Raypak 055B Electric Heater User Manual
Contents
1. For 120 V input power to the unit connect the black wire to the L1 or hot leg of the power supply Connect the white wire to the L2 or neutral leg of the power supply Attach the wire nut to the red wire There should be no connection to the red wire for 120V operation 120 volt neutral L2 120 volt hot 11 Fig 9240 For 240 V input power to the unit connect the black wire to the L1 or hot leg of the power supply Connect the red wire to the L2 or second hot leg of the power supply Attach the wire nut to the white wire There should be no connection to the white wire for 240V operation White wire with nut attache d wire Black wire 240 volt 2 Hot 240 volt L1 Hot Fig 9241 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 C221 1 Part 1 and 2 NOTE Input power to the heater 120 240V should be supplied from the load Pump side of time clock or switch Connecting heater to continuous power source will allow Fail indications Service and pressure switch when pump is not operating WIRING DIAGRAM KEY PINK CONNECTOR BLUE CONNECTOR 43 E 1201 24 U 105 24 150 EK BLRCK NUT Fig 8096 IGNITION WIRING CROSS REFFERENCE 586 58600 Fig 52. VENTING CONNECTIONS VENT TERMINAL Outdoor SIEP 1 Remove the 4 screws which fasten jacket top to heater SIEP 2 Lower outdoor top onto unit lining up slots in outdoor top with screw holes in jacket top STEP 3 Reinstall 4 screws to secure jacket top and outdoor top to unit Outdoor Top Jacket Top Fig 8137 Locate and assemble as shown Secure with screws supplied in envelope inside carton Draft Hood Mounting Screws pad di Fig 4 8143 WARNING ndoor boilers require draft hood that must be connected to a vent pipe and properly vented to the outside Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning Vent piping the same size or larger than the draft hoodoutletis recommended however when the total vent height is at least ten 10 feet draft hood relief opening to vent terminal the vent pipe size may be reduced as specified in Chapter 10 of the latest edition of the National Fuel Gas Code ANSI Z 223 Canada CAN CGA B149 1 and B149 2 As much as possible avoid long horizontal runs of vent pipe and too many elbows If installation requires horizontalor or non vertical runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at notless than five foot intervals Plumbers tape criss crossed will serve to space both horizontal and
3. deg 61 70 77 88 95 104 ohms 25 SECTION 6 REPLACEMENT PARTS LIST If determined defective by the Company and within NOTE To supply the correct part it is important that Warranty the part will be returned in kind or equal you state the model number serial number and type of Substitution freight collect Credit will not be issued gas when applicable RAYPAK INC Any part returned for replacement under standard 31111 AGOURA ROAD company warranties must be properly tagged with WESTLAKE VILLAGE CA 91361 4699 RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Company Freight Prepaid For Canada RAYPAK CANADALTD 2805 SLOUGH STREET MISSISSAUGA ONTARIO L4T 1G2 26 j 8 H 1 C 7 eA 1 1 V 1 Fig 8133 0 Fig 8132 0 27 OUT DESCRIPTION BRONZE BURNER TRAY Burner Tray w Burners Sea Level 004688F Burner 301210 4 Burner Orifice Nat 52 Sea Level 35008 1 4 Burner Orifice Pro 62 Sea Level 350086 4 CONTROLS High Limit 135 F 600889B High Limit 140 F 600890B Thermostat Control MV Mechanical 003346F Thermostat Control MV Solid State 005391F PC Board 005089B Potentiometer 005087 Temperature Sensor 005088B Thermostat Control IID Solid State 005389F PC Board 005086B Potentiometer 005087B Temperature Sensor 005088B GAS VALVE Combin
4. F to 175 F Requires 120V or 240V power supply Rated inputs suitable for up to 2000 feet elevation For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level as high elevation reduces combustion performance For Canada reduce input 10 when installed at 2000 4500 foot elevation SECTION 3 INSTALLATION INSTRUCTIONS IMPORTANT NOTICE These instructions are intended for the use of qualified personnel only specifically trained and expe rienced in the installation of this type of heating equip ment and related system components Installation and service personnel may be required by some states to be licensed If your state is such be sure your contractor bears the appropriate license Persons not qualified shall not attempt to fix this equipment nor attempt repairs according to these instructions WARNING mproper installation adjustment altera tion service or maintenance may damage the equip ment create a hazard resulting in asphyxiation explo sion or fire and will void the warranty CODE REQUIREMENTS NOTE 7he heater should not be located in an area where possible water leakage will result in damage to the area adjacent to the appliance or to the structure When such locations cannot be avoided it is recom mended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Installation must be in accordance with local co
5. The outlet of the heater is plumbed to the return line to the spa The pump filter and heater are thus plumbed in series Plumbing from the heater back to the spa must not have any valves or restriction that could prevent flow when the pump is operating To do so will void the warranty Heater must be located so that any water leaks will not damage structure of adjacent area High temperature plastic pipe CPVC may be connected directly into the heater if local codes permit FLOW RATES PIPE SIZE 1 1 4 1 1 2 MIN GPM 20 MAX GPM 60 When flow rates exceed 60 GPM an external auxil lary bypass valve is required See External auxiliary bypass valve section for details COMPANION FLANGE CONNECTIONS The inlet outlet header flange accepts a 1 1 2 copper tube or 1 1 4 galvanized pipe as a slip connec tion directly into the manifold The flange is also threaded for 1 1 2 pipe thread 1 1 2 CPVC adapters when available can also be used DO NOT use petroleum base assembly fluids such as Petroleum Jelly or lubricating oil If assembly lube is required use a silicone base compound such as Amoral etc Fig 8118 0 12 CAUTION Neverinstall PVC directly in header flanges The initial connection must be made with a higher temperature material such as CPVC or Copper PVC may be utilized immediately after the initial connection AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be int
6. adjustment is made Adjustment Knob Heat Exchanger Height Pool or Spa Heat Exchanger Height Fig 4 8152 0s NOTE f heater is installed outside of the limits shown a flow switch must be used in place of the pressure switch when mounted and wired adjacent to the heater TWO SPEED PUMPS In some cases the flow on the low speed is insuf ficient to operate the heater This is apparent when the pressure switch cannot be further adjusted or if the heater makes banging noises these cases the pump must be run at high speed when heating the water CAUTION Do not operate the heater without the func tion of a properly adjusted pressure switch 18 FLAME ROLL OUT SAFETY SWITCH The heater is 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 Fig 9177 HIGH LIMITS The heater is equipped with two automatic high limits Set to operate at 135 F and 140 F NOTE An erratic high limit is often characteristic of internal heat exchanger problem i e scale buildup U G operation Refer to troubleshooting section Fig 8159 0s HIGH LIMIT REMOVAL 1 Disconnect top portion of unit See heat ex change removal procedure step 1 thru 7 a
