PR206 Gas Fired Pool and Spa Heater

Gas-Fired Pool and Spa Heater

Product Information

The Gas-Fired Pool and Spa Heater is designed to efficiently
heat your pool or spa. It comes in six different models: Bronze
ASME and Polymer Atmospheric Heat Exchanger Models 206A, 266, 266A,
336A, 399, and 406A. The heater requires installation and service
by a qualified installer, service agency, or gas supplier. It is
important to follow the instructions exactly to avoid the risk of
fire or explosion. The manual contains information on clearances,
piping, gas, water chemistry, power, venting, controls interface,
and wiring diagrams.

Product Usage Instructions

Step 1: Water Chemistry

Before installing the Gas-Fired Pool and Spa Heater, make sure
to check the water chemistry requirements in the manual on page 5.
This will ensure that the heater functions effectively and
efficiently.

Step 2: Installation

Ensure that the heater is installed by a qualified installer,
service agency or gas supplier. Check the manual for clearances
required (page 12) and local codes that prevail. Installation
should include a pressure relief valve, sediment trap, and required
piping (see pages 15-20 for more information).

Step 3: Electrical Wiring

The Gas-Fired Pool and Spa Heater comes in two models: millivolt
models (M suffix) and digital models (E suffix). Check the manual
(pages 22-23) for acceptable input voltages and electrical power
draw. Wiring diagrams are provided on pages 24-25.

Step 4: Venting

Refer to the manual (pages 11-14) for information on venting
materials, D-2 Power Vent Kit, and Indoor Stack.

Step 5: Controls Interface

The manual (pages 26-30) contains information on the user
interface, wiring diagrams, and remote operation.

Step 6: Operating Instructions

Before start-up, visually inspect the heater and check the water
pressure switch as per manual instructions (page 36). Follow the
start-up procedures as per manual instructions (page 36).

By following these instructions, you will be able to effectively
use the Gas-Fired Pool and Spa Heater to heat your pool or spa.
Refer to the manual for more detailed information.

INSTALLATION AND OPERATION MANUAL

Gas-Fired Pool and Spa Heater
Bronze ASME and Polymer Atmospheric Heat Exchanger Models 206A, 266, 266A, 336A, 399, and 406A

THIS MANUAL CAN BE VIEWED ELECTRONICALLY USING YOUR SMART DEVICE. SEE PAGE 46 FOR QR CODE.

A S M E

HLW
BR models only
AWARNING: If the information in the instructions is 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 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 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 adjacent to the heater or in a safe place for future reference.
Effective: 08-19-22 Replaces: 05-20-22 P/N 241236 Rev. 43

QUICK START GUIDE

CLEARANCES
Space required: See page 12. Minimum and service clearances: See page 7 for
clearances table. Note that local codes prevail.
PIPING
Pressure relief valve: See page 20 for recommended PRV orientation.
Flow rates: See page 17 for flow rate values.
GAS
Distance to regulator (pipe lengths) and gas inlet sizes: See page 17.
Required pressure for Natural Gas: Min = 6″ WC, Max = 10.5″ WC
Required pressure for Propane Gas: Min = 12″ WC, Max = 13″ WC
Sediment trap is required for all installations. See page 15.

WATER CHEMISTRY
Water chemistry requirements: See page 5.
POWER
Supply voltage: See page 23 for acceptable input voltages.
VENTING
Materials: See page 11 and page 14. D-2 Power Vent Kit: See page 14. Indoor Stack: See page 11.
CONTROLS INTERFACE
Wiring diagrams: See page 24 and 25. User interface: See page 26 and 27. Remote operation: See page 30.

Revision 43 reflects the following changes: Revised callout of ” ANSI-Z21.58″ to “ANSI-Z21.56” in base riser section. Added “14-S” Base Riser to the IPL and the exploded view.
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TABLE OF CONTENTS

1. WARNINGS ……………………………………………………. 4 Pay Attention to These Terms …………………………… 4
2. WATER CHEMISTRY ……………………………………… 5 Automatic Chlorinators/Chemical Feeders………….. 5
3. BEFORE INSTALLATION……………………………….. 6 Receiving equipment……………………………………….. 6 Rating and certifications…………………………………… 6 Elevation ……………………………………………………….. 7 Ambient Temperature Rating ……………………………. 7
4. INSTALLATION………………………………………………. 7 Installation Codes……………………………………………. 7 Clearances …………………………………………………….. 7 Outdoor Heater Installation ………………………………. 8 Combustion and Ventilation Air ……………………….. 11 Vent Piping …………………………………………………… 14 D-2 Power Vent Kit………………………………………… 14 Gas Supply Connections………………………………… 15 Flow Rate …………………………………………………….. 17 ProTek Shield Assembly…………………………………. 18 Unitherm Governor Operation…………………………. 19 Internal Automatic Bypass Valve……………………… 19 External Auxiliary Bypass Valve ………………………. 19 Auxiliary Bypass Valve Adjustment ………………….. 20 Pressure Relief Valve Installation…………………….. 20 Heat Exchanger Reversal ………………………………. 20 Plumbing Diagrams……………………………………….. 21
5. ELECTRICAL WIRING………………………………….. 22 Millivolt Models (“M” suffix) …………………………….. 22 Digital Models (“E” suffix)……………………………….. 22 Electrical Power Draw ……………………………………. 23 Transformer Wiring ……………………………………….. 23

6. WIRING DIAGRAM – MILLIVOLT ………………….. 24
7. WIRING DIAGRAM – DIGITAL ………………………. 25
8. CONTROLS ………………………………………………….. 26 Control Panel Removal ………………………………….. 26 Control Adjustments – Millivolt Models ……………… 26 Control Adjustments ­ Digital Models ………………. 27 Operation …………………………………………………….. 27 Status and Diagnostics ………………………………….. 29 Remote Wiring – Digital Models Only ……………….. 30
9. OPERATING INSTRUCTIONS………………………. 36 Before Start-Up …………………………………………….. 36 Start-Up Procedures ……………………………………… 36 Visual inspection …………………………………………… 36 Water Pressure Switch…………………………………… 36
10. MAINTENANCE AND CARE…………………………. 39 Cold Weather Operation ………………………………… 39
11. TROUBLESHOOTING ………………………………….. 40 Millivolt – Flow Chart………………………………………. 42 Digital – Flow Chart………………………………………… 43 Control Logic – Flow Chart – Digital ………………….. 44
12. REPLACEMENT PARTS ………………………………. 45
13. QR CODES …………………………………………………… 46
14. ILLUSTRATED PARTS LIST………………………… 47

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1. WARNINGS

Pay Attention to These Terms

ADANGER AWARNING ACAUTION
CAUTION NOTE

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 minor personal injury or product or property damage if ignored.
CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could cause minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

ADANGER: Failure to install the drafthood on indoor
installation and properly vent the heater to the 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 installation at initial start-up, and at least annually thereafter. Refer to the venting section of this manual for more information regarding vent system inspections.
AWARNING: 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.
AWARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high-temperatures [>2192°F (1200°C)], 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 carcinogenic 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.

AWARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
AWARNING: 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.
AWARNING: 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, camouflage, or otherwise make detecting a gas leak by smell more difficult.
AWARNING: 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 manufacturer’s recommendations and/or local laws, rules, regulations, or customs.
AWARNING: 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.
AWARNING: 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. Such damage is not covered under warranty.

4

ACAUTION: Elevated water temperature can
be hazardous. The 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 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 subsequently 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 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 pools or hot tubs.
6. Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines, or anticoagulants, should not use spas or hot tubs.
ACAUTION: Propane gas is heavier than air and will
settle on the ground. Since propane can accumulate in confined areas, extra care should be exercised when lighting propane heaters.
NOTE: It is recommended that the pump be run at least 5 minutes after the heater has been turned off. This helps in taking away residual heat from the heat exchanger, thus prevents the safety hi-limits from tripping due to residual heat after the heater is turned off.
WARNING: Risk of fire. It is recommended that CO monitor and fire alarm be utilized in rooms that contain gas fired appliances.

2. WATER CHEMISTRY
NOTE: Damage due to poor water chemistry is not a warrantable defect.
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 damage the heater. Heat exchanger damage resulting from chemical imbalance is not covered by the warranty.
For your health and the protection of your pool equipment, it is essential that your water be chemically balanced. The following levels must be used as a guide for balanced water.
ACAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and is not covered under warranty.
· Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced.
· Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water, unless controlled, they can lead to excessive chlorine level which can damage your heater.
· Check valve should be installed between the heater outlet and a chlorinator or other chemical dosing device.
· 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
and Chemical Feeders
All chemicals must be introduced and completely diluted into the pool or spa water before being circulated through the heater. Do not place sanitizing chemicals in the skimmer. High chemical concentrations will result when the pump is not running (e.g. overnight).

