014841F 014845F 014849F 014853F N A 014857F 13 014861F 13 006725F N A N A N A N A 011585F 01492
5. N A 014919F N A 39 Registered Quality System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 40
6. as manufactured does not contain respirable crystalline silica However following sustained exposure to very high temperatures gt 2192F the RCF can transform into crystalline silica cristabolite The International Agency for Research on Cancer IARC has classified the inhalation of crystalline silica cristabolite as car cinogenic to humans When removing the burners or heat exchangers take precautions to avoid creating airborne dust and avoid inhaling airborne fibers When cleaning spills use wet sweeping or High Efficiency Particulate Air HEPA filtered vacuum to minimize airborne dust Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust Wear appropriate personal protective equipment including gloves safety glasses with side shields and appropriate NIOSH certified respiratory protection to avoid inhalation of airborne dust and airborne fiber particles IMPORTANT NOTICE These instructions are intended only for the use by qualified personnel specifically trained and experi enced in the installation of this type of heating equipment and related system components Installation and service personnel may be required by some states to be licensed If your state is such be sure your con tractor bears the appropriate license Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these instructions WARNING mproper installa
7. it is recommended that a suitable drain pan with adequate drainage be installed under the heater The pan must not restrict combustion air flow Clearances The required minimum clearances from combustible surfaces are shown in Table C below Outdoor Indoor Heater Side Installations Installations Unobstructed 30 in 76 2 cm 61 Clearance from top of vent terminal Table C Required Minimum Clearances from Combustible Surfaces minimaux assurer entre les parois de l appareil et les contructions combustibles c t s 12 arri re et 30po dessus When installed according to the listed minimum clear ances from combustible construction the pool heater can be serviced without removing permanent con struction around heater 10 However for ease of servicing we recommend a clearance of at least 18 45 7cm on the rear This will enable the heater to be serviced in its installed location that is without movement or removal of the heater Minimum clearance from drafthood to combustible construction 6 inches from the vent Degagement minimal de 6 po requis entre le coupe tirage et une construction combustible 2 po du conduit de raccordement Clearances less than recommended may require removal of the heater to service either the heat exchanger or the burner tray In either case the heater must be installed in a manner that will enable the heater to
8. will also be displayed and may be adjusted using the UP or DOWN buttons Operation In the POOL or SPA modes the actual water temper ature is displayed along with the desired water temperature SETPOINT When the water tempera ture is above the setpoint Water Temp will alternate with No Demand When the water temperature is below the setpoint and the heater is firing Water Temp will alternate with Heating To adjust the setpoint temperature make sure the con trol is in the appropriate mode POOL or SPA and push the UP or DOWN buttons B FOR YOUR SAFETY READ BEFORE OPERATING ep POUR VOTRE SECURITE LISEZ AVANT DE METTRE MARCHE WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life AVERTISSEMENT Quiconque ne respecte pas la lettre les instructions dans la pr sente notice risque de d clencher un incendie ou une explosion entra nant des dommages des blessures ou la mort This appliance is equipped with an ignition device which automatically lights A Cet appareil est muni d un dispositif d allumage qui allume automatiquement la veilleuse Ne the pilot Do NOT try to light the pilot by hand tentez pas d allumer la veilleuse manuellement B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour d celer une odeur
9. ANSI 2223 1 Canada CAN CSA B149 As much as possible avoid long horizontal runs of vent pipe and too many elbows If installation requires horizontal runs the vent pipe must have a minimum of 1 4 in 2cm per m per ft rise and should be supported at not more than five foot intervals Plumbers tape criss crossed will serve to space both horizontal and vertical piping Gas vents supported only by the flashing and extending above the roof more than 5 ft 1 5m should be securely guyed or braced to withstand snow and wind loads We recommend use of insulated vent pipe spacers through the roof and walls For protection against rain or blockage by snow the vent pipe must terminate with a vent cap which com plies with local codes or in the absence of such codes the latest edition of the National Fuel Gas Code ANSI 2223 1 Canada CAN CSA B149 Unrestricted Typical screened Typical screened opening or louvered opening and louvered opening 41 in 265 cm 54 in 348 38 in 245 cm 57 in 368 cm 76 in 490 cm Table D Minimum Air Net Area 4 ft 1 2m Minimum 4 ft 1 2m Minimum 4 ft 1 2m Minimum 3 ft 0 9m Minimum 1 ft 0 3m Minimum 10 ft 3m Forced Air Inlet Minimum O Fig 5 Outdoor Installation Clearances The discharge opening must be a minimum of 2 ft 0 6m vertically from the roof
10. Analog Models o Dr FLAME O CURRENT unos 134 OVAvC OVAvC 24 EE TRANS e e POWER SWITCH WATER SWITCH E PILOT HI LIMIT 1 fi HIGH TENSION HI LIMIT 2 BURNER TRAY 4 ROLL OUT SWITCH ao SPLICE HERE 4 FOR VENT OPTIONAL BK SPLICE HERE FOR FLOW SWITCH OPTIONAL E REMOTE OPTIONAL SPLICE HERE E voaskio Dnus FOR FIREMAN S SWITCH Dp qp Edgy ee o FIELD INSTALLED OPTIONAL IRIW Lol POOL BK O Ld do sb SPA O BK A TEMP 24VAC BL SENSOR Fig 20 Wiring Diagram Digital Models 25 120 240 VAC VOLTAGE I TRANS w Bk FOR 240 VOLT T SUPPLY 1 12 _ G 120 VAC P4 R BK Y BK GND S apt BURNER TRAY GAS VALVE VOLTAGE TRANS FOR 240 OPERATION SUP Time Clock Fireman s Switch To operate the heater with a time clock connect the timer to the fireman s switch connection in the heater s wiring The time clock should be of the dual switch type and set to shut off the call for heat to the pool heater ch
11. be serviced without removing any structure around the heater FLOORING This heater can be installed on com bustible flooring Base Installation Heater must be mounted on a level base such as cementable slab or cement blocks Heaters may not be installed on carpeting This heater must be installed at least 5ft 1 52m from the inside wall of a pool unless separated from the pool by a solid fence wall or other permanent solid barrier Ce chauffe piscine doit ntre install au moins 5 peds 1 52m de la paroi interne de la piscine moins d ntre isol de la piscine par un cl ture un mur ou autre barri re permanente Outdoor Installation WARNING The heater should not be located in an area where water sprinklers or other devices may cause water to spray through the cabinet louvers and into the heater This could cause internal rusting or damage electrical components and will not be covered under warranty WARNING Do not install within 3 feet 0 9m of a heat pump or an outdoor condensing unit Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury STACKLESS ASSY bad e o e e MODEL 106 24 00 MODEL 156 27 00 NOTE This heater is design certified for outdoor installation when equipped with the approved top s for outdoor use Heater with Outdoor Stackless Top Heaters must not be i
12. de gaz next to the floor because some gas is heavier than air and will settle on the floor Reniflez pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au WHAT TO DO IF YOU SMELL GAS niveau du sol Do not try to light any appliance QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Do not touch any electric switch do not use any phone in your building pas tenter d allumer d appareil Immediately call your gas supplier from a neighbor s phone Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Follow the gas supplier s instructions Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur If you cannot reach your gas supplier call the fire department Si vous ne pouvez rejoindre le fournisseur appelez le service des incendies C Use only your hand to push in or turn the gas control knob Never use tools Ifthe Ne poussez ou tournez la manette d admission du gaz qu la main ne jamais utiliser d outil knob will not push in or turn by hand do not try to repair it call a qualified Si la manette reste coinc e ne tentez pas de la r parer appelez un technicien qualifi service technician Force or attempted repair may result in a fire or explosion Le fait de forcer la manette ou de la r parer peut d clencher une explosion ou un incendie D Do not use this appliance if any part has been under wa