7. proof of the effective date of warranty must be presented otherwise the effective date will be based upon ewe r4 date of manufacture plus THIRTY 30 Days This Warranty gives you specific legal rights and you may also have other rights which vary from state to state FFFA 222 2222 Name of Owner Name of Dealer FFF 2222 2222 a FFF Address Address 222 2222 Model No Serial No EP 54 FEF Date of Purchase res 4542 4444 RAYPAK INC 31111 Agoura Road Westlake Village CA 91361 818 889 1500 FAX 818 889 4522 Litho in U S A e RAYPAK CANADA LTD 2805 Slough Street Mississauga Ontario L4T 1G2 905 677 7999 FAX 905 677 8036 i 777 VAAEAAMAEAEKEAAAKAEIADJXAAAAAAAAASAAAAAEAAAKEAJSAEIAAAAAAAAAAAAAAAUAVAAAAMA IST HHY Certified Quality System www raypak com Raypak Inc 31111 Agoura Road Westlake Village CA91361 4699 818 889 1500 FAX 818 889 4522 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Raypak Australia Pty Ltd 7 Geddes St Mulgrave Victoria Australia 3170 6139 560 4944 FAX 6139 560 4974 Litho in U S A
8. switch should be checked and adjusted for proper operation by a quali fied service person at the time of installation and periodically checked thereafter Refer to pressure switch servicing instruction in Section 4 of this manual WARNING Operation of the heater without water circulation will cause rapid and severe damage to the heater SECTION 2 CAUTION Elevated water temperature can be hazardous and the U S Consumer Product Safety Commission recommends the following guidelines 1 Spa or hot tub water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is considered safe for a healthy adult opecial caution is suggested for young children 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subse quently result in drowning 3 Pregnant women beware Soaking in water over 102 F 39 C can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as four degrees Fahrenheit 2 2 C 5 Persons with a medical history of heart disease circulatory problems diabetes or blood pres sure problems should
9. up 21 Liming Bypassing too much water Inspect bypass for movement if no movement replace U G not functioning Replace if no movement when heated Leaking at well OVeracid Replace well and maintain water chemistry properly Leaking at heat exchanger He ete Replace heat exchanger and maintain chemistry properly Gasket brittle and leaking Heater running after pump overheated See pressure switch adjustment Refractory Replace refractory Sooted Determine cause of sooting and correct ELECTRICAL MILLIVOLT RAYPAK POOL OR SPA HEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION For qualified service personnel only Filter must be on with adequate water flow through heater Gas valve must be ON position Thermostat set higher than pool water temperature Jumpers are for temporary check only If left in place they could cause the heater to burn up Light pilot If pilot burner goes out If pilot burner when main burner lights does not light or when gas valve knob Jump across both TH is released Check gas supply gas wires on gas valves line size gas pressure Also check for insects If main burner fires If main burner does not remove jumper fire remove jumper Remove both TH or debris in pilot output wires from gas valve Jump across pressure switch termin
10. year to ensure that waterways are clear ELECTRICAL WIRING NOTE f it is necessary to replace any of the original wiring it must be replaced with 105 C wire or its equivalent except all black wire must be replaced with 150 C wire or its equivalent MILLIVOLT SYSTEM The Millivolt System Residential Heater 15 equipped with a self generating electrical system in which the electric current is provided by means of a pilot generator No external electrical connections are required ELECTRONIC INTERMITTENT IGNITION DEVICE SYSTEM IID NOTE When the electrical hookup to the heater requires both 24V 115V 240V each input voltage must be isolated in separate conduit The Electronic Intermittent Ignition Device auto matically lights the pilot and main burners upon a call for the heat The heater is supplied with a dual voltage transformer for 120 or 240V input power hookup NOTE D Propane Units Only Heater is equipped with an electronic ignition device with a 100 safety lockout feature If the heater fails to start or lockout Reset the ignition device by inter rupting the power to the heater for 60 seconds CAUTION f service replacement of the electronic ignition device is required Replace only with a 100 Safety lockout device with 90 second trial for pilot ignition Robertshaw Intermittent Ignition Device Fig 8085 Honeywell Intermittent Ignition Device Fig 8929 1
11. 11k at maximum setting replace circuit board Above 11k ohms replace potentiometer 0 ohms short circuit replace potentiometer SENSOR RESISTANCE AT VARIOUS TEMPERATURES tiger er e mo zz a e os ni deg 61 70 77 88 95 104 ohms 23 WARNING HIGH VOLTAGE 7 For qualified Technicians ONLY 7 LLL NOTE Some heaters be equipped with an ignition module that shuts off pilot gas if pilot fails to light To reset interrupt power to heater ELECTRICAL ELECTRONIC IGNITION IID SS Intermittent Pilot System TROUBLESHOOTING HONEYWELL 58600 f IN 22222222222222222222222222222222222222222222222222222222222 NOTE Before troubleshooting familiarize yourself with the start up and checkout TURN GAS SUPPLY OFF procedure TURN THERMOSTAT CONTROLLER TO CALL Check line voltage power low voltage transformer limit controller thermostat FOR HEAT controller and wiring POWER TO MODULE YES CROSS Pull ignition lead and check spark at module SPARK ACR IGNITER SENSOR GAP Spark YES YES Che
12. 6094 Thermostat Lock Cover 006492 VENTING Stackless Top Outdoor 003709 003722 CONVERSION KITS Gas Conversions Nat to Pro MV Units 004696B Pro to Nat MV Units 004697B Nat to Pro IID Units NA Pro to Nat IID Units NA Gas Conversions are to be done only by a qualified agency 29 22222252252252222222225222222222222222522222222222222252222222222 i i ia i RAYPAK ENT UU amp SPA HEATERS Fara an 4 4 4 GENERAL i Inc warrants that all parts of this product will be free from defects in materials and workmanship under normaluse service L 4 fora period of TWO YEARS FROM THE DATE OF ORIGINAL PURCHASE FOR A SINGLE FAMILY RESIDENCE ONE YEAR IF OTHER THAN FOR SINGLE FAMILY RESIDENCE USE Inaccordance with the terms of this warranty we willfurnishaRaypak a a replacementforany defective part or repair the part atour option The replacementor repair will be warranted foronlytheunexpired Parr c4 4 portion of the original warranty Labor costs for removal or reinstallation of parts are not covered by this warranty nor are shipping 22 2 2 41 Charges to or from Raypak s designated repair center This warranty does not cover rusting or corrosion on cabinet or burnersthat Kc c asc rrr does not affect heater s operation TA 5 WARRANTY CONDITIONS P eme This warranty applies only to the heater at its original plac