Recommended Level(s)

Fiberglass Pools

Fiberglass Spas

Water Temperature

68-88°F (20-31°C)

89-104°F (31-40°C)

pH

7.3-7.4

7.3-7.4

Total Alkalinity (ppm)

120-150

120-150

Calcium Hardness (ppm)

200-300

150-200

Salt (ppm)

4500 Maximum

4500 Maximum

Free Chlorine (ppm)*

2-3

2-3

Total Dissolved Solids (ppm)

3000 Maximum**

3000 Maximum**

*Free Chlorine MUST NOT EXCEED 5 ppm! **In saltwater chlorinated pools, the total TDS can be as high as 6000 ppm.

Table A. Pool Water Chemistry

Other Pool and Spa Types 68-104°F (20-40°C) 7.6-7.8 80-120 200-400 4500 Maximum 2-3 3000 Maximum**
5

Chlorinators must feed downstream of the heater and have an anti-siphoning device to prevent chemical backup into the heater when the pump is shut off.
See “Plumbing Diagrams” on page 21.
NOTE: High chemical concentrates from feeders and chlorinators that are out of adjustment will cause rapid corrosion to the heat exchanger. Such damage is not covered under the warranty.

Be sure that you receive the number of packages indicated on the Bill of Lading.
Model Identification Number
The model number of a boiler can be found on the Sales Order and the boiler’s rating plate. The example below identifies what the characters of the model number represent.

3. BEFORE INSTALLATION

Receiving Equipment
The manufacturer recommends that this manual be reviewed thoroughly before installing the pool/spa heater. If there are any questions that this manual does not answer, please contact the factory or your local representative.
On receipt of your equipment visually check for external damage to the carton. If the carton is damaged, a note should be made on the Bill of Lading when signing for the equipment. Remove the heater from the carton. If it is damaged, report the damage to the carrier immediately. Save the carton.
These items are shipped inside a box in the carton with the heater:
Standard Unit (POLYMER HEADERS)
1. “Pagoda” top 2. 2″ CPVC union half with “O” rings (2) 3. Plastic pipe finish flange for gas line 4. Bonding lug with mounting screw (Digital) models
only) ASME Unit (BRONZE HEADERS)
1. “Pagoda” top 2. 2″ CPVC union half with “O” rings (2) 3. Plastic pipe finish flange for gas line 4. Bonding lug with mounting screw (Digital models
only) 5. Pressure Relief Valve (PRV) 6. Protek ShieldTM Adapter with Protek Shield Assy,
O-ring and wing nut
THE MODEL AND SERIAL NO. CAN ALSO BE FOUND INSIDE THE BEZEL ABOVE THE DISPLAY

When ordering parts, you must specify the model and serial numbers of the heater. See example below for location of serial number. When ordering under warranty conditions, you must also specify date of installation.

MODEL AND SERIAL NO. LOCATED ON RATING PLATE

F10640-1

Figure 1. Rating Plate Location

6

Rating and Certifications
These heaters are design-certified and tested under the latest requirements of the ANSI Z21.56 / CSA 4.7 Standard for Gas-Fired Pool Heaters. All heaters can be used either indoor or outdoors when appropriate venting is installed.

The appropriate top designated for each type of use is required. If necessary, the top can be changed at a later date to change from outdoor to indoor or vice versa.
All Bronze header units have heat exchangers which are ASME-certified (BPV Section IV part HLW) and are registered with National Board.
Elevation
Rated inputs are suitable for up to 2,000 ft (610 m) elevation. For elevations above 2,000 ft (610 m), reduce input 4% for each 1,000 ft (305 m) above sea level, as high elevation reduces combustion performance.
Ambient Temperature Rating
Heater Components
Millivolt Heater with Honeywell Gas Valve 32°F to 175°F (0°C to 79°C)
Millivolt Heater with Robertshaw Gas Valve 0°F to 175°F (-18°C to 79°C)
Electronic Ignition Heater -32°F to 175°F (-35°C to 79°C)
Requires 120 or 240VAC, 1 Ph, 60 Hz Power Supply
4. INSTALLATION
AWARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber. RCF, as manufactured, does not contain respirable crystalline silica. However, following sustained exposure to very high-temperatures (>2192°F), 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 carcinogenic 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 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. If your state is such, be sure your contractor bears the appropriate license. Persons not qualified shall not attempt to fix the equipment nor attempt repairs according to these instructions.

AWARNING: Improper installation, adjustment,
alteration, service or maintenance may damage the
equipment, creating a hazard resulting in asphyxiation, explosion or fire. Such damage is not covered under warranty.

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, it is recommended that a suitable drain pan, with adequate drainage, be installed under the heater. The pan must not restrict combustion air flow.

RECOMMENDATION: For regions with snow, Raypak recommends installing these units indoors.

Installation Codes
Installation must be in accordance with local codes, or, in the absence of local codes, with the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and National Electrical Code, ANSI/NFPA 70, and for Canada, the latest edition of CAN/CSA-B149 Installation Codes, and Canadian Electrical Code, CSA C22.1 Part 1 and Part 2.
Clearances

All Heaters
For indoor and outdoor clearances from combustible surfaces, see the chart below.

Location
Top * Front Vent Floor ** Back Right-Side Left-Side

Indoor Installation
30″ (762 mm) Drafthood Alcove (Open) 6″ (152 mm) 0″ 6″ (152 mm) 12″ (305 mm) Water Side 6″ (152 mm) Opposite Water Side

Location

Outdoor Installation

Top *

Unobstructed (Outdoor Stack)

Top ***

36″ (914 mm) (Stackless Top)

Floor

0″

Back

6″ (152 mm)

Right-Side 12″ (305 mm) Water Side

Left-Side 6″ (152 mm) Opposite Water Side

• Clearance from top of vent terminal ** Do not install on carpeting *** Clearance from top of heater

Table B. Minimum Clearances from Combustible Surfaces

7

When installed according to the listed minimum clearances from combustible construction, the pool heater can still be serviced without removing permanent construction around the heater.
However, for ease of servicing, we recommend a clearance of at least 24″ (610 mm) in the front, and at least 18″ (457 mm) on the water connection side. This will enable the heater to be serviced in its installed location, that is, without movement or removal of the heater.

Description

Location

Back

a. 3-1/2″ (89 mm) thick masonry walls without ventilated air space

Right Left Vent Indoor Top

Outdoor Top

Back

b. 1/2″ (13 mm)insulation Right

board over 1″ (25 mm) Left

glass fiber or mineral

Vent

wool batts

Indoor Top

Outdoor Top

c. 0.024″ sheet metal over Back

1″ (25 mm) glass fiber Right

or mineral wool batts

Left

reinforced with wire on Vent

rear face with ventilated Indoor Top

air space

Outdoor Top

Back

d. 3-1/2″ (89 mm) thick masonry wall with ventilated air space

Right Left Vent Indoor Top

Outdoor Top

Back

Right

e. 0.024″ sheet metal with Left

ventilated air space

Vent

Indoor Top

Outdoor Top

Back

f. 1/2″ (13 mm) thick insulation board with ventilated air space

Right Left Vent Indoor Top

Outdoor Top

Back

g. 0.024″ sheet metal with Right

ventilated air space over Left

0.024 sheet metal with Vent

ventilated air space.

Indoor Top

Outdoor Top

h. 1″ (25 mm) glass fiber or mineral wool batts sandwiched between two sheets 0.024 sheet metal with ventilated air space

Back Right Left Vent Indoor Top Outdoor Top

Derived from National Fuel Gas Code, Table 10.2.3

Distance
in. (mm)
9 (229) 9 (229) 9 (229) 5 (127) 39 (991) Unobstructed 6 (152) 6 (152) 6 (152) 3 (76) 30 (762) Unobstructed 4 (102) 4 (102) 4 (102) 3 (76) 24 (610) Unobstructed 6 (152) 6 (152) 6 (152) 6 (152) 39 (991) Unobstructed 4 (102) 4 (102) 4 (102) 2 (51) 24 (610) Unobstructed 4 (102) 4 (102) 4 (102) 3 (76) 24 (610) Unobstructed 4 (102) 4 (102) 4 (102)
3 (76)
24 (610) Unobstructed
4 (102) 4 (102) 4 (102) 3 (76) 24 (610) Unobstructed

Table C. Reduction of Clearances to Protected Surfaces

Clearances less than these 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 be serviced without removing any structure around the heater.
Flooring
This heater can be installed on combustible flooring. The combustible clearances listed can be reduced by protecting the exposed combustible surfaces as shown in Table C.
Outdoor Heater Installation
These heaters are design-certified for outdoor installation, when equipped with the approved tops designated for outdoor use. AWARNING: 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. Such damage is not covered under warranty. AWARNING: Do not install within 3′ (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.
PAGODA TOP INSTALLATION
F10646-1
Figure 2. Heater with Outdoor Stackless Top

8

4′ (1.2 m) Minimum

4′ (1.2 m) Minimum

3′ (0.9 m) Minimum

10′ (3 m) Minimum

4′ (1.2 m) Minimum
1′ (0.3 m) Minimum

Forced Air Inlet
Figure 3. Minimum Distances to Building Openings from Where Flue Products Exit the Boiler
Heaters must not be installed under an overhang of less than 3′ (0.9 m) 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 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 4′ (1.2 m) below, 4′ (1.2 m) horizontally from, or 1′ (0.3 m) above any door, window or gravity inlet into any building. The top surface of the heater shall be at least 3′ (0.9 m) above any forced air inlet, or intake ducts located within 10′ (3 m) horizontally.
For Canadian installations, pool heaters shall not be installed with the top of the vent assembly within 10′ (3 m) below, or to either side, of any opening into the building. Refer to the latest revisions of CAN/CSA-B149.
A minimum of 6′ (1.8 m) is required from the heater to an inside corner wall for proper outdoor venting.