13. nec essary to locate the heater a minimum of 3 ft 0 9m from high vertical walls or install a wind break so the heater is not in direct wind current In areas of daily high winds it may be necessary to replace the outdoor stackless top with a stack adapter in combination with a wind resistant weather proof outdoor stack See Fig 4 OUTDOOR STACK Fig 4 Outdoor Stack The outdoor stack serves the same function as the low profile stackless top and should be installed in accor dance with the same clearance requirements Follow the installation instructions provided with the Outdoor Stack Kit for installation Indoor Installation The heater is design certified for indoor installation when equipped with the approved drafthood NOTE For Canada indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with an occupied area Refer to the latest edition of CAN CSA B149 for specific requirements WARNING Indoor heaters require a drafthood that must be connected to a vent ppe and properly vented to the outside Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning Locate heater as close as is practical to a chimney or gas vent Heater must always be vented to the out side See Vent Piping section for details Minimum allowable space is shown on the rating plate Follow the installation instruction
14. surface and at least 2 ft 0 6m higher than any part of the building within 10 ft 3m vent stack shall be at least 5 ft 1 5m in vertical height above the drafthood outlet The vent cap loca tion shall have a minimum clearance of 4 ft 1 2m horizontally from and in no case below unless a 4 ft 1 2m horizontal distance is maintained from electric meters gas meters regulators and relief equipment ye CAP 2 0 6m MIN 2 0 6m S T VENT 10 3m OR LESS DRAF THOOD Fig 6 Vent Piping Requirements The weight of the vent stack or chimney must not rest on heater drafthood Support must be provided in compliance with applicable codes The heater top and drafthood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from combustible construction Type B double wall or equivalent vent pipe is recom mended However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z223 1 Canada CAN CSA B149 Gas Connections Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve locat ed outside the heater jacket All gas piping should be tested after installation in accordance with local codes CAUTION Do not use 5 10 or 20 gallon 19 38 or 76 Lite
15. these instructions PROBLEM Harmonics or whining noise Heater going on and off continuously Liming or scale forming in exchanger Sooting Pilot outage or Weak Flame signal Yellow lazy flame Outer jacket very hot paint blistered Takes too long to heat pool or spa Leaking at well Leaking at heat exchanger Gasket brittle and leaking overheated CAUSE IG inoperative Debris or restriction in system Debris in Gas lines cocer eee ET Dirty OT eus Low water level in pool External bypass setting out of AUS WANT Pressure switch out of adjustment Bypassing too much High TOW Fa8l65 icio rere U G Improper venting Insects or debris clogging burner intake ports LOW gas pressure 2 Restricted dirty Weak pilot generator Low gas Insects or debris clogging burner intake ports Broken refractory caused by shipping damage or improper COIIDUSHODSe ee Excessive sooting of heat exc
16. 107 F 41 7 C Control Lockout The heater is equipped with a Control Lockout feature to prevent unauthorized tampering or adjustment of the control settings To lock out the controls press the DOWN button and MENU SET button for 5 seconds Choose a three digit PIN using the UP and DOWN buttons to select the digits and the MENU SET button to lock in selections Confirm your selection and record your PIN To unlock the controls press any button to bring up the Enter PIN menu Enter the PIN that was used to lock the control Note that power cycling will not clear the lockout Successfully unlocking the control will display Lockout Cleared Failure to enter the correct PIN will display Invalid PIN In the event that the user selected PIN is lost or does not clear the Control Lockout use the Program Button to Set Factory Defaults This will clear the PIN and allow normal operation and selection of a new PIN if desired See the Program Button directions on this page for details NOTE Both the POOL and SPA setpoints will revert back to 65 F 18 5 C and the POOL and SPA maxi mum temperature settings will be 104 F 40 0 C These setpoints will need to be readjusted to desired settings NOTE The LCD temperature display may not agree with temperature reading of your pool or spa ther mometer The heater reads the water temperature at the inlet Due to the circulation characteristics of any pool or spa the w
17. 3F 011586F 011587F N A 014869F 011594F 011595F 011596F 014874F N A 008259F 011600F 006714F 011601F 006716F 006717F 011602F 006721F 014882F 011635 006723F 006724F 014883F 014913F 011605F N A 004817B 004818B 009493F ALTITUDES ABOVE 2 000 FEET ABOVE SEA LEVEL CONSULT THE FACTORY WARNING The Hydraulic conditions or water chemistry that caused the tube 014842F 014846F 014850F 014854F N A 014858F 19 014862F 19 006725F 013464F 013640F 013733F 014866F N A N A N A N A 009577F 014867F 014867F 014868F 014868F 014870F 015547F 011595F 011596F 014875F N A 008259F 011600F 006714F 015548F 006716F 006717F 011602F 006721F 014882F 011635 006723F 006724F N A N A N A 006736F N A N A 009493F bundle to fail have very likely also damaged the bypass valve We recommend you inspect the bypass assembly Failure to do so could cause premature failure of this replacement part 37 CALL oT DESCRIPTION 106A 156A MISCELLANEOUS COMPONENTS Pressure Switch 1 75 PSI 006737F Pressure Switch 11 PSI Special See Adj in Service Manual 009133F Thermostat Knob 009499F Knob Stop 006886F Dial Plate Analog 014912F PRV 125 PSI Optional 008091F Deliming Kit not shown 052871F Wire Harness Analog not shown 014884F Wire Harness Digital not shown N A Control Bezel Digital Includes Switch Decal N A Switch Decal Membrane N A Control Bezel Cover N A Line Cord 011609F Roll
18. ING INSTRUCTIONS Control Adjustments Analog The pool or spa water temperature is controlled by the thermostat on the upper front panel of the heater The control center contains an On Off toggle switch and a thermostat The switch functions as a means for turn ing the heater On or Off The thermostat is fitted with a means of limiting the upper temperature limit below the maximum level The knob stop adjustment ring shown in Fig 17 is adjustable by loosening the set screw rotating the knobstop ring to the desired location and retightening the set screw HOT Fig 17 Water Temperature Thermostat NOTE Maximum temperature is 104 F 40 C Control Adjustments Digital The pool heater chauffe piscine touchpad located on the upper front panel of the heater allows the user to select either POOL or SPA operation and to adjust the setpoint temperature The LCD display window indicates the mode OFF SPA POOL and the actual water temperature A manual power switch provided below the touchpad turns the control power ON or OFF MENU SET Fig 18 Digital Control Adjustment MENU SET Button The MENU SET button is used to select either POOL or SPA operation It also allows the user to turn the heater off electronically The LCD remains energized and displays OFF while also continuing to show the actual water temperature Temp Buttons If the heater is in POOL or SPA mode the desired water temperature SETPOINT
19. INSTALLATION amp OPERATING INSTRUCTIONS Atmospheric Above Ground Pool amp Spa Heater Chauffe Piscine Models 106 amp 156 English French WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppli er s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Effective 01 15 15 AVERTISSEMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage mat riel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil CE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupte
20. OFF and call your service technician or gas supplier ENTR E DE GAZ 19 Thermostat Operation Advanced Flame Technology AFT Board pas oor BY ore cu 1 3 8 Bn J gu Service Menu and Fault History To access the Service Menu and fault history press the MENU SET and UP buttons simultaneously for 3 to o seconds The heater will continue to operate nor mally while in the Service Menu The first screen displayed is the Flame Strength indicator which indi cates the pilot flame current using a bar graph and numerical display A signal of less than 4 indicates a weak flame signal and may require service Refer to Section 5 Troubleshooting for possible causes and corrections FLAME STRENGTH INDICATOR Press the DOWN button The Supply Voltage screen indicates the voltage supplied to the control board Normal readings range from 24 to 29 volts SUPPLY VOLTAGE INDICATOR 20 Program button Press the DOWN button The Run Time indicates the total hours of operation for the pool heater as meas ured by the amount of time that the main gas valve has been powered The Cycle count indicates the number of on off cycles of the heater as measured by the number of times the pilot valve has been powered RUN TIME INDICATOR Press the DOWN button The Fault History can dis play up to ten faults in memory The order of the faults begins with Fault Last which is the most recent fau
21. Out Safety Switch 005899F Touch up Paint Cool Dark Gray 750256 Warm Dark Gra 750258 PILOT Pilot Nat 002003F Pilot Pro 002003F Pilot Orifice Nat 003903F Pilot Orifice Pro 004308F Pilot Mounting Bracket 014889F Pilot Tube 004078F Hi Tension Wire w Pilot Electrode N A SHEETMETAL Jacket Top 014892F Jacket Left 014894F Jacket Right 014896F Jacket Upper Front 014898F Jacket Lower Rear 014899F Flue Collector 014900F Door Panel Raypak 014902F Rheem 014903F Ruud 014902F Access Panels 014904F Control Panel Analog 014905F Digital N A Control Cover Analog 014778 N A Stackless Top Outdoor 014907F Access Panel Hot 014909F Drafthood w Adapter Indoor 014357 Outdoor Stack w Adapter Outdoor 014718 Stack N A Stack Adapter 014910F CONVERSION KITS 106A 156A For Altitudes Over 2 000 Feet Above Sea Level Consult Factory Natural to Propane Copper Heat Exchanger 014914F Cupro Nickel Heat Exchanger N A Propane to Natural Copper Heat Exchanger 014918F Cupro Nickel Heat Exchanger N A Gas Conversions are to be done only by a qualified agency 38 006737F 009133F 009499F 006886F N A 008091F 052871F N A 014885F 014886F 014887F 014888F 011609F 005899F 750256 750258 002003F 002003F 003903F 004308F 014889F 004078F N A 014893F 014895F 014897F 014898F 014899F 014901F 014902F 014903F 014902F 014904F N A 014906F N A N A 014908F 014909F 014358 014719 N A 014911F 014915F
22. Remove 4 screws as shown in the image 8 Disconnect wiring from gas valve 9 Remove 2 screws holding the control panel up 10 Flipthe control panel forward 11 Disconnect ignition wire and remove with burner tray 12 Reverse above procedure to reinstall 29 Gas Valve Removal 1 Remove burner tray 2 Disconnect pilot tubing from gas valve 3 Rotate the gas valve counter clockwise to remove valve from nipple 4 Reverse above procedure to reinstall E N an in 3 J 2 SCREWS HOLDING TRAY IN PLACE Fig 27 Gas Valve Removal Pilot Removal 8 Cleaning 1 Remove burner tray from heater 2 Disconnect tubing from gas valve 3 Remove 2 screws holding pilot bracket in place see image 4 Remove the pilot assembly by pushing the pilot 5 Remove the locating pilot screw from the bracket to release the pilot assembly SCREWS 6 Reverse above procedure to reinstall Fig 29 Pilot Bracket Screws Fig 28 Spark to Hood Pilot 30 Heat Exchanger 1 Shut water gas and electricity off close valves and relieve pressure then remove relief valve Remove side inspection panels 2 Remove
23. air has been evacuated from the system and the water flow rate meets the requirements listed in Table H Water Pressure Switch Adjustment Adjustment Knob Fig 23 Water Pressure Switch Adjustment 1 With pump and heater on turn adjustment knob clockwise until a click is heard from the gas valve 2 Turn adjustment knob counter clockwise 1 4 turn 3 Turn pump off and on several times Heater should shut off immediately If it does not repeat the above steps NOTE If heater is installed outside of the limits shown a higher pressure rated 11 psi 76 kPa switch may be used A flow switch mounted and wired adjacent to the heater may be used in place of the factory mounted pressure switch See Illustrated Parts List for 11 psi 76 kPa water pressure switch Two Speed Pumps In some cases the flow on the low speed is insuffi cient to operate the heater This is apparent when the water pressure switch cannot be further adjusted or if the heater makes banging noises or shuts off on high limit In these cases the pump must be run at high speed when heating the water CAUTION Do not operate the heater without the function of a properly adjusted water pressure switch or flow switch Pilot Safety The heater employs a pilot safety which closes the main gas valve within 8 10ths of a second whenever the pilot flame is interrupted The pilot flame is auto matically lit when the device is powered The heat
24. allation at initial start up and at least annually thereafter Refer to the venting section of this manual for more information regarding vent system inspections WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the heater free of combustible materials gasoline and other flammable liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the heater WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to the owner s operating instructions provided in this manual Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Gasoline as well as other flammable materials and liquids adhesives solvents etc and the vapors they produce are extremely dangerous Do not handle use or store gasoline or other flammable or combustible materials in the vicinity of a heater WARNING Both natural gas and propane have an odorant added to aid in detecting a gas leak Some people may not physically be able to smell or recognize this odorant If you are unsure or unfamiliar with the smell of natural gas or propane ask your local gas supplier Other conditions such as odorant fade which causes the odorant to diminish in intensity can also hide camouflag
25. an main burners and pilot burner of dust and lint 3 Inspect and operate all controls gas valve and pressure relief valve if equipped 4 Make visual check of the burner and pilot flames Flame pattern on the main burner and pilot is illus trated in the Post Start Up Inspection section Yellow flame means restriction of the air openings Lifting or blowing flame indicates high gas pres sure Low flame means low gas pressure Should these occur shut the heater off and contact your gas supplier or qualified service agency 27 5 indoor heaters clean room intake openings to ensure adequate flow of combustion and ventila tion air 6 Keep area around heater clear and free from com bustible materials gasoline and other flammable and corrosive vapors and liquids SERVICE Verify proper operation after servicing S assurer que l appareil fonctionne ad quatement une fois l entretien termin Water Pressure Switch The water pressure switch ensures that the heater operates only when the filter pump is in operation It is located on the In Out header It is factory set at 1 75 PSI 12kPa for deck level installations When the heater is located below the level of the spa or pool it may be necessary to adjust the pressure switch to compensate for the no flow static head If it is neces sary to adjust the water pressure switch utilize the following procedure CAUTION Do not adjust the pressure switch until all
26. any valves or restriction that could prevent flow when the pump is operating Heater must be located so that any water leaks will not damage the structure of adjacent area PVC pipe may be glued directly into supplied CPVC header unions Flow Rates 106 156 20 GPM 75L 70 GPM 265 L When flow rates exceed maximum 70 GPM an external auxiliary bypass valve is required See External Auxiliary Bypass Valve sec tion for details Table H Water Flow Rates Polymer Headers Before attaching the supplied 2 inch 5 cm CPVC unions to the In Out header make sure the O rings are properly seated in the grooves Use AquaLube or equivalent non petroleum based lubricant on the O ring Hand tighten the unions Glue PVC or CPVC piping directly to the unions In Out Header O Ring Tail Piece Fig 10 In Out Header for 2 Installation Ko Header Hose Connector Hose Fig 11 Optional In Out Header for 1 1 2 3 8 cm or 1 1 4 3 2 cm Hose Connection If there is any possibility of back siphoning when pump stops it is recommended that a check valve or valves also be installed in the system Internal Automatic Bypass Valve A built in automatic bypass valve is provided in the In Out header The internal bypass valve automatical ly responds to changes in water pressure in the piping system The proper amount of water flow is maintained through the heater under varying pressures dictated by the condit