13. 86 58600 WIRING DIAGRAM MILLIVOLT UNITS WITH MECHANICAL THERMOSTAT Hi LIMIT HI LIMIT MANUAL THERMO de SWITCH SWITCH STAT THERMAL VALVE ALL WIRING IS BLACK PILOT GENERATOR Fig 1934e WIRING DIAGRAM MILLIVOLT UNITS WITH SOLID STATE THERMOSTAT EI MANUAL POT VALVE SHITCH HILIMIT HILIMT PRESS BK SWITCH TO FIREMAN S FIELD INSTALLED GENERATOR Fig 2246e 15 WIRING DIAGRAM 152178 Model 055 IID FACTORY WIRED FOR 240V AC BK L1 Y Q R L2 SOLID STATE THERMOSTAT POTENTIOMETER 120 240V DUAL VOLTAGE TRANS 30VA MANUAL SWITCH IGNITION PRESS THERMAL SWITCH HIGH JU TENSION ALTERNATE SOLID STATE THERMOSTAT POTENTIOMETER MANUAL SWITCH TEMP SENSOR TEMP SENSOR IGNITION TRANSFORMER HIGH LIMIT 16 SECTION 4 SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS HIGH LIMITS Located in the Inlet Outlet header Pressure Switch Burner amp Pilot Thermal Fuse CONTROLS ADJUSTMENTS REPLACEMENTS CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD make sure electrical power to the heater is disconnected to avoid potential serious injury of damage to components TEMPERA
14. CATALOG NO 6100 52 K Effective 3 01 00 Replaces 3 15 99 OPERATING AND INSTALLATION INSTRUCTIONS Models 055B VERSA SPA and HOT TUB HEATER WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier 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 This manual should be maintained in legible condition and kept adjacentto the heater or kept in a safe place for future reference Part No 240428 Contents PART ONE Owner s Operating Instructions SECTION 1 START UP PROCEDURES Before Start Up Lighting Instructions amp Shut Off Procedures manually lighted pilot MV Operating Instructions amp Shut Off Procedures automatically lighted pilot IID After Start Up SECTION 2 CAUTION SECTION 3 MAINTENANCE amp CARE PROCEDURES Pool amp Spa Water Chemistry Winterizing the Pool and Spa Heater PART TWO Installatio
15. M EQUIVALENT PIPE LENGTH Natural Gas 1000 BTU FT M 60 Specific Gravity 0 5 WC Pressure Drop Propane Gas 2500 BTU FT 1 53 Specific Gravity 0 5 WC Pressure Drop 1 2 3 4 MODEL N P N P 055B 90 200 200 250 GAS PRESSURE REGULATOR The gas pressure regulator is preset and sealed at 4 W C for natural gas and Il W C for propane gas Between the gas valve and the burners is 1 8 pipe plug The pressure at this point taken with a manome ter should be about 3 7 W C natural gas and 10 5 W C propane gas If an adjustment is needed remove seal and turn adjustment screw clockwise lt w to increase pressure or counter clockwise to decrease pressure 11 Gas Pressure Manual Shut Gas Valve 4 Gas Pressure Test at Gas Valve P Gas Pressure Test at Heater Fig 8149 05 ROBERTSHAW W C Adjustment Fig 8199 HONEYWELL VALVE MV amp IID W C Adjustment W C Adjustment Fig 8081 0 PLUMBING FOR WATER CONNECTIONS LOCATION The VERSA heater requires water flow and posi tive 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
16. TING INSTRUCTIONS STOP Read the safety information above Set the thermostat on the lowest setting Turn On Off switch to the Off position Remove heater door panel Push in gas control knob slightly and turn clock wise lt to Off OU I NOTE Knob cannot be turned from Pilot to Off unless knob is pushed in slightly Do not force ROBERTSHAW PILOT Wait 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Locate pilot mounted on the left side of the burner drawer For burner drawer location see location of control section page 18 Gas control knobs shown in Off position ET 10 HONEYWELL GAS VALVE MILLIVOLT Fig 48081 0 ROBERTSHAW GAS VALVE 11 12 MILLIVOLT 13 Fig 8199 1 Setthe thermostat to the lowest setting 4 2 Turn On Off switch to the Off position 3 Remove heater door panel 9 HONEYWELL PILOT Fig 8083 0 Fig 8084 0 Turn knob on gas control counter clockwise to Pilot Fusn in control knob all the way and hold in Immediately place flame to pilot to light Continue to hold control knob in for about 1 minute after the pilot is lighted release knob and it will pop back up Pilot should remain lighted If it goes out repeat steps 5 through 9 If knob does not pop up when released stop and immediately call your service technician or g
17. TURE CONTROLS The water temperature is controlled by the heater 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 turning 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 illustrated below is adjust able by loosening the set screw rotating the knobstop ring to the desired location and retightening the set screw 8 L 17 11 23 olid State Thermostat 84 Ignition Control Fig 8160 1s Typical Comfortable Typical Pool Comfortable Temperature Spa Range PRESSURE SWITCH The pressure switch or heater actuator insures that the heater operates only when the filter pump is in operation It is factory set at 1 75 PSI for deck level installations When the heater is located below the level of the spa or pool it may be necessary to reset the pressure switch to compensate for the no flow static head If it is necessary to reset the pressure switch we recommend that following procedure 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 steps above until proper
18. V supply correct as necessary TEMPERATURE 105 106 F Control ok RESISTANCE O OHMS SHORT CIRCUIT Check system for shorted wires or open circuits Replace sensor if necessary DON T MATCH Replace sensor Reconnect all leads and check out system If the pool spa hot tub water is too hot troubleshoot the system as follows Check voltage at 24 V terminals VOLTAGE BETWEEN 21 5 28 5 V Set control to max temperature After 2 3 cycles check water temperature TEMPERATURE ABOVE 108 F Disconnect sensor leads from circuit board Measure sensor resistance with ohmmeter RESISTANCE 1 14k OHMS Check water temperature estimate expected sensor resistance from chart below MATCH 1111 20 PERCENT Disconnect potentiometer leads from circuit board Measure resistance with ohmmeter If resistance 15 0 100 ohms at minimum setting 9k to 11k at maximum setting replace circuit board Above ohms replace potentiometer 0 ohms short circuit replace potentiometer Reconnect all leads and check out system VOLTAGE OUTSIDE RANGE 21 5 28 5 V Check transformer 120 V supply correct as Necessary TEMPERATURE 105 106 F Control ok RESISTANCE ABOVE 15k OHMS OPEN CIRCUIT OR SHORT CIRCUIT Fix loose or broken wires Replace sensor if necessary DON T MATCH Replace sensor Reconnect all leads and check out system SENSOR RESISTANCE AT VARIOUS TEMPERATURES 1