For installations in Florida and Texas, that must comply with the Florida or Texas Building Code, follow the directions shown in Figure 5 for the installation of hurricane tie-down brackets for all models.
Indoor Heater Installation
The heater is also design-certified for indoor installation when equipped with the approved drafthood and a codecompliant vent stack.
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. Locate heater as close as is practical to a chimney or gas vent. Heater must always be vented to the outside. See section “Vent Piping” on page 14 for details. Minimum allowable space is shown on the nameplate.
AWARNING: Indoor heaters require a drafthood 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.
Base Riser (for Canada only)
For all Canada installations, the unit must be installed on a base riser that is shipped along with the unit. This is in accordance with ANSI-Z21.56. See IPL for replacement kit information on page 52 (Item 14-S).

Pagoda Top Installation
1. Insert tabs into keyhole (4 places). See Figure 4, detail A.
2. Snap tabs into keyholes so as not to pull out. See Figure 4, detail B.

DETAIL A

DETAIL B

OUTDOOR TOP

(SHIPPED LOOSE WITH HEATER)

Figure 4. Outdoor Top Installation

9

INSTRUCTIONS FOR THE STATE OF FLORIDA AND FOR AREAS OF TEXAS DESIGNATED BY THE TEXAS DEPARTMENT OF INSURANCE
WIND SPEED = 150 MPH, 3 SECOND GUST EXPOSURE = C

Model
206A 266/266A
336A 399/406A

B in. (mm)
20 (508) 23 (584) 26 (660) 29 (737)

38″ (965 mm)

2″ x 6″ x 1/8″ Pallet Anchor Bracket (4 Total) (Kit# 011636)

B
F10648
28″ (711 mm)
3″ (76 mm) Min. Conc. Pad by others

1/4″ x 2-1/4″ S.S. Tapcon Bolt and Washer (Field-Supplied) NOTE: Use hole closest to unit with washer overlapping edge of unit.

Min. Edge Distance
6″ (152 mm)

Min. Edge Distance 6″ (152 mm)

3″ (76 mm) Min. Conc. Pad by others
HOT
F10646-2

(1)­1/4″ x 2-1/4″ S.S. Tapcon Bolt & Washer (Field-Supplied) Ea. Pallet Anchor Bracket Use hole closest to unit (4 total)

(1)­1/4″ x 2-1/4″ S.S. Tapcon Bolt & Washer (Field-Supplied) Ea. Pallet Anchor Bracket Use hole closest to unit (4 total)

Figure 5. Hurricane Tie-Down Bracket Installation 10

Outdoor and Indoor Stacks
The outdoor and indoor stacks are optional equipment and do not come standard with the heater. Refer to installation instructions inside box for instructions on how to install outdoor/indoor stack.

Model

Outdoor Stack

Indoor Stack

206A

009834

009838

266/266A

009835

009839

336A

009836

009840

399/406A

009837

009841

Table D. Outdoor and Indoor Stack Kit Number

OUTDOOR STACK KIT

(1) Outdoor drafthood, painted

(1) Adapter plate

(3) Mounting brackets (clips)

(1) Top panel cover

(2) 1-foot sections of metal tape

(3) Screws (1) Instructions

Clips

Combustion and Ventilation Air

Indoor Units Only
The heater must have both combustion and ventilation air. The minimum requirements are listed in the latest edition of the National Fuel Gas Code (U.S. ANSI Z223.1 or Canada CAN/CSA-B149) and any local codes that may have jurisdiction. The most common approach is the “2-opening” method, with combustion air opening no more than 12″ from the floor and the ventilation opening no more than 12″ from the ceiling. For opening sizes using this method, see below.

All Air from Inside the Building:

Each opening shall have a minimum net free area as noted:

Model

Sq. in. (m2)

206A

200 (0.13)

266/266A

266 (0.17)

336A

333 (0.21)

399/406A

399 (0.26)

Table E. Opening Minimum Net Free Requirements Indoor Air

All Air from Outdoors:
When air is supplied directly from outside the building, each opening shall have a minimum net free area as noted:

Figure 6. Outdoor Stack Kit Components
NOTE: The outdoor drafthood kit does not require any additional vent pipe for proper operation. This drafthood functions as the vent termination.
INDOOR STACK KIT (1) Drafthood, unpainted (1) Adapter plate (3) Mounting brackets (clips) (3) Screws (1) Instructions

Model

Unrestricted Opening
sq. in. (m2)

Typical Screened or Louvered Opening
sq. in. (m2)

Typical Screened and Louvered Opening sq. in. (m2)

206A 266/266A
336A 399/406A

50 (0.03) 67 (0.04) 84 (0.05) 100 (0.06)

75 (0.05) 101 (0.06) 126 (0.08) 150 (0.1)

100 (0.06) 134 (0.09) 168 (0.11) 200 (0.13)

Table F. Opening Minimum Net Free Requirements Outdoor Air
ACAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the heater. Such damage will not be covered by the warranty.

Clips

Figure 7. Indoor Stack Kit Components

11

Specifications and Dimensions
B

C Indoor Drafthood

D

J*

Amp Draw

120 VAC, 1Ph, 60Hz 240 VAC, 1Ph, 60Hz

4

2

4-3/8″ (111 mm) (3-3/8″ ASME) (86 mm)
WATER INLET 2″ SLIP

CL Flue 10″
(254 mm)
8-7/8″ (225 mm) 6-5/8″ ASME (168 mm)

WATER OUTLET 2″ SLIP

38″ (965 mm)
GAS, 3/4″ NPT

13-1/4″ (337 mm)
gas connection

A
Figure 8. Front View

26-5/8″ (676 mm) 28-5/8″ ASME (727 mm
ASME)
F10646

32-11/16″ (830 mm) Electrical Connection

40″ (1016 mm) Stackless Outdoor Top

28″ (711 mm)
Figure 9. Side View

F10646-4

Residential – Copper Heat Exchanger

Shipping Weights lbs. (kg)

Heater Mode

BTUH Input (kwh)

(A)

(B)

(C)

Cabinet Flue Indoor

(D)

(J)*

Width Dia. Drafthood in. (mm) in. (mm)

in. (mm) in. (mm) in. (mm)

Standard Heater
w/Stackless Top

Indoor DraftHood

206A 266/266A
336A 399/406A

199.5 (58.4)
266.0 (77.9)
332.5 (97.4)
399 (116.9)

20 (508)
23 (584)
26 (660)
29 (737)

6 (152)
7 (178)
8 (203)
9 (229)

61-5/8 (1565)
62 (1575)
63 (1600)
64-9/16 (1640)

10.0 (254)
11.5 (292)
13 (330)
14.5 (368)

11-3/4 (298)
11 (279)
10-5/8 (270)
12-1/8 (309)

187 (85)
210 (95)
230 (104)
249 (113)

14 (6.4)
16 (7.3)
19 (8.6)
21 (9.5)

*Note: For outdoor stack height, use “J” dimension for appropriate size plus 6 inches (152 mm). Table G. Residential – Copper Heater Specifications and Dimensions

12

Residential – Cupronickel Heat Exchanger

Shipping Weights lbs. (kg)

Heater Mode

BTUH Input (kwh)

(A)

(B)

(C)

Cabinet Flue Indoor

Width Dia. Drafthood

in. (mm) in. (mm) in. (mm)

(D) in. (mm)

(J)* in. (mm)

Standard Heater
w/Stackless Top

P-_206A-EN-X

180.0 (52.7)

20 (508)

6 (152)