27. ater temperature at the inlet to the heater may differ from that observed at a given location in the pool or spa STATUS AND DIAGNOSTICS The digital thermostat models are programmed to display a variety of status and diagnostic messages depend ing on the operating conditions The following heat status messages are displayed in Pool Spa and Remote modes when there are no active fault conditions Display Call for heat established flame present Spark operating Heat demand is satisfied The following conditions are displayed in Pool Spa and Remote modes Thermistor temperatures disagree by more than 2 F 1 1 C Thermistor sensor failed open Below 20 F 29 C Thermistor sensor failed short Above 217 F 103 C Board is sensing flame when both main and pilot valves are command ed shut Pilot gas valve output is not in com manded state Main gas valve output is not in com manded state Board fault replace board Memory fault reset set points replace board if fault does not clear Time clock fireman switch circuit is open Water temperature below 36 F 2 C No Demand Display Sensor Failure Sensor Open Flame w o n PV Output Fault MV Output Internal Fault EEPROM Fireman Sw Low Temp Lockout Os eo Ole amp 22 The following conditions are displayed only while there 15 demand for heat present Displa
28. auffe piscine 15 to 20 minutes prior to shut ting down the pool pump On analog heaters splice into the red white wire to connect the time clock For digital heaters the fireman s switch connection is locat ed on the 14 pin header connected to the digital control board Splice into the red wire jumper tagged Where necessary add Fireman s switch circuit here to connect the time clock The fireman s switch con nection on both analog and digital heaters must be a dry contact and must not supply power to the heater Powering the fireman s switch connection externally may damage the heater and is not cov ered by warranty Digital heaters Do not exceed 15 2 m of total wiring using 18 AWG stranded copper wire rated for 221 F 105 C minimum NOTE When using a time clock the heater will display Clock Fireman Sw when fireman s switch is open indicating that the time clock has shut off the call for heat Post Start Up Inspection 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 N utilisez pas cet appareil s il a ete plonge dans l eau meme partiellement Faites inspecter l appareil par un technicien qualifie et remplacez toute partie du sys teme de controle et toute commande qui ont ete plonges dans l eau WARNING Shoul
29. be 104 F 40 0 C The Control Lockout PIN will be cleared and the control will resume normal operation Clear Faults Refer to step one above to access the program screen Press the MENU SET button until Clear Faults appears on the digital display Press and hold both UP and DOWN buttons for 5 7 seconds until Faults Cleared appears This operation resets the Fault History file to 0 and clears all the stored faults Fahrenheit or Celsius Refer to step one above to access the program screen Press the MENU SET button until Fahrenheit or Celsius appears on the digital display The digital display is capable of displaying Celsius as well as Fahrenheit temperatures The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display Choose the desired temperature scale Spa Max Temp Spa Set Point Maximum Adjustment Refer to step one above to access the program screen Press the MENU SET button until Spa Max Temp appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The control can be set for a maximum of 107 F 41 7 C Pool Max Temp Pool Set Point Maximum Adjustment Refer to step one above access into the program screen Press the MENU SET button until Pool Max Temp appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your desired value The control can be set for a maximum of
30. bled ATTENTION OBSERVE PRECAUTIONS C 4 ELECTROSTATIC 1 SENSITIVE DEVICES A Note Electrostatic Discharge ESD damage can be caused by direct or indirect contact with the wiring or circuit board When one walks to the heater area an electrostatic charge accumu lates on the body Contact of a finger allows the body to discharge possibly causing device damage This damage can be limited if the service person discharges himself following ESD preventive removal practices and holds on to the heater enclo sure for 5 seconds before proceeding REMOTE CONTROL WIRING Important Installation Notes for Remote or External Wiring Configuration e Remote wiring must be run in a separate conduit e Remote wiring must not be run parallel to high voltage lines e runs of under 30 feet 9 1m remote wiring should have stranded conductors with a minimum of 22 AWG 600 cable twisting 1 5 to 2 5 in 3 8 to 6 4cm lay and jacketed e For runs over 30 feet 9 1m the conductors should be a minimum of 20 AWG 600V cable twisting 1 5 to 2 5 inch 3 8 to 6 4cm lay that is shielded and jacketed e Maximum cable length is 200 feet e For both two and three wire remote systems the provided 7 pin wiring connector must be utilized Please refer to the wiring instructions NOTE The remote wires must be connected to the 7 pin connector before the connector is plugged into the board 2 Wire Remote Control On Off This applicat
31. d overheating occur or the gas supply fail to shut off turn off the manual gas control to the appliance AVERTISSEMENT En cas de surchauffe ou si l alimentation en gaz ne s arrete pas fermez manueliement ie robinet d arret de l admission de gaz Feel the inlet and outlet pipes Outlet pipe should be only slightly warmer than the inlet should not be hot With the heater on remove the door and make a visu al check of the burner 26 PILOT Fig 21 IID Pilot Location Cold Weather Operation Moderate Climate Heater operation can continue during short term cold spells When temperatures are between 0 17 C and 32 F 0 C flow continuous pump operation must be maintained CAUTION Do not use the heater to maintain water temperatures just above freezing or for freeze protection When heater is used during freezing weather care must be taken to avoid freeze ups Continuous pump operation is a must Additional protection may be required The heater is not warranted against freeze ups Cold Climate Prolonged operation with water temperatures below 50 F 10 C is not recommended When starting the heater wi
32. e or otherwise make detecting a gas leak by smell more difficult WARNING UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications wherein there is a potential for an explosive mixture of fuel gas to accumulate and their installation should be in accordance with the detector manufacturers recommendations and or local laws rules regulations or customs WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING Do not install within 3 feet 0 9 m of a heat pump or an outdoor condensing unit Strong air intake from this type of equipment can disturb the combustion process and cause damage or personal injury WARNING The heater shall not be located in an area where water sprinklers or other devices may cause water to spray through the cabinet louvers and into the heater This could cause internal rusting or damage electrical components and void the warran ly WATER CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your water chemistry according to Table A If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and damaging the heater If the pH drops below 7 2 this will cause corrosion of the heat exchanger and severely dama
33. e heater to a remote system identify whether it is a two or three wire remote system Select the appropriate instruction listed below to prop erly install the remote to the heater OFF Mode Heating in the POOL Mode Pool Common BLK ORN Spa Common _ 24VAC HOT BLU 7 PIN Remote Interface Harness REMOTE OPERATION The AFT model heaters are equipped with the ability to work with external remote controls The supplied 7 pin remote wiring connector supplies power out to either a toggle switch or the switch contacts of a third party remote The remote works by either making or breaking the circuit created by the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is supplying its own voltage to the heater it will not work with this heater and may damage the digital circuit board For operation of the heater using the onboard thermo static controls with a time clock see the Time Clock Fireman s Switch section Remote Mode Heating in the SPA Mode ACTIVATING THE REMOTE To activate or deactivate the remote function follow these steps Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds The second line of the dis play will alternate even when the unit is off No Demand MENU SET NOTE When in remote operation the keypad mode and temp buttons are disa