19. als If pilot burner remains lit Relight pilot If burner does not remain lit attach millivolt meter If main burner fires If main burner does not and read pilot output remove jumper fire remove jumper Problem is a wire or component short to Ifabove 500mV cabinet or low gas j Clean filter Jump across thermostat replace gas valve Check for adequate water flow from filter If pilot burner stays on If below 500mV check gas pressure Also check for insects or debris in the pilot burner Replace pressure switch If output is still low If main burner fires If main burner does replace pilot generator NOT fire remove jumper Replace thermostat np die n high limit and remove jumper Replace high limit that caused heater to fire 22 ELECTRICAL SOLID STATE THERMOSTAT MILLIVOLT If the pool spa hot tub water is too cold troubleshoot the system as follows Check voltage at and terminals Polarity is critical Check pilot generator correct as necessary Set control to max temperature After 2 3 cycles check water temperature TEMPERATURE BELOW 105 F TEMPERATURE 105 108 F Disconnect sensor leads from circuit board Control ok Measure sensor resistance with ohmmeter NOTE 108 F is the upper control limit RESISTANCE 1 14k OHMS RESISTANCE O OHMS SHORT CIRCUIT OR Check water temperature estimate expected OPEN CIRCUIT GREATER THAN 14 K sensor resistance from chart bel
20. as supplier If the pilot does not stay lit after several tries turn the gas control knob to Off and call your service technician or gas supplier Stand to the side of the heater and turn the gas control knob counter clockwise to Replace heater door panel Turn On Off switch to the On position Set thermostat to the desired setting TO TURN OFF GAS TO APPLIANCE Push the gas control knob slightly and turn clockwise to lt Off Do not force Replace heats panel CAUTION Propane gas is heavier than air and will settle on the ground Since propane can accumulate confined areas extra care should be exercised when lighting propane heaters hOPFRATING INSTRUCTIONS AND SHUT OFF PROCEDURES AUTOMATICALLY LIGHTED PILOTS ELECTRONIC IGNITION SYSTEMS A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to
21. ation Valve Nat MV 003898 Combination Valve Pro 003899 Combination Valve Nat IID 003900 Combination Valve Pro 004306F HEAT EXCHANGER Heat Exchanger Assy Complete 004694F Header Tubed Kit 004695F Baffle Kit 004715F Unitherm Governor 600885 U G Cap 400734 U G Spring 850247 Drain Valve 500719 Sensor Well 350336 Bulb Retainer clip 300203 U G Gasket 800276 Bypass Baffle 306079 Inlet Outlet Flange 002432F Flange Gasket 800013B MISCELLANEOUS COMPONENTS Pressure Switch 062237B Pressure Switch Tube Assy 003543F Thermostat Knob 006885F Knob Stop 006886F Dial Plate MV 900741 Dial Plate IID 900742 Transformer 10 Unit 005345F Toggle Switch 650595 Wire Harness MV 004010F Wire Harness 10 004011F Thermal Fuse 005899 altitudes above 2 000 feet above sea level consult the factory 28 OUT DESCRIPTION BRONZE PILOT Pilot Nat MV 600525B Pilot Pro MV 600575B Pilot Nat IID 002003F Pilot Pro IID 002064F Pilot Orifice Nat MV 003901F Pilot Orifice Pro MV 003902F Pilot Orifice Nat IID 003903F Pilot Orifice Pro IID 004308F Pilot Generator MV 600019B Ignition Control Nat 004817B Ignition Control IID Pro 004818B Pilot Mounting Bracket IID 004716F Pilot Mounting Bracket MV 004717F Pilot Tube 004078F Hi Tension Wire IID 002654B 1 R Refractory Block Kit 003544F SHEETMETAL Jacket Top 002525F Flue Collector 002530F Door Assy 004689F Upper Jacket Control Panel 003791F Wiring Box 30
22. ck ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures TURN GAS SUPPLY ON Check that all manual gas valves are open supply tubing and pressures are good PILOT BURNER LIGHTS and pilot burner orifice is not blocked YES Check electrical connections between module and pilot operator on gas control Check for 24 Vac across PV MV PV terminals on module If voltage is okay replace gas control if not replace module NOTE If S8600H goes into lockout reset system Lockout is used on L P G models SPARK STOPS WHEN Check continuity of ignition cable and ground wire PILOT IS LIT Clean flame rod YES Check electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If problem persists replace module Check for 24 Vac across MV MV PV terminals If no voltage replace module MAIN BURNER LIGHTS Check electrical connections between module and gas control If okay replace YES gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system SYSTEM RUNS UNTIL CALL FOR HEAT ENDS Check continuity of ignition cable and ground wire YES NOTE If ground is poor or erratic shutdowns may occ
23. d repair center Ifthe dealer for any reason is not available or write Raypak directly at the address 44 444 shown below Attention Warranty Service After such notification has been given Raypak has advised the location of its E designated repair center which may be the dealer bring or ship transportation prepaid the defective partfor replacementorrepair 2 4 5 FEEF FEEF FEEF to the designated repair center However Raypak reserves the right at all times to inspect the claimed defect and verify warranty ii coverage at its factory 2 74404 MISCELLANEOUS Nooneis authorized to make any other warranties on our behalf ANY IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR i 45444 FITNESS FORAPARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECI 94549 FIEDABOVE RAYPAK S SOLE LIABILITY WITH RESPECT TO ANY DEFECT SHALL AS SET FORTH INTHISWARRANTY 277 22224 ANDANY CLAIMS FORINCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING DAMAGE FROMWATERLEAKAGE ARE zai EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or a consequential damages so the above limitation or exclusion may not apply to you 2222 5 We Suggest you immediately complete the information below retain this Warranty Certificate in the event warranty service is needed Reasonable
24. des or inthe absence of local codes with the latest editions of the National Fuel Gas Code ANSI Z223 1 and the National Electrical Code ANSI NFPA 70 For Canada the latest edition of CAN CGA B 149 1 and B 149 2 BASE INSTALLATION Heater must be mounted on a level surface It can be installed on combustible flooring Heaters may not be installed on carpeting CLEARANCES WARNING The heater shall not be located in an area where water sprinklers or other devices may cause water to spray through the cabinet louvers and into the heater This could cause heavy internal rusting or damage some electrical components and this would void the warranty ALLHEATERS For clearances from combustible surfaces see chart below Clearances from Combustible construction Indoor Installation Drafthood 35 Vent 6 Back 2 Right Side 6 Left Side 6 Floor 0 Outdoor Installation Stackless Top unobstructed Back 2 Sides 6 Clearance from Top of Vent Terminal For servicing provide at least 24 in front of the heater for burner tray removal and at least 18 on the left side of the heater to inspect and delime the heat exchanger OUTDOOR HEATERS These heaters are design certified for outdoor installation when equipped with the approved top des ignated for outdoor use Heater with outdoor Top Fig 8139 WARNING Do not install within 3 feet of a Heat Pump or an outdoor condensi