61-5/8 (1565)

10.0 11-3/4 (254) (298)

187 (85)

P-_266A-EN-X

240.0 (70.3)

23 (584)

7 (178)

62 (1575)

11.5

11

(292) (279)

210 (95)

P-_336A-EN-X

300.0 (87.9)

26 (660)

8 (203)

63 (1600)

13 10-5/8 (330) (270)

230 (104)

P-_406A-EN-X

360.0

29

(105.5) (737)

9 (229)

64-9/16 14.5 12-1/8 (1640) (368) (309)

249 (113)

*Note: For outdoor stack height, use “J” dimension for appropriate size plus 6 inches (152 mm). Ta b l e H . Residential – Cupronickel Heater Specification and Dimensions

Indoor DraftHood
14 (6.4)
16 (7.3)
19 (8.6)
21 (9.5)

Commercial – ASME Copper or Cupronickel Heat Exchanger

Shipping Weights lbs. (kg)

Heater Mode

BTUH Input (kwh)

(A) Cabinet Width in. (mm)

(B) Flue Dia. in. (mm)

(C) Indoor Drafthood in. (mm)

(D) in. (mm)

B-_206A-EN-(C or X)

199.5 (58.4)

20 (508)

6 (152)

61-5/8 (1565)

10.0 (254)

B-_266A-EN-(C or X)

266.0 (77.9)

23 (584)

7 (178)

62 (1575)

11.5 (292)

B-_336A-EN-(C or X)

332.5 (97.4)

26 (660)

8 (203)

63 (1600)

13 (330)

(J)* in. (mm)
11-3/4 (298)
11 (279)
10-5/8 (270)

ASME Heater w/Stackless
Top
206 (94)
229 (104)
249 (113)

Indoor DraftHood
14 (6.4)
16 (7.3)
19 (8.6)

B-_406A-EN-(C or X)

399 (116.9)

29 (737)

9 (229)

64-9/16 14.5 12-1/8 (1640) (368) (309)

268 (122)

21 (9.5)

*Note: For outdoor stack height, use “J” dimension for appropriate size plus 6 inches (152 mm). Ta b l e I . Commercial – Heater Specifications and Dimensions

13

Vent Piping
AWARNING: Indoor heaters require a drafthood 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.

Flue materials must be certified to CATEGORY I or better. Type “B” double-wall or equivalent vent pipe is recommended. A draft of -0.01″ to -0.08″ WC must be maintained. 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).

When properly installed outdoors, only the outdoor stackless top (provided) is required. If installed indoors, a drafthood is required, connected to a CATEGORY I (a heater that operates with a non-positive vent static pressure and a vent gas temperature that avoids excessive condensate production in the vent.) vent per the National Fuel Gas Code and local requirements.
Vent piping the same size as the drafthood outlet is recommended, however, when the total vent height is at least 10 ft (3 m) (drafthood relief opening to vent terminal), the vent pipe size may be reduced by no more than one (1) size as specified in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1 (Canada – CAN/CSA-B149).

D-2 Power Vent Kit
Another option for an installation that requires horizontal runs is the D-2 power vent kit option.

Model 206A 266/266A 336A 399/406A

120 VAC P/N 010744 010744 010745 010745

240 VAC P/N 009832 009832 009833 009833

Table J. Power Vent Kit Part Numbers

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. per ft rise (20.8 mm per meter rise) and should be supported at not more than five foot (1.5 m) intervals.
Plumber’s 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 (1.5 m) 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.

NOTE: The D-2 Power Vent operates with a positive vent static pressure and with a vent gas temperature that prevents excessive condensate production in the vent, and as such, is a CATEGORY III appliance. For more information consult the D-2 Power Vent manual, (P/N: 241243). CATEGORY I vent material such as B-vent must not be used under CATEGORY III conditions.

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 Z223.1 (Canada – CAN/CSA-B149).
The discharge opening must be a minimum of 2′ (0.6 m) vertically from the roof surface and at least 2′ (0.6 m) higher than any part of the building within 8′ (2.4 m). Vent stack shall be at least 5′ (1.5 m) in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4′ (1.2 m) horizontally from, and in no case below, unless a 4′ (1.2 m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.
The weight of the vent stack or chimney must not rest on the 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 supported to maintain proper clearances from combustible construction.

Figure 10. D-2 Power Vent Option
The power vent system is a fan-assisted vent system designed for use on models 206A-406A.
The power vent system, when installed as directed, is capable of operating in applications such as through-thewall venting with reduced horizontal and vertical vent pipe sizes in new and current installations. The unit is factorywired for 240 VAC, with capability of field-rewiring for 120 VAC.
For more information consult the D-2 Power Vent manual, (P/N: 241243). This Manual can be viewed on your smart device. See QR Code on page 46. This manual can also be found in the document library at www.raypak.com.

14

2′ MIN (0.6 m)

8′ (2.4 m) OR LESS

VENT PIPE

VENT CAP
2′ MIN (0.6 m)
5′ MIN (1.5 m)

Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shutoff valve located outside the heater jacket. All gas piping should be tested after installation in accordance with local codes.
ACAUTION: The heater and its manual shutoff valve
must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 psi (3.45 kPa). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shutoff valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER-PRESSURIZED GAS VALVES ARE NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test. DO NOT use open flame.

DRAFT HOOD

HEATER
Figure 11. Venting Clearances NOTE: For common venting of two or more heaters, contact the factory.

Gas Supply Connections

MANUAL SHUTOFF VALVE (Field-supplied)
GAS INLET
FINISH FLANGE

HEATER JACKET GAS VALVE

Supply Pressure
ACAUTION: Do not use Teflon tape on gas line pipe
thread. Only sealant tape or a pipe compound rated for use with natural and propane gases is recommended. Apply sparingly only on male pipe ends, leaving the two end threads bare.

A minimum of 6 in. WC and a maximum of 10.5 in. WC upstream pressure under load and no-load conditions must be provided for natural gas. A minimum of 12 in. WC and a maximum of 13 in. WC are required for propane gas under load and no-load conditions.

Gas Pressure Regulator

The gas pressure regulator is preset at 4.0 in. WC for

natural gas, and 10.5 in. WC. for propane gas. The

pressure at the gas valve, taken with a manometer, should

be about 4.0 in. WC natural gas and 10.5 in. WC propane

gas. If an adjustment is needed, remove seal and turn

adjustment screw clockwise

to increase pressure or

counter-clockwise

to decrease pressure.

MANUAL SHUT-OFF
VALVE

3″ MIN (76 mm) Typical

UNION (Field-supplied)

SEDIMENT TRAP (Field-supplied)

Figure 12. Gas Supply Plumbing

UNION
F10640-2
Figure 13. Manual Shutoff Valve Installation
15

Gas Pressure Adjustment Locations
Millivolt Gas Valve

GAS PRESSURE ADJUSTMENT
Figure 14. Robertshaw 7000 (Heater Models 206A – 406A)

Electronic Ignition Gas Valves GAS PRESSURE ADJUSTMENT

GAS PRESSURE ADJUSTMENT

Figure 15. Honeywell VR8340 (Heater Models 206A – 406A) GAS PRESSURE ADJUSTMENT

Figure 17. Robertshaw 7000 BDER (Heater Models 266A 336A)
GAS PRESSURE ADJUSTMENT

Figure 16. Robertshaw 7200 (Heater Model 206A)

Figure 18. Robertshaw 7000 DERHC (Heater Model 406A)

16

Pipe Sizing for Gas Connection
These capacities shown below based on using SCH 40 black iron pipe. For capacities using other materials, consult local code.