34. e rapid corrosion to the heat exchanger Such damage is not covered under the warranty Recommended Level s Fiberglass Pools Fiberglass Spas Other ee Spa Water Temperature 7 3 7 4 68 88 F 20 31 C 89 104 F 31 40 C 68 104 F 20 40 C 7 3 7 4 7 6 7 8 Total Alkalinity ppm 120 150 120 150 80 120 ET f _ Free Chlorine MUST 5 ppm In salt water chlorinated pools the total TDS can be as high as 6000 ppm 200 400 4500 Maximum 3000 Maximum Table A Water Chemistry Filter Check Valve Skimmer Spa i Heater QO 1 Auto Chlorinator a pu Gmg mn E 108 of Seth 2 Check Valve M Return to Spa Fig 1 Spa Chlorinator Setup SAFETY This appliance is to be installed and operated by trained personnel in accordance with this Installation and Operation Manual Be sure to read and under stand the entire Installation and Operation Manual before attempting to install or operate this appliance Failure to follow the warnings listed at the beginning of this manual could result in a fire or explosion causing property damage bodily injury or death Should you have any problems understanding the warnings and instructions in this manual STOP and get help from a qualified installer service technician or the gas supplier Water Temperature Safety Elevated water temperature can be hazardous T
35. elow replace Circuit Board Heating will display briefly Temp Degrees C 4 4 10 15 6 Resistance 261 1199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Water Sw Open Pressure switch Verify water flow and pressure CLEAN FILTER STRAINER backwash if neccessary Hi Limit 1 Fault High limit switch Verify water flow Inspect internal Hi Limit 2 Fault Thermostat Unitherm Governor and bypass valve Rollout Sw Open Rollout Sensor Check for blocked heat exchanger and soot Atmospheric Units Replace fusible link Flame icon displayed Lo NOx Units Press manual reset button and flashing Clock Fireman Sw Fireman or Remote switch connected to safety loop is in the OR OFF mode Water temp displayed Vent Field Sw 1 Vent switch open Check connections to the board pilot lit and rectified If extractor installed troubleshoot extractor Ignition Lockout Ignition lockout Check power at pilot valve Check spark bad ignition circuit or hi tension wire Verify clean pilot orifice and clearance from igniter to ground hood Ignition Failure Ignition failure Verify gas to the heater Verify valve operation gas present at tube fitting H Fired Verify power at MV on P 4 Terminal on digital circuit board eater rire Verify power to valve MV voltage Replace valve 33 ANALOG CONTROL LOGIC FLOW CHART START Turn knob to a desired temperature zone J L The ho
36. er performs its own safety check and opens the main valve only after the pilot is proven to be lit Flame Roll Out Safety Switch Fig 24 Flame Roll Out Safety Switch 28 Heaters are equipped with a thermal cutoff device to prevent flame roll out in the event the heat exchanger becomes blocked This is a single use type fusible link or thermal fuse that must be replaced when dis abled by an over temperature condition caused by excessive restriction in the heat exchanger flue pas sage roll out high winds etc High Limits The heater is equipped with two automatic high limits Both are located in the In Out header Both are set to open at 135 F 57 C NOTE An erratic high limit is often characteristic of an internal heat exchanger problem e g scale build up defective bypass Refer to Troubleshooting section High Limit Removal Fig 25 High Limit Switch Shut off main electrical power switch to heater 2 Remove rear In Out inspection panel 3 Remove defective high limit and replace with a new high limit 4 Replace inspection panel PILOT PLACEMENT BRACKET BURNER TRAY PANEL Fig 26 Burner Tray Assembly Burner Tray 1 Shut off main electrical power switch to heater 2 Shutoff gas upstream of heater 3 Remove front door 4 Disconnect gas line from gas valve 5 Remove 3 screws holding the anti rotation brack et in place 6 Remove bracket an set aside 7
37. es instructions pour une installation appropri e INTRODUCTION Ratings amp Certifications This pool amp spa heater chauffe piscine is design cer tified and tested under the latest requirements of ANSI 221 56 CSA 4 7 Standard for Gas Fired Pool Heaters Chauffe Piscines The heater can be used either indoors or outdoors Installer l int rieur ou l ex t rieur If necessary the top of the heater can be changed after installation to accommodate indoors or outdoors WARNING Use of any parts not manufactured and or approved by manufacturer may cause non warrantable damage Ambient Temperature Rating of Components Analog heater 40 F to 175 F 40 C to 79 4 C Electronic heater 32 F to 175 F 35 5 C to 79 4 C Model Identification The model identification number and heater serial number are found on the heater rating plate Fig 2 Location of Heater Rating Plate The model identification number will be similar to the example shown below P R 106 A E N C Plastic Header n o C Copper M Rheem D Ruud N Natural Model No P Propane Model Rev E Electronic A Analog Specifications Shipping Weight Model e Std No Heater w Drafthood NPT Stackless Assembly Top 105 000 BTU hr 30 75 KW 1 1 2 in or 2 in 3 8cm 150 000 or 5 BTU hr cm 43 93 KW 100 Ibs 45 4 kg
38. ferred to make connection to the load pump side of the time clock WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing CAUTION Label all wires prior to disconnection when servicing controls wiring errors can cause improper and dangerous operation Installation Instructions 240 Volt CAUTION This heater has provisions to be connected to an alternate supply source To reduce the risk of electric shock disconnect all connections before servicing Disconnect the 120V power cord from power source 2 Remove knurled screw from the lower front panel 3 Remove the front panel and set aside 4 Remove the two stainless screws holding the con trol panel in place 5 Lower the control panel and then sway it forward The 120V wiring should be visible next to the transformer 6 Disconnect and remove the 120V power cord from the heater 7 Bring the 240V supply line into the control box 8 Install a wire nut on the white transformer wire See Fig 16 9 Wire nut the 240V supply lines to the red and black wires on the transformer See Fig 16 240V HOOK UP BLACK L2 HEATER WHITE Fig 16 240V Hook Up Wire nut the supply ground line to the green trans former wire See Fig 16 Reposition the control panel back in place and re install the two screws Re install front panel and knurled screw OWNER S OPERAT
39. for this heater The maxi mum pressure relief valve setting is 125 psi 862 kPa This relief valve needs to be installed on the outlet pipe from the header as noted in Fig 14 below PIPE ONTO DISCHARGE SIDE OF PIPING D ce ee gt D CG c C GE ED D 2 D D D ED C D cA D ED gt Fig 14 Pressure Relief Valve Installed If required this needs to be installed in a field supplied fitting external to the heater The valve shall be installed in a vertical position Do not over tighten Install the pressure relief valve hand tight plus 1 2 turn WARNING avoid water damage or scalding due to relief valve operation drain pipe must be connected to valve outlet and run to a safe place of discharge Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve No shut off valve shall be installed between the relief valve and the drain line The valve lever should be tripped at least once a year to ensure that waterways are clear If the relief valve does not f
40. ge the heater Heat exchanger damage resulting from chemical imbal ance is not covered by the warranty For your health and the protection of your pool equip ment it is essential that your water be chemically balanced The following levels must be used as a guide for balanced water CAUTION Free chlorine must not exceed 5 ppm which can damage the heater and is not covered under warranty e Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced e Automatic chemical dosing devices and salt chlo rinators are usually more efficient in heated water unless controlled they can lead to excessive chlo rine level which can damage your heater e Further advice should be obtained from your pool or spa builder accredited pool shop or chemical supplier for the correct levels for your water Automatic Chlorinators amp Chemical Feeders All chemicals must be introduced and completely dilut ed into the pool or spa water before being circulated through the heater Do not place sanitizing chemi cals in the skimmer High chemical concentrations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the pump is shut off See Fig 1 NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will caus