25. e ofinstallation This warranty will be void if the heater is installed in violation Of applicable local codes and ordinances or if the rating plate or serial number is altered or removed FEFA 232224 WARRANTY EXCLUSION ue This warranty does not cover defects or malfunctions resulting from 2222 iz 6 s 1 Failure to properly install operate or maintain the heater in accordance with our printed instructions 2 Abuse alteration accident fire flood freeze and the like 3 Misuse or neglect including but not limited to freeze ups operating the heater with the cabinet door off having flow E F i restrictions or obstructions between the heater outlet and the spa or not maintaining a proper chemical balance iia pere PH level must be between 7 4 and 7 8 and total alkalinity between 100 and 150 PPM Total dissolved solids TDS pci cio ci must be no greater than 3000 PPM 4 Useofnon factory authorized accessories other components in conjunction with the heater 7 HOW MAKE CLAIM Immediately notify the dealer from whom the heater was purchased supplying model and serial numbers of the unit date of purchase FF anda description of the problem The dealer should then promptly contact Raypak about the warranty claim and for the location of farii Raypak s nearest designate
26. e to re install MAIN BURNER AND ORIFICE REMOVAL 1 Remove burner drawer See burner drawer re moval procedure 2 Remove screws and burner hold down bracket NOTE f the heat exchanger is sooted badly the burner hold down bracket and spacer can become distorted from direct flame impingement and this usu ally necessitates replacement of these parts 3 Lift burners from slotted spacers and slide from orifices Clean with a wire brush 4 Orifices usually do not need to be replaced To clean run either copper wire or wood toothpick through orifice Do not enlarge hole To remove orifice use a socket wrench and remove from manifold DO NOT overtighten when reinstalling PILOT REMOVAL AND CLEANING 1 Remove burner drawer See burner drawer re moval procedure Disconnect pilot tubing disconnect wires from gas valve Disconnect pilot bracket from burner shield Remove pilot from bracket Remove pilot orifice and air opening Honeywell MV unit only and clean with wire or small brush CAUTION DO NOT enlarge hole in pilot orifice Reverse above procedure to re install ei pa 19 Air Opening Orifice HONEYWELL PILOT Pilot Orifice Fig 8102 0s Fig 8045 1 ROBERTSHAW PILOT HEAT EXCHANGER REMOVAL 1 N Due 10 11 12 Shut water gas and electricity off close valves relieve pressure Drain heat exchanger Loosen and remove flan
27. ement the function of the automatic bypass valve particularly when start ing the heater in winter or early spring when the spa or pool temperature is down below 55 F It also serves to eliminate needless pressure drop through the heater and accompanying reduction in the flow rate to the spa jets etcetera From Heater To Heater 7 t To Pool From Pool Auxiliary Bypass Valve do not use gate valve Fig 8150 05 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 comfortable 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 necessary to install a pressure relief valve A 3 4 pressure relief valve having a capacity equal to BT U HR output of the model to be installed is recommended for this appliance Drain Pipe Drain Pipe Heater Outlet Heater Outlet Fig 8157 05 NOTE avoid water damage or scalding due to valve operation drain pipe must be connected to valve outlet and run to a Safe place of discharge Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve No shut off valve shall be installed between the relief valve and the drain line Valve lever should be tripped at least once a
28. follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier ee TURN OFF GAS TO APPLIANCE Set the thermostat at the lowest setting 2 Turn off all the electric power to the appliance if service is to be performed 3 Remove heater door panel 4 Pushin gas control knob slightly and turn clockwise to Off 5 Replace door panel AFTER START UP Feel the inlet and outlet pipes Outlet pipe should be only slightly warmer than the inlet It should not be hot WARNING Should overheating occur or the gas sup ply failto shut off turn off the manual gas control valve to the appliance VISUAL INSPECTION With the heater on remove the door and make a visual check of the pilot and burner The flame should be blue with a well defined pattern Fig 8144 0 MAIN BURNER FLAME PILOT BURNER FLAME A yellow or floating flame indicates restricted air Openings or incorrect orifice size Should this occur shut the heater off and contact your installer or gas supplier WATER PRESSURE SWITCH A water pressure switch is provided in the heater to shut off the burners in the event that water supply to the heater is interrupted It is very important to verify that the switch electrically opens and shuts off the gas valve when water flow to the heater is interrupted Otherwise rapid and severe damage will likely occur to the heater The water pressure
29. ge bolts Remove flange and inlet outlet pipes from the header Remove drain valve from rear header Remove outdoor stackless top or indoor stack top from unit Remove jacket top flue collector and baffle Remove upper front jacket panel and disconnect wires at toggle switch Remove capillary bulb from inlet outlet header Disconnect press switch tube from inlet outlet header Disconnect hi limit wire from thermostat and pres sure switch Lift heat exchanger straight up from combustion chamber using caution not to damage refractory Reverse above procedure to re install DESOOTING PROCEDURE CAUTION SOOT IS COMBUSTIBLE EXERCISE EXTREME CARE NEVER USE A WIRE BRUSH Soot can clog areas between fins and cause even tual tube failure Any sign of soot at the base of the burners or around the outer jacket indicates a need for cleaning 1 Disconnect top portion of unit changer removal procedure steps 1 through 6 See heat ex 2 Remove burner tray See burner tray removal procedure 3 Take a garden hose and wash heat exchanger making sure soot is removed completely from be tween fins Avoid excessive water against refrac tory NOTE n extreme cases it may be necessary to re move the heat exchanger completely for cleaning The simplest method is steam cleaning at the local car wash DO NOT WIRE BRUSH COMBUSTION CHAMBER REMOVAL 1 Remove heat exchanger See heat exchanger removal procedure Lift up a