Maximum Equivalent Pipe Length (ft) (m)

Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in WC Pressure Drop

Propane Gas 2500 BTU/FT3 1.53 Specific Gravity @ 0.5 in WC Pressure Drop

3/4″

1″

1-1/4″

1-1/2″

Model

NAT PRO NAT PRO NAT PRO NAT PRO

206A

25 60 90 215 360 (7.6) (18.3) (27.4) (65.5) (109.7)

266/266A

15 (4.6)

35 50 125 (10.7) (15.2) (38.1)

210 (64.0)

480 445 (146.3) (135.6)

336A

10 20 30 80 140 320 290 (3.0) (6.1) (9.1) (24.4) (42.7) (97.5) (88.4)

399/406A *

15 20 55 95 225 215 480 (4.6) (6.1) (16.8) (29.0) (68.6) (65.5) (146.3)

• A 3/4″ gas line can be used for up to 5′ (1.5 m) maximum length from the gas valve in addition to the sediment trap.
  Table K. Gas Pipe Sizing

Flow Rate

Model

Pipe Size

Min. GPM (lpm)

206A 1-1/4″­1-1/2″­2″ 20 (75)

Max. GPM (lpm)
100 (378)

266/266A 1-1/4″­1-1/2″­2″ 25 (95)

100 (378)

336A 1-1/4″­1-1/2″­2″ 35 (132)

100 (378)

INLET

OUTLET

F10637-1

Figure 21. Bronze Header (ASME) Water Flow

Flow GPM (lpm)
20 (75) 25 (95) 30 (113) 35(132) 40 (151) 50 (189) 60 (227) 70 (265) 80 (303) 90 (340) 100 (378)

Pressure Drop (Ft. of Head) (m of Head)

206A
4.0 (1.2) 4.0 (1.2) 4.0 (1.2) 4.0 (1.2) 4.6 (1.4) 4.6 (1.4) 4.6 (1.4) 4.6 (1.4) 4.6 (1.4) 6.9 (2.1) 8.1 (2.5)

266/266A 336A 399/406A

4.6 (1.4) 5.2 (1.6) 5.8 (1.8) 5.8 (1.8) 6.3 (1.9) 6.9 (2.1) 8.1 (2.5) 9.2 (2.8) 10.4 (3.2) 11.0 (3.4)

5.2 (1.6) 5.2 (1.6) 6.9 (2.1) 6.9 (2.1) 9.2 (2.8) 9.8 (3.0) 10.4 (3.2) 12.1 (3.7)

5.2 (1.6) 6.9 (2.1) 6.9 (2.1) 9.2 (2.8) 9.8 (3.0) 10.4 (3.2) 12.1 (3.7)

Table L. Polymer Heat Exchanger Pressure Drop Residential Models – (UG Fully Open)

399/406A 1-1/4″­1-1/2″­2″ 40 (151)

100 (378)

• When flow rates exceed maximum GPM an external auxiliary bypass valve is required. See external bypass valve section for details.
  Figure 19. Min/Max Flow Rates

INLET

OUTLET

F10638-1

Figure 20. Polymer Header Water Flow 17

Flow GPM (lpm)

Pressure Drop – Ft. of Head (m of Head)

206A

266A

336A

406A

20 (75) 30 (113) 40 (151) 50 (189) 60 (227) 70 (265) 80 (303) 90 (340) 100 (378)

8.2 (2.5) 9.5 (2.90) 9.5 (2.90) 9.7 (2.95) 9.7 (2.95) 11 (3.3) 13.4 (4.08) 10 (3.0) 9.8 (2.98) 12.2 (3.7) 13.4 (4.08) 11 (3.3) 10.4 (3.17) 13.7 (4.2) 13.5 (4.1) 11.5 (3.5) 10.9 (3.3) 14.3 (4.3) 14 (4.3) 12.6 (3.8) 12 (3.6) 15.5 (4.7) 15 (4.6) 14 (4.3) 13 (4.0) 16.2 (4.9) 16.2 (4.9) 15 (4.6) 14.2 (4.3) 17.5 (5.3) 16.7 (5.1)

Table M. Bronze Heat Exchanger Pressure Drop – ASME Models (UG Closed)
NOTE: Table capacity is based on schedule 40 black iron pipe. For capacity using other material, consult local codes.

O-RING
HEADER FLANGE (CPVC)
HEADER FLANGE NUT (CPVC)

HEADER

PROTEK SHIELD ASSEMBLY

PLUMBING
F10664

Figure 23. Inlet/Outlet Header ­ Bronze
NOTE: Some jurisdictions require the addition of a flow switch on ASME installations. Kit # 015889F for flange connection or 015890F for NPT connection can be ordered that will allow a standard ASME unit to comply with the code requirements.

Polymer Headers (Residential Models)
Before attaching the 2-inch unions to the inlet/outlet header, make sure the O-rings are properly seated in the grooves. Use Aqualube or equivalent non- petroleumbased lubricant on the O-ring. Hand tighten the unions. Glue PVC piping directly to the unions.

ProTek Shield Assembly
This heater is equipped with a ProTek Shield Assembly (located under the inlet connection on polymer headers) and in the ProTek Shield Adapter assembly shipped loose in the accessory carton for field-installation on bronze ASME headers.

PROTEK SHIELD ASSY

O-RING
HEADER FLANGE (CPVC)
PLUMBING

NOTE: ProTeK Shield not available on ASME models until end of Q3 2020.
This component provides protection to the heat exchanger against galvanic corrosion, when properly bonded to the heat exchanger. It should be replaced when the weight of the ProTek Shield is reduced to about 40% of the original weight (1.46 #).

HEADER FLANGE NUT
(CPVC)
F10641

Figure 22. Inlet/Outlet Header ­ Polymer
High-temperature CPVC header flanges and header flange nuts are provided. If there is any possibility of backsiphoning when the pump stops, it is suggested that a check valve (or valves) also be installed in the system.

F10715
Figure 24. ProTek Shield Assembly

Bronze Headers (ASME Models)
Heater must be located so that any water leaks will not damage the structure of adjacent area. Before attaching the ProTek Shield Adapter to the inlet connection and the 2-inch unions, make sure the O-rings are properly seated in the grooves. Use Aqualube or equivalent non-petroleumbased lubricant on the O-ring. Hand tighten the unions. Glue PVC piping directly to the unions.

ACAUTION: STOP the pool pump before attempting to
remove ProTek Shield Assy. Failure to do so may result in damage to ProTek Shield Assy, loss of pool water, or personal injury.
CAUTION: Do not use tools to remove (twist) the ProTek Shield Assy or the wing nut on the stud of the ProTek Shield Assy. Non-warrantable damage may occur.

18

Follow the steps below to replace the ProTek Shield Assy:
1. Shut off the pool pump and bleed pressure from the system.
2. Close isolation valves to minimize pool/spa water loss.
3. Remove wing nut from bottom stud on ProTek Shield Assy.
4. Remove bonding wire ring terminal from stud.
5. Rotate ProTek Shield Assy clockwise (by hand) to unscrew it from the assembly.
6. Inspect/replace as necessary and reverse above procedure to reinstall. Hand tighten only! Do not use tools.

Internal Automatic Bypass Valve
In addition to the Unitherm Governor, a built-in automatic bypass valve is provided in the In/Out header. While the Unitherm Governor responds to the changes in water temperature in the heater, the internal bypass valve automatically responds to changes in water pressure in the piping system. Proper amount of water flow is maintained through the heater under varying pressures dictated by the conditions of the pump and filter.
UG/BYPASS ASSY

NOTE: Make sure the O-ring is properly seated in the O-ring groove before installation.

BYPASS DISC

Unitherm Governor Operation

SPRING “YELLOW” – 206/266 “GREEN” – 336/406

ACAUTION: The patented Unitherm Governor is
a thermostatic mixing valve specifically designed to maintain constant heater internal temperature between 105°F (41°C) and 115°F (46°C) despite continually changing flow rates from the filter and changing pool temperatures. This narrow range is needed to prevent damaging condensation on the burners which will occur if the heater runs for any length of time below 100°F (38°C). It is also needed to inhibit scale formation in the tubes by maintaining temperatures well below accelerated scaling temperatures.
UG PLUG UNITHERM GOVERNOR
GASKET
F10725
Figure 25. Unitherm Governor – Polymer UG/BYPASS ASSY

F10642-3
Figure 27. Internal Automatic Bypass Valve – Bronze
NOTE: The Unitherm Governor and Bypass Valve Assy are not individually- replaced components on ASME units. If either needs to be replaced, the entire UG/ Bypass assy must be replaced. The “yellow” spring is used on models 206A, 266A. The “green” spring is used on models 336A, 406A.

External Auxiliary Bypass Valve
Where Required – An auxiliary bypass valve should be used when flow rates exceed 100 GPM (378 lpm). Usually a high-performance pump size larger than two horsepower will exceed this flow rate. This valve is required to complement 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.

FROM HEATER

TO HEATER

FULL PORT BALL VALVE OR GLOBE
VALVE

UNITHERM GOVERNOR
F10642-2
Figure 26. Unitherm Governor – Bronze

TO POOL/SPA

FROM POOL/SPA

BYPASS VALVE
*Do not use a gate valve. Figure 28. Auxiliary Bypass Valve

19

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 or greater than to the BTU output of the model to be installed, is recommended for this heater.
A 3/4″ NPT connection is provided in the Polymer header for installation of a pressure relief valve. The valve shall be installed in a vertical position. Do not over-tighten. Install pressure relief valve hand-tight plus 1/2 turn.
PRESSURE RELIEF VALVE
PRV DISCHARGE CONNECTION

NOTE: To avoid water damage or scalding due to valve operation, drain pipe must be connected to valve outlet and run to a safe place of discharge. Drain pipe must be the same size as the valve discharge connection throughout its entire length and must pitch downward from the valve. No shutoff valve shall be installed between the relief valve and the drain line. Valve lever should be tripped at least once a year to ensure that waterways are clear.
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. See Figure 32 and Figure 33. 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 (Salt generators and chemical feeders must be downstream of the pool heater).
Plumbing from the heater back to the pool or spa must not have any valves or restriction that could prevent flow when the pump is operating.