41. hanger Under sized heater Filter not running long enough BUE Gas line or meter undersized Gveracidec ecc Heater running after pump shuts off Refractory Sooted heater ER acer Indicates symptom which usually occurs on initial start up 32 SOLUTION Check movement by putting in hot water 110 F 43 3 C or higher If no movement replace Locate the restriction and remove Flush system and clean Remove debris or blow out gas line Scale forming in heat exchanger clean heat exchanger and check pool pH and total alkalinity Clean or replace filter Raise water level Adjust bypass Adjust pressure switch See Water Chemistry on page 5 Inspect bypass for movement if no movement replace Replace if no movement when heated Reduce by adding manual bypass valve Adjust manual bypass valve until heater outlet water temperature is between 105 F and 110 F 40 5 C and 43 3 C Check movement by putting in hot water 110 F 43 3 C or higher If no movement replace Refer to installation instructions Follow recommended installation instructions Clean burners Adjust gas pressure Clean pilot and or electrode Replace pilot Adjust gas pressure Clean burners Replace refractory panels Determine cause of sooting amp cor
42. he U S Consumer Product Safety Commission has these guidelines 1 Spa water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is considered safe for a healthy adult Special cau tion is suggested for young children 2 Drinking of alcoholic beverages before or during spa or hot tub use may cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant Women Beware Soaking in water over 102 F 39 C may cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 F 2 2 C 5 Persons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain a physician s advice before using spas or hot tubs 6 Persons taking medications which induce drowsi ness such as tranquilizers antihistamines anticoagulants or recreational drugs should not use spas or hot tubs AVERTISSEMENT La U S Consumer Product Safety Commission indique que des temp ratures de l eau lev es deuvent tre dangereuses Voir la notice d installation et de fonctionnement pour le r glage de lat temp rature Suivre l
43. ion assumes that only one heating function pool or spa is required 1 Turn on power to the heater 2 For a 2 Wire Remote Control from a remote without its own sensor push the MENU SET button to the POOL or SPA mode and set the desired setpoint eg 102 F 39 C for Spa 3 For a 2 Wire Remote Control from a remote with its own sensor push the MENU SET button POOL or SPA mode and set the temperature to the highest setting available on the control The actual setpoint will be controlled by the remote control 4 Turn the MENU SET button to OFF and remove power from the heater 5 Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and con nect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wire to the Remote Interface Harness 7 Install the 7 Pin Remote Interface Harness to the P8 connector and turn power On to the heater To activate the remote control see page 23 3 Wire Remote Control Using Three Position Switch Pool Off Spa or Low Off High This application assumes that both heating functions pool and spa are required 1 Turn on power to the heater 2 Push the menu set button to the POOL or SPA mode and set the desired temperature for each 80 F 27 C for Pool and 102 F 39 C for Spa 3 Turn the MENU SET button to OFF and remove power from the heater
44. ions of the pump and filter Bypass DUX JN Bypass Body Fig 12 Internal Automatic Bypass Valve External Auxiliary Bypass Valve An auxiliary bypass valve must be used when flow rates exceed 70 GPM 265 LPM Usually a high per formance pump size larger than one horsepower will exceed this flow rate This valve is required to comple ment the function of the automatic bypass valve particularly when starting the heater in winter or early spring when the spa or pool temperature is below 50 F 10 C It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets etc To Heater t From Heater Full Port Ball Valve or Globe Valve From Pool Spa To Pool Spa Bypass Valve Fig 13 Auxiliary Bypass Valve 16 NOTE Do not use a gate valve as bypass valve Auxiliary Bypass Valve Adjustment To set bypass With clean filter adjustment is made by feeling the inlet and outlet pipes at the heater Outlet pipes should be slightly warmer than inlet and comfort able to the touch If pipe is hot close bypass if cold open bypass Pressure Relief Valve Installation To conform to local building codes it may be neces sary to install a pressure relief valve A 3 4 1 9 cm pressure relief valve having a capacity equal to or greater than the BTUH input of the heater to be installed is recommended
45. lt and proceeds through ten most recent messages in chronological order The second line of the display shows the fault message If there are no faults in the history buffer the second line reads All Faults Clear FAULT HISTORY Program Button 1 Remove the two screws holding the control cover and swing the panel down so the back side of the board is visible see page 19 Locate the Program Mode button marked as SW1 as shown on page 19 Press and hold the button 5 7 seconds until Set Factory Defaults appears on the display Release the program button 2 Press the MENU SET button sequentially until the desired program event is reached There are 5 dif ferent events that can be programmed They appear in the sequence listed below Resets board to factory default settings Resets faults in the History File Change from Fahrenheit to Celsius SPA setpoint maximum adjustment POOL setpoint maximum adjustment Set Factory Defaults Refer to step one above to access the program screen Set Factory Defaults should appear on the screen If it does not press the MENU SET button until Set Factory Defaults appears on the digital display Press and hold both UP and DOWN buttons for 5 7 seconds until Defaults Set appears This operation resets the operating program to its factory default val ues Both the POOL and SPA setpoints will revert to 65 F 18 5 C and both POOL and SPA maximum temperature settings will
46. m cabinet 2 Remove burner tray 3 Remove heat exchanger from the heater and wash with a garden hose making sure soot is removed from spaces between fins 4 Reverse above procedure to reinstall NOTE In extreme cases it may be necessary to do high pressure cleaning at a local car wash DO NOT WIRE BRUSH Replacement Parts NOTE When ordering parts it is important that the heater model number serial number and type of gas are specified Any part returned for replacement under standard company warranties must be properly tagged with a return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty a like part or equal substitution will be returned freight collect Credit will not be issued MANUFACTURER 2151 EASTMAN AVENUE OXNARD CA 93030 SSS MW Extension Pieces 2 Auger with Carbide Tip Wire Brush Fig 30 Tube Cleaning Kit 31 TROUBLESHOOTING Mechanical IMPORTANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the installation of this type of heating equipment and related system components Installation and service personnel may be required by some states to be licensed Persons not qualified shall not attempt to install this equipment nor attempt repairs according to
47. me circuit breaker may have tripped Check and reset if necessary Turn switch on After six 6 seconds does the pilot spark Is there power to the heater Verify that the time clock is in the ON position Check to see if the pump strainer basket is full Remove debris if necessary Check to see if the filter is dirty If it is backwash or clean the filter The pump may have lost its prime and be running dry Check the pressure on the filter If there is no pressure then there is not enough moving water in the system or the gauge is broken Attempt to make the pump run at its normal flow rate ee The setpoint may be lower than the actual temperature Turn the knob counterclockwise to raise it Check the high limits Both are normally closed Check the rollout switch must be normally closed Check the wiring in the control box against the wiring diagram Ensure that the heater is OFF Attempt each of the following steps individually and manually restart the heater after each attempt Check the gas line for air in the system Ensure that the high tension wire is not grounding out to metal Is the pilot lit or to other voltage wiring Verify that the high tension wire is properly connected to the ignition module Check the gas valve There must be 24VAC between PV and MV PV Do the burners light Check the gas valve There must be 24VAC J ves D between PV and MV PV X LM