30. he carton If the carton is damaged a note should be made on the Bill of Lading when signing for equipment Remove the heater from the carton and if it is damaged report the damage to the carrier immediately On occasion we ship some items loose Be sure that you receive the number of packages indicated on the Bill of Lading When ordering parts you must specify model and serial number of heater When ordering under warranty conditions you must also specify date of installation Raypak recommends that this manual be reviewed thoroughly before installing your Raypak pool spa heater If there are any questions that this manual does not answer please contact the factory or your local Raypakrepresentative SECTION 2 GENERAL SPECIFICATION These heaters are design certified and tested under the requirements of ANSI 221 56 5 4 7 American National Standard CSA standards for gas fired pool heaters The heater is interchangeable and can be used either indoor or outdoors The appropriate top designated for that type of use is required If desired the top can be changed at alater date to change from outdoor to indoor or vice versa Millivolt heaters contain a self generating electrical system operating between 25 and 75 volts AMBIENT TEMPERATURE RATING OF HEATER COM PONENTS Millivolt Heater with Honeywell Gas Valve 32 F to 175 F Millivolt Heater with Robertshaw Gas Valve O F to 175 F Electronic Ignition Heaters 32
31. in direct wind current INDOOR HEATERS The design is also certified for indoor installation when equipped with the approved draft hood For Canada indoor installation is restricted to an enclosure that is not occupied and does not directly communicate with occupied area Refer to the latest edition of CAN CGA B149 1 and 149 2 for specific requirements Locate heater as close as practical to a chimney or gas vent Heater must always be vented to the outside See VentPiping Section for venting details Minimum allowable space is shown on the nameplate Heater with Indoor Top Fig 8138 COMBUSTION AIR INDOOR UNITS ONLY Air For combustion And Ventilation Indoor Units Only The heater must have both combustion and venti lation air Minimum requirements for net free air supply openings one 12 inches from ceiling for ventilation and one 12 inches from the floor for combustion air as outlined in the latest edition ofthe National Fuel Gas Code 2223 1 149 1 B149 2 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 a All Air From Inside The Building Each opening shall have a minimum of 50 net free square inches b All Air From Outdoors When air is supplied directly from outside of building each opening shall have a minimum of 13 net free square inches
32. ing equipment and related system components Installation and service personnel may be required by some states to be licensed Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions MECHANICAL FOR QUALIFIED SERVICE PERSONNEL ONLY PROBLEM Harmonics or whining noise CAUSE U G inoperative Debris or restriction in system Debris in gas line LOW TOW diete moveat Heater going on and off continously Dirty filter oe Low water level in pool External bypass setting out of adjustment Pressure switch out of adjustment Liming or scale forming on 7 8 heat exchanger Sooting U G Inoperative starvation Improper venting Insects or debris clogging burner intake ports Pilot outage Low gas Restricted pilot Weak pilot generator Yellow lazy flame Low gas pressure Insects or debris clogging burner intake ports Outer jacket very hot paint blistered Broken refractory caused by shipping damage or improper combustion Excessive sooting of heat Takes long time to heat Calculate tempe
33. n Service Instructions SECTION 1 RECEIVING EQUIPMENT SECTION 2 GENERAL SPECIFICATIONS SECTION 3 INSTALLATION INSTRUCTIONS Code Requirements Base Installation Clearances Combustion Air Venting Connections Gas Supply Connections Plumbing for Water Connections Electrical Wiring SECTION 4 SERVICING INSTRUCTIONS General Location of Controls Control Adjustments Replacements Pressure Switch Flame Roll Out Safety Switch High Limit High Limit Removal Pilot Safety Burner Drawer Removal Gas Valve Main Burner amp Orifice Pilot Removal amp Cleaning Heat Exchanger Removal Desooting Procedure Combustion Chamber Removal Control Immersion Well Replacement Unitherm Governor Replacement SECTION 5 TROUBLESHOOTING GUIDE Mechanical Electrical MV Units Electrical IID Units SECTION 6 REPLACEMENT PARTS 1 PART ONE OWNER S OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLO SION MAY RESULT CAUSING PROPERTY DAM AGE PERSONAL INJURY OR LOSS OF LIFE SECTION 1 START UP PROCEDURES BEFORE START UP BURNERS WATER Clean main burners and air louvers of dust lint and First thing insure that system is filled with water debris Keep heater area clear and free from com have pump operating Water must be flowing bustibles flammable liquids and chemicals Do not through the heater during operation obstruct
34. nd step 10 2 Remove defective high limit and replace with new high limit 3 Reverse above procedure to reinstall PILOT SAFETY Millivolt System The heaters equipped with the standing pilot milli volt system have pilot generators which actas a safety device to shut off the flow of gas to the main burners and the pilot burner in case the pilot flame is extinguished The pilot burner must be manually relighted to place the heater in operation again Refer to the lighting instruc tions provided on the heater label PILOT SAFETY IID Units ELECTRIC IGNITION The heater employs a pilot safety which closes the main gas valve within 8 10ths of a second whenever the pilot flame is interrupted Pilot flame is automatically lit when the device is powered Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit BURNER DRAWER REMOVAL Shut off main electrical power switch to heater Shut off gas upstream of heater Remove front door Disconnect gas line from gas valve Remove 2 screws that mount burner tray to unit Disconnect wires that terminate at gas valve and thermal fuse Slide out burner tray Reverse above procedure to reinstall oo oy N 8 GAS VALVE REMOVAL 1 Remove burner tray See burner tray removal procedure Disconnect pilot tubing from gas valve Remove gas valve with manifold from burner tray Remove manifold from gas valve Reverse above procedur
35. nd remove front and rear refractory shield Remowve refractory panels 2 3 4 Reverse above procedure to re install Fig 8155 05 Refactory Panel Top View 20 CONTROL IMMERSION WELL REPLACE 1 Remove plumbing and top portion of unit See heat exchange removal procedure steps 1 through 6 Remove U G spring U G and copper shield Collapse well tube at open end with chisel Push well up through header Insert new well and roll in place If a roller is not available solder the well in place with silver solder oR ON Fig 8126 06 UNITHERM GOVERNOR U G REPLACEMENT 1 Shutwater gas and electricity off close valves and relieve pressure 2 Drain heat exchanger 3 Disconnect inlet amp outlet pipes with flange from in out header 4 Grasp retainer spring from inlet side of header and slide thru inlet hole 5 Remove shield 6 Remove U G with seating gasket and stainless steel baffle not shown 7 Reverse above procedure to re install U G U G Shiel Retainer Spring Outlet Inlet Inlet Outlet Header Fig 8158 1 To test the operation of the Unitherm Governor place in hot water over 110 F and watch for movement against spring If there is no movement replace unit SECTION 5 TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heat