IN/OUT HEADER

F10662

Figure 29. Field-Supplied Pressure Relief Valve, Residential Units
A 3/4″ NPT connection is provided in the header for installation of a 75 PSI (517 kPa) pressure relief valve. The PRV is shipped loose in the accessory carton with the pagoda top. The pressure relief valve shall be installed in a vertical position.

ACAUTION: An additional source of heated water,
e.g. a solar system, must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source. If the primary system provides adequate heat to maintain setpoint, the heater will not fire. Be advised that the control panel will then display sensed water temperatures downstream of the primary heating system, rather than the temperature of the water exiting the pool.
Heater must be located so that any water leaks will not damage the structure of adjacent area. PVC pipe may be glued directly into the headers unions.
Heat Exchanger Reversal

Procedure for Residential Models
1. Remove right and left-side access panels. See Figure 31.

F10663

PRESSURE RELIEF VALVE

Figure 30. Pressure Relief Valve, Commercial Units

20

F10652
Figure 31. Access Panels

Plumbing Diagrams
Water Connection

THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER
Figure 32. Single Heater Installation

ISOLATION VALVE
BALL VALVE
PRESSURE RELIEF VALVE PUMP UNION CHECK VALVE

THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER
Figure 33. Multiple Heater Installation
21

2. Disconnect wires at high limit, AGS (automatic gas shutoff), water pressure switch on the in/out header and ProTek Shield bonding wire. See Figure 34.

5. Reconnect high limit, AGS, water pressure switch wires, and ProTek Shield bonding wire.
6. Digital Models: Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting. Tighten 1/2 turn past hand-tight.

F10653
Figure 34. Component Wiring Locations – In/out Header
3. Digital Models: Remove the thermostat temperature sensor by loosening the compression fitting nut. Reroute the sensor to left-side of the heater. See Figure 35.
Millivolt Models: Remove the temperature sensor bulb and retainer clip by loosening the compression fitting nut. Re-route the sensor bulb to the left- side of the heater. See Figure 36.

Millivolt Models: Insert sensor bulb and retainer clip into sensor well. 7. Allow for water flow through the heater and check for leaks. 8. Re-attach access panels to the opposite sides. For instructions on reversing the heat exchanger connections on ASME models, call your factory representative.
5. ELECTRICAL WIRING
NOTE: If it is necessary to replace any of the original wiring, use 105°C wire or its equivalent, and/or 150°C wire or its equivalent, like the original wiring.
AWARNING: Digital heaters are factory-wired for
240 VAC, 1 Ph, 60 Hz power supply. DO NOT attempt to operate at 208 VAC.

SENSOR

Millivolt Models (“M” suffix)

F10654
Figure 35. Digital Temperature Sensor Location

The Millivolt models are equipped with a self-generating electrical system in which the electrical current is provided by a pilot generator. No external electrical connections are required.
When installing a remote switch, do not exceed 10 ft (3 m) of wiring from the heater. Use 18-gauge stranded wire.
Digital Models (“E” suffix)

SENSOR
F10667
Figure 36. Millivolt Temperature Sensor Location 4. Remove (12) nuts holding the inlet/outlet and return
headers to the tube sheets. Clean off tube sheet area where the gasket seats. Also clean off the header and the gasket. Apply a non-petroleum-based lubricant to the gasket such as Aqualube. Re-attach the headers to the opposite sides, making sure they are installed in an upright position. Do not over-tighten. Torque should not exceed 7 ft/lb. See Figure 35. 22

The standard field-wiring connection is on the right-side of the heater.
To wire the heater from the left-side, follow these steps:
1. Remove the two (2) screws that hold the front door to the heater. Remove and set aside door for better access to wiring.
2. Remove the four (4) screws that hold down the junction box to the sway brace.
3. Remove the transformer cover located on the far right by removing one (1) screw.
4. Remove the two (2) screws that hold down the transformer.
5. Remove the one (1) screw that holds down the ground wires.
6. Disconnect P6 connector from PC board.
7. Remove transformer from its current location and relocate it on the far left-side of the heater.

8. Re-route all high-voltage wires and ground wires through the left jacket side of heater.
9. Re-install P6 connector, ground wires (SPG), transformer, junction box, front door, and plug rightside with the left-side’s grommet plug.
NOTE: 7/8″ diameter holes not utilized on jacket and control box can be used for fireman switch, auxiliary control interface or power vent (D-2) wiring.

There should be no connection to the red wire for 120 VAC operation. Attach a wire nut to the red wire.

HOT L1
BLACK

BLACK

SUPPLY SIDE

RETURN or
NEUTRAL
GROUND

WHITE GREEN

WHITE GREEN

HEATER 4 WIRES

Electrical Power Draw
ACAUTION: Heater must be electrically grounded and
bonded. Bonding lug is provided loose with the heater. Install bonding lug on lower right or left-side of jacket as necessary for bonding the heater. Mounting hole is provided on the jacket.
NOTE: Failure to ground the heater electrically could affect the heater’s electronics.
NOTE: See “Time Clock/Fireman’s Switch” on page 31 for further instructions if using a time clock/fireman’s switch.
The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call-for-heat. The heater is supplied with a dual-voltage transformer for 120 VAC or 240 VAC input power hookup. When operating on 120 VAC power, units draw 4 amps. When operating on 240 VAC power, units draw 2 amps.

RED

Figure 38. 120 VAC Wire Connection

240 VAC Wiring
For 240 VAC 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. There should be no connection to the white wire for 240 VAC operation. Attach a wire nut to the white wire.
AWARNING: DO NOT attempt to operate the heater
at 208 VAC.

HOT L1
BLACK

BLACK

L2
SUPPLY SIDE

HOT RED
GREEN

RED GREEN

HEATER 4 WIRES

OPTION LOCATION LEFT SIDE FIELD WIRING

CONTROL BOX (FACTORY MOUNTED LOCATION)

WHITE
Figure 39. 240 VAC Wire Connection

SWAY BRACE

BONDING LUG (OPTIONAL LOCATION)

F10650

BONDING LUG (STANDARD LOCATION)

Figure 37. Heater Wiring Locations

Transformer Wiring
120 VAC Wiring
For 120 VAC 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 “Ret” or neutral leg of the power supply.

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.)
ACAUTION: If the transformer’s primary side is wired
for 120 VAC and 240 VAC is applied, damage to the transformer and PC board may result. Such damages are not covered under manufacturer’s limited warranty.
NOTE: Input power to the heater (120 or 240 VAC) can be supplied from the load (pump) side of time clock or directly from the GFCI power source. It is preferred that full-time power be supplied to the heater from the GFCI power source, and that the heater be controlled by the fireman’s switch connection or using a two or three-wire remote. If using a switched GFCI power source, the heater could display false service indicators on the display panel if the pump is turned off.

23

6. WIRING DIAGRAM – MILLIVOLT
24

7. WIRING DIAGRAM – DIGITAL
25

APPROVED UNCONTROLLED DOCUMENT IF PRINTED

8. CONTROLS
CONTROL BEZEL

PRESSURE SWITCH TEMP SENSOR HL1 – HIGH LIMIT HL2 – HIGH LIMIT
UNITHERM GOVERNOR

NOTE: Caution must be used to not damage controls or wiring.
KNURLED SCREW

ROLL-OUT SWITCH

GAS VALVE

F10640-2

PROTEK SHIELD ASSY

Figure 40. Location of Controls (View One)

F10646-5
Figure 42. Knurled Screw Location

Control Adjustments –
Millivolt Models
The water temperature is controlled by the heater thermostat on the upper front panel of the heater. The control center contains an On/Off switch and one thermostat.
The thermostat is fitted with a means of limiting the upper temperature just below the maximum level. The knob stop adjustment ring illustrated below is adjustable by loosening the set screw, rotating the knob stop ring to the desired location and re-tightening the set screw.

SPA TEMPERATURE RANGE

POOL TEMPERATURE RANGE

DRAIN PLUG IN REAR HEADER

F10640-3

PILOT

KNOB STOP RING

SET SCREW

STAND-BY TEMPERATURE

Figure 41. Location of Controls (View Two)
Control Panel Removal
1. Remove screw from front door. Set aside door for serviceability.
2. Remove (4) screws from sides of control panel. 3. Rotate control panel down until panel stops. Do not
force.