48. nspection Cold Weather Operation MAINTENANCE SERVICE Water Pressure Switch Flame Roll Out Safety Switch High Limits Burner Tray Removal Gas Valve Removal Pilot Removal amp Cleaning Heat Exchanger Removal Tube Cleaning Procedure De sooting Procedure Replacement Parts TROUBLESHOOTING Mechanical Electronic Control Logic Flowchart Analog Control Logic Flowchart ILLUSTRATED PARTS LIST WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause CAUTION minor personal injury or product or property damage if ignored Indicates special instructions on installation operation or maintenance which NOTE M are important but not related to personal injury hazards DANGER Failure to install the drafthood on indoor installation and properly vent the heater to outdoors as outlined in the venting section of this manual can result in unsafe operation of the heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this heater unless it is properly vented and has an adequate air supply for proper operation Be sure to inspect the vent system for proper inst
49. nstalled under an overhang of less than 3 ft 0 9m from the top of the heater Three sides must be open in the area under the overhang Roof water drainage must be diverted away from heaters installed under overhangs with the use of gut ters Ne pas installer ce chauffe piscine sous une saillie mesurant moins de 3 pi de hauteur La partie sous la saillie doit etre ouverte sur 3 c tes For U S installations the point from where the flue products exit the heater must be a minimum of 4 ft 1 2m below 4 ft 1 2m horizontally from or 1 ft 0 3m above any door window or gravity inlet into any building The top surface of the heater shall be at least 3 ft 0 9m above any forced air inlet or intake ducts located within 10 ft 3m horizontally See Fig 5 e For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 ft 3m below or to either side of any opening into the building Refer to the latest revisions of CAN CSA B149 The heater must be raised 7 in 0 2m above the surface which could support snow ice or debris Refer to the latest revisions of CAN1 2 21 M85 3 00 TYP Fig 3 Overall Dimensions Outdoor Stack NOTE The outdoor stack is optional equipment and does not come standard with the heater Use part number 014718 for the 106 and 014719 for the 156 High Wind Conditions Outdoor Units Only In areas where high winds are frequent it may be
50. on this y compris pr s du plancher pour d celer une odeur de gaz Si vous sentez une odeur de gaz label If you don t smell gas go to the next step ARRETEZ Passez l tape des instructions de s curit sur la portion sup rieure de cette tiquette T Turn gas control knob counter clockwise to ON S il n y a pas d odeur de gaz passez l tape suivante 8 Turn on all electric power to the appliance cas contro T Tourner le bouton de commande de gaz dans le sens antihoraire y la position Marche ON 9 Set thermostat to desired setting ON POSTON By m 8 Mettez l appareil sous tension 10 If the appliance will not operate follow the caz monte one CR 9 R glez le thermostat la temp rature d sir e Pe 10 Si l appareil ne se met pas en marche suivez les instructions intitul es Comment couper CO instructions To Turn Off Gas To Appliance l admission de gaz de l appareil et appelez un technicien qualifi ou le fournisseur de gaz COMMENT COUPER L ADMISSION DE GAZ L APPAREIL 1 Setthe thermostat to the lowest setting 1 R glez le thermostat la temp rature la plus basse 2 Turn off all electrical power to the appliance if service is to be performed 2 Coupez l alimentation lectrique de l appareil s il faut proc der l entretien 3 Turn gas control knob clockwise w to OFF 3 Tournez le bouton de commande de gaz dans le sens horaire la position Arret
51. r propane tanks like those used with con sumer barbecues to supply gas to this heater CAUTION The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test do not use open flame GAS INLET HEATER JACKET MANUAL SHUT OFF VALVE field supplied GAS VALVE field supplied SEDIMENT TRAP field supplied Fig 7 Gas Line Sediment Trap NOTE Do not use Teflon tape on gas line pipe thread A flexible pipe sealant suitable for LP gases is recommended Gas Pressure Regulator The gas pressure regulator is preset at 4 0 in W C 1 0kPa for natural gas and 10 0 in W C 2 5kPa for propane gas If adjustment is needed remove plug and turn adjust ment screw clockwise to increase pressure or counter clockwise to decrease pressure Pressure Natural Gas Propane Gas Max Inlet 10 5 in WC 13 in WC static 2 6 kPa 3 2 kPa Min Inlet 5 in WC 11 in WC dynamic 1 2 2 7 Manifold Gas 4 in WC 10 in WC dynamic 1 0 2 5 Static means without heater operating dynamic refers to heater operating Table F Gas Pressure Gas Pressure Adjustment Locations Gas Pressure Adjustment Under plug shown
52. rect Calculate heating capacity of heater Htr output BT UH Pool gallonage x 8 33 or refer to heater sizing chart This does not take into account heat loss due to weather Reset time clock Clean filter Refer to installation instructions Replace well and maintain proper water chemistry Replace heat exchanger and maintain proper water chemistry See Pressure Switch Adjustment Replace refractory Determine cause of sooting and correct ELECTRONIC CONTROL LOGIC FLOW CHART Is the water Check On Off switch under lid on control panel temperature displayed Check for 120 240 volts to the transformer time clock circuit breaker wire connections Check for 24 volts to Circuit Board P6 connector Push MODE Remote and Water Temperature displayed switch to select a remote control is controlling the heater Pool or Spa Note Disconnect the remote by turning the remote function off See page 36 for instructions Push Temp arrow to scroll to desired temperature Water temperature and set temperature displayed Is a fault code displayed and flashing Diagnostic Readouts 5 66 Sensor Failure Sensor Open or Sensor Short Temperature sensor out of range replace sensor Sensor Failure Inspect thermister wires and connector at Terminal P1 Check resistance value of the thermister Reference to chart below Replace thermister if not within 1096 of values shown b
53. s provided with the Indoor Drafthood Kit for installation This drafthood must be installed without alteration see rating plate Ce coupe tirage doit tre install sans modification Voir la plaque signal tique Combustion amp Ventilation Air Indoor Units Only The heater must have both combustion and ventilation air Minimum requirements for net free air supply openings are one opening that is 12 inches 30 5 cm from the ceiling for ventilation and one opening that is 12 inches 30 5 cm from the floor for combustion air as outlined in the latest edition of the National Fuel Gas Code ANSI 2223 1 Canada CAN CSA B149 and any local codes that may have jurisdiction CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty Do not store chlorine bromine baquasil or acid in the same room as the heater e All Air from inside the building each opening shall have a minimum net free area as noted in Table E Table Minimum Area e All air from outdoors when air is supplied directly from outside the building each opening shall have a minimum net free area as noted in Table D Vent Piping Vent piping the same size as the drafthood outlet is recommended however when the total vent height is at least 10 ft 3m drafthood relief opening to vent ter minal the vent pipe size may be reduced as specified in the National Fuel Gas Code