36. ng unit Strong air intake from these equipment can disturb the combustion process and cause damage or personal injury Heaters must not be installed under an overhang of less than three 3 feet from the top of the heater Three 3 sides must be open in the area under the overhang Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters For U S installations the point from where the flue products exit the heater must be a minimum of four 4 feet below four 4 feet horizontally from or one 1 foot above any door window or gravity inlet to a building The top surface of the heater shall be at least three 3 feet above any forced air inlet or intake ducts located within ten 10 feet horizontally For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 feet below orto either side of any opening into the building Refer to the latest revision of CAN CGA B149 1 and B149 2 7 4 7 4 foot Minimum 3 foot Minimum 10 foot Minimum Forced Air Inlet U S Installation Only 4 foot Minimum 1 foot Minimum Fig 8245 1 HIGH WIND CONDITIONS OUTDOOR UNITS ONLY In areas where high winds are frequent it may be necessary to locate the heater a minimum of 3 from high vertical walls or install a wind break so the heater is not
37. obtain a physician s advice before using pools or hot tubs 6 Persons taking medications which induce drowsiness such as tranquilizers antihista mines or anticoagulants should not use spas or hot tubs SECTION 3 MAINTENANCE AND CARE PROCEDURES To be followed one month after start up and then semi annually 1 Inspect top of heater and draft hood for soot a sticky black substance around finned tubes baffle and open flue gas passageways CAUTION Soot may be combustible Wet sooted surfaces completely prior to cleaning Do not use steel wire brush 2 Clean main burners and pilot burner of dust and lint 3 Inspect and operate all controls gas valve and pressure relief valve 4 Make visual check of the burner and pilot flame Flame pattern on the main burner and pilot is indicated in the previous illustration Yellow flame means restriction of the air openings Lifting or blowing flame indicates high gas pressure Low flame means low gas pressure Should this occur shut the heater off and contact your gas supplier or qualified service agency 5 On indoor heaters clean room intake openings to assure adequate flow of combustion and ventilation air CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty POOL amp SPA WATER CHEMISTRY Chemical imbalance can cause severe damage to your heater and associated equipment Maintain your
38. ow Check system for shorted wires or open circuits Replace sensor if necessary TIMATED RESIST MEASURED AN MATED RESISTANCE MATCH WITHIN 20 PERCENT DON T MATCH Disconnect potentiometer leads from circuit board Replace sensor Reconnect all leads and check Measure resistance with ohmmeter If resistance is out system 0 100 ohms at minimum setting 9k to 11k at maximum setting replace circuit board Above 11k ohms replace potentiometer 0 ohms short circuit replace potentiometer all leads and check out system If the pool spa hot tub water is too hot troubleshoot the system as follows Check voltage at and terminals VOLTAGE BETWEEN 0 2 V and 0 75 V Polarity is critical Check pilot generator correct as necessary Set control to max temperature After 2 3 cycles check water temperature TEMPERATURE ABOVE 108 F TEMPERATURE 105 1087 Disconnect sensor leads from circuit board Control ok Measure sensor resistance with ohmmeter NOTE 108 F is the upper control limit RESISTANCE ABOVE 15k OHMS OPEN Check water temperature estimate expected sen CIRCUIT OR SHORT CIRCUIT sor resistance from chart below Fix loose or broken wires Replace sensor if MATCH WITHIN 20 PERCENT DON T MATCH Disconnect potentiometer leads from circuit board Replace sensor Reconnect all leads and check Measure resistance with ohmmeter If resistance is out system 0 100 ohms at minimum setting 9k to
39. push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion D Do use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to re place any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS FRR STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Remove heater door panel Push in gas control knob slightly and turn clock wise lt to Off Knob cannot be turned to Off unless it is pushed in slightly Do not force 7 Wait 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety infor mation previously stated If you don t smell gas go to the next step Gas control lever shown in the On position 8 Turn gas control knob counterclockwise 4 to On Do I n Gas control knob shown in ON position GAS VALVE IID Fig 8112 9 Replace heater door panel 10 Turn on all electrical power to appliance 11 Set thermostat to desired setting 12 If the appliance will not operate
40. rature in hr pool or spa Filter not running long enough Dirty TIGE Gas line or meter undersized Pool water High flow SOLUTION Check movement by putting in hot water 110 F 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 Backwash filter Raise water level Adjust bypass Adjust pressure switch Recommended pH should be between 7 4 and 7 8 total alkalinity 100 150 PPM maximum Hard ness 150 400 PPM maximum Reduce by adding manual bypass valve and adjust by putting thermometer in header 1 4 NPT drain opening Set bypass so thermometer reads between 105 and 110 F Check movement by putting in hot water 110 F or higher If no movement replace Refer to installation instructions Follow recommended installation instructions Clean burners Adjust gas pressure Clean pilot Replace pilot Adjust gas pressure Clean burners Replace refractory panels Determine cause of sooting amp correct Heat rise hr 2 Heater Output 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 Usually occurs on initial start
41. re below freezing flow continuous pump op eration must be maintained CAUTION Do not use the heater to maintain water temperatures just above freezing or for freeze protec tion When heaters are used during freezing weather care must be taken to avoid freeze ups Continuous pump operation is a must Additional protection may be required heater is not warranted against freeze ups COLD CLIMATE Prolonged operation with water temperatures below 50 F is not recommended When starting the heater with pool temperatures below 50 F operate the heater continuously until higher tempera tures are reached Operating the heater for prolonged periods with pool water below 50 can seriously dam age the heater and is not covered by the warranty For cold climate areas please follow the winterizing procedures listed below WINTERIZING THE SPA HEATER When heaters installed outdoors in freezing cli mate areas are to be shut down for the winter observe the following step by step procedure 1 Turn off gas valve manual gas valve and electri cal supply to the heater 2 Open drain cock located on the return header 3 Disconnect compression fittings from the pressure switch and header that connect to the 1 4 copper tube and allow the tube to drain PART 2 INSTALLATION SERVICE INSTRUCTIONS SECTION 1 RECEIVING EQUIPMENT On receipt of your equipment itis suggested that you visually check for external damage to t