KNOB STOP SHOWN ABOVE IS IN THE SPA TEMPERATURE RANGE.
Figure 43. Control Adjustment ­ Millivolt Models

26

Control Adjustments ­ Digital Models
The pool heater touch-pad 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 touch-pad turns the control power ON or OFF. See Figure 44.
TEMP ADJUST BUTTONS MODE BUTTON

Program Mode Button (SW1) Figure 46. Thermostat Program Button (SW1)

TEMP

MODE

LCD DISPLAY

ON OFF

Figure 44. Control Adjustment ­ Digital Models

Mode Button
The MODE button is used to select POOL or SPA operation. It also allows the user to turn the heater off electronically, allowing the LCD to remain energized and to continue showing the actual water temperature.
Temp Buttons
If the heater is in POOL or SPA mode, the desired water temperature (SETPOINT) will be displayed and may be adjusted using the UP or DOWN buttons.

Operation
In the POOL or SPA modes, the actual water temperature is displayed along with the desired water temperature (SETPOINT). When the water temperature 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 control is in the appropriate mode (POOL or SPA) and push the UP or DOWN buttons.
By default, the setpoint range is 50-104°F (10-40°C). See MAX Settings on page 28 to increase the MAX setting, if necessary.

Service Menu and Fault History
To access the Service Menu and fault history, press the Mode and UP buttons simultaneously for 3 to 5 seconds. The heater will continue to operate while in the Service Menu. The first screen displayed is the Flame Strength indicator, which indicates the pilot flame current using a bar graph and numerical display. A signal of less than 4 bars indicates a weak flame signal and may require service. Refer to the Troubleshooting section for possible causes and corrections.
Figure 47. 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.
Figure 48. Supply Voltage Indicator Press the DOWN button. The Run Time indicates the total hours of operation for the pool heater, as measured 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.

Figure 45. Alternating Display During Heating

Figure 49. Run Time/Cycles 27

Press the DOWN button. The Fault History displays up to ten faults in memory. The order of the faults begins with “Fault Last,” which is the most recent fault, 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.”

Both the POOL and SPA setpoints will revert to 65°F (18°C) and both POOL and SPA maximum temperature settings will be 104°F (40°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 MODE 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.

Figure 50. Fault History Indicator
Program Button
1. Remove the four screws holding the control cover, and swing the panel down so the back side of the board is visible. Locate the Program Mode button (SW1). See Figure 46. Press and hold the button for 5-7 seconds until SET FACTORY DEFAULTS appears on the display. Release the program button.
2. Press the MODE button sequentially until the desired program event is reached. There are 5 different events that can be programmed. They appear in the sequence listed in Figure 51.
Resets board to factory default settings.
Resets faults in the History File.

Fahrenheit or Celsius
Refer to step one above to access the program screen. Press the MODE button until FAHRENHEIT or CELSIUS appears on the digital display. The UP or DOWN buttons will select FAHRENHEIT or CELSIUS on the temperature display. Choose the desired temperature scale.
Spa Max Temp ­ Spa Setpoint Maximum Adjustment
Refer to step one above to access the program screen. Press the MODE 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 (42°C).
Pool Max Temp ­ Pool Setpoint Maximum Adjustment
Refer to step one above access into the program screen. Press the MODE 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 107°F (42°C).

Change from Fahrenheit to Celsius.
SPA setpoint maximum adjustment. POOL setpoint maximum adjustment.
Figure 51. Programmable Events
Set Factory Defaults Refer to step one above to access the program screen. SET FACTORY DEFAULT should appear on the screen. If it does not, press the MODE button until it appears on the digital display. Press and hold both UP and DOWN buttons for 5-7 seconds until DEFAULT SET appears. This operation resets the operating program to its factory default values.

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 MODE button for 5 seconds. Choose a three digit PIN, using the UP and DOWN buttons to select the digits and the MODE 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.

28

NOTE: Both the POOL and SPA setpoints will revert back to 65°F (18°C) and the POOL and SPA maximum temperature settings will be 104°F (40°C). These setpoints will need to be readjusted to desired settings.

NOTE: The LCD temperature display may not agree with the temperature reading of your pool or spa thermometer. The heater reads the water temperature at the inlet. Due to the circulation characteristics of any pool or spa, the water 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 models are programmed to display a variety of status and diagnostic messages, depending 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

Condition

Heating

Call-for-heat established, flame present.

Spark

Spark operating.

No Demand Heat demand is satisfied.

Table N. Heater Status Messages – No Active Faults

The following conditions are displayed in Pool, Spa and Remote modes.

Display

Condition

Sensor Failure Sensor Open Sensor Short Flame w/o CFH

Thermistor temperatures disagree by more than 2°F (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 commanded shut.

PV Output Fault

Pilot gas valve output is not in commanded state.

MV Output Fault
LoNox Tab Fault Internal Fault EEPROM Fault Clock/Fireman Sw

Main gas valve output is not in commanded state.
Voltage is sensed at the Lo NOx terminal on a non -Lo- NOx heater (Lo NOx tab is intact).
Board fault, replace board.
Memory fault, reset setpoints, replace board if fault does not clear.
Time clock/fireman switch circuit is open.

Low Temp Lockout

Water temperature below 36°F (2°C).

Table O. Heater Status Messages – Active Faults

The following conditions are displayed only while there is a demand for heat present.

Display

Condition

Water Sw Open Water pressure switch open.

Vent/Field Sw #1

Vent spill switch/field switch #1 open.

High limit 1 open. For ASME units Hi Limit 1 is open ONLY, this is a manual- reset fault.
Press the MODE button to reset.

High limit 2 open. For ASME units Hi Limit 2 is open ONLY, this is a manual- reset fault.
Press the MODE button to reset.

Rollout Sw Open Rollout switch open.

Flow/Field SW #2

Field-supplied flow switch/field switch #2 open.

Ignition Lockout (Propane Tab Broken)
Ignition Failure (Propane Tab Not Broken)
Ign 60 min Delay (Propane Tab Not Broken)

Alternating with “No pilot sensed” – Pilot flame not established 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.
Alternating with “No pilot sensed” – Pilot flame not established 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 60 minutes before retrying.

Table P. Heater Status Messages – Demand for Heat

High Limit Events

ASME units ONLY.
Figure 52. High Limit Events
TO ELIMINATE HIGH LIMIT EVENTS
1. Confirm circulation pump is running during heating cycle.
2. Pump should shutoff a minimum of 5-minutes after heating cycle ends.
Failure to follow these steps may cause residual heat buildup – triggering a High Limit event.
If issues persist, contact your service installer.

29

Remote Control Installation and Operation
ACAUTION: Before installing remote controls to
the digital 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 Figure 53. The touch pad on the control 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 the heater to a remote system, identify whether it is a two- or three-wire remote system. Select the appropriate instruction listed below to properly install the remote to the heater.

Millivolt models are not designed for operation with remote control system.
Activating the Remote
To activate or deactivate the remote function:
1. Press and hold the UP and DOWN arrow buttons for 3 to 5 seconds.
The second line of the display will alternate even when the unit is off (“No Demand”).
NOTE: When in remote operation, the keypad mode and temp buttons are disabled.

Remote Operation (Digital models only)
The 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 thermostatic controls with a time clock. See “Time Clock/Fireman’s Switch” on page 31.

Figure 54. Remote Control Menu – Activation
Remote Control Wiring Digital Models Only
ATTENTION OBSERVE PRECAUTIONS
ELECTROSTATIC SENSITIVE DEVICES

OFF Mode Heating in the POOL Mode Heating in the SPA Mode Remote Mode Figure 53. Remote Control Menu – Remote Operation

ACAUTION: 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 accumulates 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 enclosure for 5 seconds before proceeding.
Important Installation Notes for Remote or External Wiring Configuration:
· Remote wiring must be run in a separate conduit.
· Remote wiring must not be run parallel to high voltage lines.
· For runs of under 30′ (9 m), remote wiring should have stranded conductors with a minimum of 22 AWG, 600V, cable twisting 1.5″ to 2.5″ (3.8 to 6.4 cm) lay and jacketed.
· For runs over 30′ (9 m), the conductors should be a minimum of 20 AWG, 600V, cable twisting 1.5″ to 2.5″ (3.8 to 6.4 cm) lay that is shielded and jacketed.
· Maximum cable length is 200′ (61 m).

30

· For both two- and three-wire remote systems, the 3. Turn the MODE button to “OFF” and remove power

provided 7-pin wiring connector must be utilized.

from the heater.

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 application 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 MODE button to the “POOL” or “SPA” mode and set the desired setpoint (e.g. 102 °F (39°C) for Spa).
3. For a 2-Wire Remote Control from a remote with its own sensor, push the MODE 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 MODE button to “OFF” and remove power from the heater.
5. On the “Remote Interface Harness”, connect the BLUE wire to one side of the “REMOTE” switch and connect the other side to either the ORANGE/BLACK wire for “SPA” operation or the BLACK/ORANGE wire for “POOL” operation. See Figure 55.