54. ter Immediately call a D N utilisez pas cet appareil s il a t plong dans l eau m me partiellement qualified service technician to inspect the appliance and to replace any part of the Faites inspecter l appareil par un technicien qualifi et remplacez toute partie control system and any gas control which has been under water du syst me de contr le et toute commande qui ont t plong s dans l eau INSTRUCTIONS DE MISE EN MARCHE 1 STOP Read the safety information above on this label 1 ARRETEZ Lisez les instructions de s curit sur la portion sup rieure de cette tiquette 2 Set the thermostat to the lowest setting 2 Reglez le thermostat a la temp rature la plus basse 3 Turn off all electric power to the appliance 3 Coupez l alimentation lectrique de l appariel 4 This appliance is equipped with an ignition device which automatically lights 4 Cet appareil est muni d un dispositif d allumage qui allume automatiquement la veilleuse Ne the pilot Do NOT try to light the pilot by hand tentez pas d allumer la veilleuse manuellement 5 Turn gas control knob clockwise to OFF 5 Tournez le bouton de la vanne de gaz dans le sens horaire x la position Arret OFF 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the 6 Attendre cinq 5 minutes pour laisser chapper tout le gaz Reniflez tout autour de l appareil floor If you smell gas STOP Follow B in the safety information above
55. th water temperatures below 50 F 10 C operate the heater continuously until higher tempera tures are reached Operating the heater for prolonged periods with pool water below 50 F 10 C can seri ously damage the heater and is not covered by the warranty For cold climate areas please follow the winterizing procedures listed in the next section Winterizing the Pool Spa Heater chauffe piscine Heaters installed outdoors in freezing climate areas may be shut down for the winter Observe the follow ing procedure for winterizing the heater Turn off gas valve manual gas valve and electri cal supply to the heater 2 Open drain plug located on the In Out header under the water pipes 3 Remove the 2 wires from the water pressure switch and unscrew the water pressure switch to break any vacuum in the system Remove the pressure switch and dry it before re installing Excessive moisture in the pressure switch may freeze damaging the switch l Drain m Fig 22 In Out Header Drain Plug Location MAINTENANCE The following preventative maintenance is to be per formed one month after start up and semi annually thereafter 1 Inspect top of heater and drafthood for soot a sticky black substance around finned tubes and V baffles and open flue gas passageways Any visible soot should be cleaned for proper opera tion See the De sooting Procedure in the Service Section 2 Cle
56. the 8 top jacket holding screws Remove the jacket top 3 Remove screws holding down collec tor Remove collector 4 Remove upper in out access panel 5 Disconnect all electrical wiring from in out header 6 Remove temperature sensor from in out header 7 Disconnect flange nuts on In Out header 8 Lift heat exchanger straight up using caution not to damage refractory 9 Reverse above procedure to reinstall Tube Cleaning Procedure Establish a regular inspection schedule the frequency depending on the local water conditions and the sever ity of service Do not let the tubes clog up solidly NOTE Please remove heat exchanger from heater prior to reaming or removing debris Clean out deposits over 1 16 0 16cm in thickness Use the Tube Cleaning Kit 052871F to ream the tubes as necessary After reaming mount the wire brush in place of the auger and clean out debris remaining in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhib ited de scale solvent for severe scale build up De sooting Procedure CAUTION Soot may be combustible Wet sooted surfaces completely prior to cleaning Do not use steel wire brush Soot will clog areas between fins and cause eventual tube failure Any sign of soot at the base of the burn ers or around the outer jacket indicates a need for cleaning 1 Remove top and flue collector fro
57. tion adjustment alteration service or maintenance may damage the equip ment create a hazard resulting in asphyxiation explosion or fire and will void the warranty FLORIDA BUILDING CODE 2010 TIE DOWN METHOD ULTIMATE WIND SPEED 170 MPH 3 SECOND GUST NOMINAL WIND SPEED 132 MPH EXPOSURE D GAS HEATER MODELS 106 amp 156 1 1 4 x 2 1 4 5 5 CONC SCREW 8 FLAT WASHER WHERE SHOWN 4 TOTAL TOP VIEW 1 1 4 x 2 1 4 5 5 CONC SCREW 8 FLAT WASHER WHERE SHOWN 4 TOTAL MIN EDGE DISTANCE TYP MIN EDGE DISTANCE l TYP 2 END VIEW SIDE VIEW Installation Codes Installations must be in accordance with local state provincial and national codes laws regulations and ordinances In the absence of local codes installations must be in accordance with the latest editions of the National Fuel Gas Code ANSI 2223 1 54 National Electrical Code ANSI NFPA 70 For Canada only CAN CSA B149 Installation Code 149 and CSA 22 1 C E C Part 1 and 2 AVERTISSEMENT Cet appareil doit tre install conform ment au National Fuel gas Code ANSI 2223 1 et aux exigences de l autorit competente NOTE The heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the heater or to the structure When such locations cannot be avoided
58. unction properly replace it immediately Heat Exchanger Pressure Drop Table Flow GPM Pressure Drop ft of Head Table I Pressure Drop Electrical Connections Be sure that electrical service to the heater has prop er overload fuse or circuit breaker protection wire size and connections which comply with all applicable codes If any of the original wire as supplied with the appli ance must be replaced it must be replaced with type 302 F 150 C wire or its equivalent Si un des fils original fourni avec l appareil doit tre remplac utilisez un fil 302 F 150 C ou l quivalent The heater comes standard with a 120 VAC 3 prong power cord For 240 VAC applications see figure 16 Power source must be a wired ground with ground fault circuit interruption circuitry Fig 15 Electronic Heater Power ATTENTION Au moment de l entretien des commandes tiquetez tous les fils avant de les debrancher Des erreurs de cablage peuvent un fonctionnement inad quat et entrainer dangereux The heater must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 Canada Canadian Electrical Code CSA C22 1 Part 1 and Part 2 NOTE Input power to the heater 120 VAC can be supplied from the load pump side of time clock or directly from the GFCI power source It is pre
59. ur ne pas vous servir des t l phones se trouvant dans la b timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivre les instruc tions du fournisseur Si vous ne pouvez rejoindere le fournisseur appelez le service es incendies L installation et l entretien doivent tre assur s par un installeur qualifi ou par le fournisseur de gaz This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference CATALOG NO 6100 62C Replaces 12 18 13 P N 241519 Rev 4 Rev 4 reflects the following Changes to Program Button on page 20 Illustrated Parts List on page 35 38 Additions None Deletions None WARNINGS Pay Attention to These Terms WATER CHEMISTRY Automatic Chlorinators amp Chemical Feeders SAFETY Water Temperature Safety INTRODUCTION Ratings amp Certifications Model Identification Specifications Unpacking INSTALLATION Installation Codes Installation Codes Clearances Base Installation Outdoor Installation Indoor Installation Combustion amp Ventilation Air Gas Connections Water Connections Electrical Connections OWNER S OPERATING INSTRUCTIONS Control Adjustments Analog Control Adjustments Digital CONTENTS an A 091 OM Thermostat Operation Advanced Flame Technology AFT Board Status and Diagnostics Remote Control Installation Wiring Diagrams Post Start Up I
60. y Water pressure switch open Open Vent Field Vent spill switch field switch 1 Sw 1 open Hi Limit 1 T High limit 1 open Hi Limit 2 High limit 2 open SW Rollout switch open Open Flow Field Field supplied flow switch field SW 2 switch 2 open Alternating with pilot sensed Pilot flame not estab lished within the required time 15 sec or 90 sec Alternating with Main Ign Failure Pilot flame lost during the 8 second trial to ignite the main burner Ignition Lockout Propane Tab Broken Ignition Failure Propane Tab Not Broken Alternating with No pilot sensed Pilot flame not estab lished within 90 seconds Alternating with Main Ign Failure Pilot flame lost 4 times within the 8 second trial to ignite the main burner Heater will lockout for 6 minutes before retrying Ign 6min Delay Propane Tab Not Broken REMOTE CONTROL INSTALLATION AND OPERATION CAUTION Before installing remote controls to the AFT thermostat model heaters read the following The digital thermostat model is remote ready in most cases The digital liquid crystal display LCD shows the actual pool temperature operating status and service codes See examples below The touch pad on the con trol panel allows you to select the desired pool or spa temperature It also indicates when a remote system is controlling the heater by displaying Remote in the display When connecting th
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