42. roduced and completely diluted into the pool or spa water before being circulated through the heater Do not place chlorine tablets or bromine sticks in the skimmer High chemical concen trations will result when the pump is not running i e overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the pump is shut off NOTE High chemical concentration from feeders and chlorinators that are out of adjustment will cause very rapid corrosion to the heat exchanger in the heaters Such damage is not covered under the warranty UNITHERM GOVERNOR OPERATION The patented Unitherm Governor is a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105 115 F de spite continually changing flow rates from the filter and changing pool temperatures This narrow range is needed to prevent damaging condensation on the burn ers which will occur if the heater runs for any length of time below 100 F It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures Unitherm Governor Fig 8158 1 Outlet EXTERNAL AUXILIARY BYPASS VALVE Where required An auxiliary bypass valve should be used when flow rates exceed 60 GPM usually a high performance pump size larger than 1 1 2 HP will exceed this flow rate This valve is required to compl
43. t pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z 223 1 1988 Canada CAN CGA B149 1 and B149 2 10 10 OR LESS fo CAP DRAFT HOOD HEATER GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve located outside the heater jacket All gas piping should be tested after installation in accordance with local codes Manual Shut Off Valve Sediment Fig 8156 CAUTION heater its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 psig 3 45 KPA Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRES SURED GAS VALVES NOT COVERED BY WARRANTY The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test Do NOT use open flame NOTE Donotuse teflon tape on gas line pipe thread A flexible sealant is recommended A minimum of 7 W C and a maximum of 14 W C upstream pressure under load and no load conditions must be provided for natural gas or a minimum of 12 W C and a maximum of 14 for propane gas PIPE SIZING FOR GAS CONNECTIONS MAXIMU
44. the flow of combustion and ventilating air Fig 881395 CAUTION Propane gas is heavier than air and will settle on the ground Since propane can accumulate confined areas extra care should be exercised when lighting propane heaters amm LIGHTING INSTRUCTIONS AND SHUT OFF PROCEDURES MANUALLY LIGHTED PILOTS MILLIVOLT SYSTEM A This appliance has a pilot that must be lighted by hand When lighting the pilot follow these instructions exactly C B BEFORE LIGHTING smell all around the appli ance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS D Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instruc tions If 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 do not try to repair it Call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to re place any part of the control system and any gas control which has been under water LIGH
45. ur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue f checks are okay replace module CALL FOR HEAT ENDS Check for proper thermostat controller operation SYSTEM SHUTS OFF Remove MV lead at module if valve closes recheck temperature controller and YES wiring if not replace gas valve Repeat procedure until trouble free operation is obtained 24 ELECTRICAL SOLID STATE THERMOSTAT IID If the pool spa hot tub water is too cold troubleshoot the system as follows Check voltage at 24 V terminals VOLTAGE BETWEEN 21 5 28 5 V Set control to max temperature After 2 3 cycles check water temperature TEMPERATURE BELOW 105 F Disconnect sensor leads from circuit board Measure sensor resistance with ohmmeter RESISTANCE 1 14k OHMS Check water temperature estimate expected sensor resistance from chart below MEASURED AND ESTIMATED RESISTANCE MATCH WITHIN 20 PERCENT Disconnect potentiometer leads from circuit board Measure resistance with ohmmeter If resistance is 0 100 ohms at minimum setting 9k to 11k at maximum setting replace circuit board Above 11k ohms but less than 15 k ohms replace potentiometer Above 15k ohms fix loose or broken wires replace potentiometer if necessary all leads and check out system VOLTAGE OUTSIDE RANGE 21 5 28 5 V Check transformer 120
46. vertical piping Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recommend use of insulated vent pipe spacer through the roofs and walls For protection against rain or blockage by snow the vent pipe must terminate with a vent cap which complies with the local codes or in the absence of such codes to the latest edition of the National Fuel Gas Code ANSI 2223 1 1988 Canada CAN CGA B149 1 and B149 2 The discharge opening must be a minimum of two feet vertically from the roof surface and at least two feet higher than any part of the building within ten feet Vent stack shall be atleast five feet in vertical height above the draft hood outlet The vent cap location shall have a minimum clearance of 4 feet horizontally from and inno case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regula tors and relief equipment The weight of the vent stack or chimney must not rest on heater draft hood Support must be provided in compliance with applicable codes The heater top and draft hood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from supported to maintain proper clearances from combustible construc tion Type B double wall or equivalent vent pipe is recommended However single wall metal ven
47. water pH between 7 4 and 7 8 and total alkalinity between 100 and 150 p p m If the mineral content and dissolved solids in the water become too high scale forms inside the heat exchanger tubes reducing heater efficiency and also damaging the heater If the pH drops below 7 2 the heater will be severely dam aged This will result in corrosion of the heat ex changer Heat exchanger damage resulting from chemical imbalance is not covered by the war ranty COLD WEATHER OPERATION 6 Keep area around heater clear and free from combustible materials and other flammable and corrosive vapors and liquids BASIC TIPS IF HEATER WILL NOT FIRE 1 If you have no electrical power it may be your circuit breakers have tripped Try re setting them 2 If you have electrical power but the heater will not fire check the following 3 The time clock must be moved to the ON position 4 Your pump strainer basket may be full If so remove debris 5 Your filter may be dirty If so backwash or clean filter To tell if your filter is dirty the gauge pressure will be higher than usual 6 The pump may have lost its prime It may be running dry check the pressure gauge on the filter If there is no pressure then you are not moving water or your gauge is broken Try to get the pump to run at it s normal flow rate MODERATE CLIMATE Heater operation can con tinue during short term cold spells When tempera tures a
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