BLU – 24VAC
ORN/BLK – To Spa (COMM) Wire Nut BLK/ORN – To Pool (COMM)
Figure 56. 2-Wire Remote Harness Installation on the P8 Connector of the Board

Pool Common (BLK/ORN)

Spa Common (ORN/BLK)

BLU – 24VAC ORN/BLK – To Spa (COMM)

24VAC HOT (BLU)
Figure 55. 7-Pin Remote Interface Harness
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. See Figure 56.
For activation of the remote control, see section on page 30.
3-Wire Remote Control Using ThreePosition Switch (Pool-Off-Spa, or Low- OffHigh)
This application assumes that both heating functions (pool and spa) are required.
1. Turn on power to the heater.
2. Push the MODE button to the “POOL” or “SPA” mode and set the desired temperature for each (e.g. 80°F (27°C) for Pool and 102°F (39°C) for Spa).

BLK/ORN – To Pool (COMM)
Figure 57. 3-Wire Remote Harness Installation on the P8 Connector of the Board
4. On the “Remote Interface Harness” connect the BLUE wire to one side of the “REMOTE” switch and connect the ORANGE/BLACK wire for “SPA” operation and the BLACK/ORANGE wire for the “POOL” operation. See Figure 55.
5. Install the “Remote Interface Harness” to the P8 connector and turn power ON to the heater. See Figure 57.
For activation of the remote control, see section on page 30.
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 (chauffe- piscine) 15 to 20 minutes prior to shutting down the pool pump.

31

For millivolt heaters, the fireman’s switch connection is a wire nut located in the Violet/Black wiring between the manual toggle switch and the gas valve. heaters, splice into the red/white wire to connect the time clock.
For digital heaters, the fireman’s switch connection is located 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 connection on both millivolt 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 covered by warranty.
Millivolt heaters: Do not exceed 15 ft (4.5 m) of total wiring using 14 AWG stranded copper wire rated for 105°C minimum.
Digital heaters: Do not exceed 50 ft (15 m) of total wiring using 18 AWG stranded copper wire rated for 105°C minimum.
NOTE: When using a time clock, the digital heater will display “Clock/Fireman Sw” when the fireman’s switch is open, indicating that the time clock has shut off the call-for-heat.

8. While the heater is running, check the adjustment by turning the pump off and on several times. The burners should shut off immediately when the pump is turned off. If it does not, repeat the above steps until proper operation is observed.
F10671
Figure 58. Water Pressure Switch Assembly NOTE: The sheet metal access panel should be in place at all times to protect the water pressure switch from rain and other environmental factors.
MAY REQUIRE ADJUSTMENT FOR LOWER PRESSURE

Water Pressure Switch
The water flow 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 for deck-level installations.
Water Pressure Switch Adjustment
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 necessary to adjust the water pressure switch, utilize the following procedure:
1. Make sure the pool filter is clean before adjusting the switch.
2. Set the heater control to the OFF mode.
3. Turn the filter pump ON and confirm that the pressure switch is closed (use a multimeter to check). If the pressure switch fails to close, either the switch setting is too high or not enough pressure is being supplied by the filter pump.
4. Turn the heater ON.
5. Manually turn the pressure adjustment knob clockwise until the heater shuts off. (A flat screwdriver may be necessary if knob is too tight.)
6. Slowly turn the adjustment knob counter-clockwise until the heater calls for heat again.
7. Turn an additional 1/2 turn counter-clockwise.

MAY REQUIRE ADJUSTMENT FOR HIGHER PRESSURE
5 ft. (1.52 m) MAX

5 ft. (1.52 m) MAX

POOL OR SPA

Figure 59. Pressure Switch Adjustment Requirements
NOTE: If heater is installed outside of the limits shown, a switch rated for a higher pressure (11 psi / 76 kPa) 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” on page 47 for 11 psi / 76 kPa water pressure switch.
Two-Speed Pumps
In some cases, the flow on the low-speed is insufficient 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.

32

ACAUTION: Do not operate the heater without the
function of a properly-adjusted water pressure switch or flow switch.
Flame Roll-Out Safety Switch
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 disabled by an over- temperature condition, caused by excessive restriction in the heat exchanger flue passage.
F10668
Figure 60. Flame Roll-Out Safety Switch
High Limits
The heater is equipped with two high limits. On residential units (polymer headers), both are automatic and are located in the inlet/outlet header. Both are set at 135°F (57°C). On commercial units (bronze headers), both are located on the inlet/outlet header. HL1 is automatic reset and set to open at 160°F (71°C). HL2 is automatic reset and 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” on page 40.
AUTO RESET

Pilot Safety – Millivolt Models
Heaters equipped with the standing pilot (millivolt system) employs a pilot which act as a safety device to shut down 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 re-lighted to place the heater in operation again. Refer to the lighting instructions provided on the heater label.
Pilot Safety – Digital Models
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 automatically lit when the device is powered. The heater performs its own safety check and opens the main valve only after the pilot is proven to be lit.
Burner Tray Removal
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit, and (2) screws that secure gas valve to jacket.
6. Disconnect wires that terminate at gas valve.
7. Disconnect hi-tension wire from PC board.
8. Carefully slide out burner tray assembly.
9. Reverse above procedure to reinstall.
GAS VALVE

BURNER PILOT
BURNER HOLD-DOWN
BRACKET

GAS ORIFICE

F10669-2
Figure 61. High Limit Switches

Figure 62. Burner Tray Assembly

High Limit Removal
1. Shut off main electrical power switch to heater. 2. Remove inlet/outlet sheet metal access panel. 3. Remove defective high limit and replace with the
correct new high limit. 4. Replace access panel.

Gas Valve Removal
1. Shut off gas supply to the heater. Remove gas piping to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if required.
3. Remove burner tray from heater.

33

4. Turn vertical gas pipe from manifold slightly and unscrew gas valve.
5. Reverse above procedure to reinstall.
Main Burner And Orifice Removal
1. Remove burner tray, following above procedure. 2. Remove screws and burner hold-down bracket.
NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct-flame impingement and this usually 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 over-tighten when reinstalling.
Pilot Removal And Cleaning
1. Disconnect pilot tubing and wires from gas valve. 2. Remove pilot assembly from burner tray. 3. Remove pilot from bracket. 4. Remove pilot orifice and air opening, and clean with
wire or small brush. ACAUTION! Do not enlarge hole in pilot orifice. 5. Reverse above procedure to reinstall.
PILOT
AIR OPENING ORIFICE

Heat Exchanger Removal
1. Shut water, gas and electricity off, close valves and relieve pressure, then remove relief valve. Remove side access panels.
2. Remove top jacket holding screws.
3. Remove rear top panel.
4. Remove screws mounting the rain shield to the rear panel. Also remove the screws that mount the rain shield to the sway brace. Remove rain shield.
5. Remove the four (4) screws holding down the flue collector. Remove the flue collector.
6. If ProTek Shield Assy is attached to the heater; disconnect flange nuts on Inlet/Outlet header, remove ProTek Shield Assy bonding wire from heat exchanger stud, loosen union at gas pipe and slide heater away from piping.
7. Lift heat exchanger straight up using caution not to damage refractory.
8. Reverse above procedure to reinstall. Make sure the insulation strips are properly replaced on top of the refractory retainer.
Tube Cleaning Procedure
Establish a regular inspection schedule, the frequency depending on the local water conditions and the severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16″ (1.6 mm) in thickness.
The heater may be cleaned from the return header side, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the ground-up lime dust does not get into the system. Note that you do not remove the top panel or the heater exchanger, generally.
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-inhibited descale solvent for severe scale build-up.

Figure 63. Millivolt Pilot

Extension Pieces (2)

Auger

Wire Brush

with Carbide Tip

Figure 64. Digital Pilot 34

Figure 65. Tube Cleaning Kit (P/N: 052871F)
Desooting Procedure
AWARNING: Soot Is Combustible. Exercise Extreme
Care.
Soot will clog areas between fins and cause eventual tube failure. Any sign of soot at the base of the burners or around the outer jacket indicates a need for cleaning.

1. Remove top and flue collector from cabinet. 2. Remove “V” baffles from heat exchanger. 3. Remove burner tray. See page 33. 4. If ProTek Shield Assy is attached to the heater,
remove ProTek Shield Assy bonding wire from heat exchanger stud. 5. Remove heat exchanger from the heater and wash with a garden hose, making sure soot is removed from spaces between fins. 6. Reverse above procedure to reinstall.
NOTE: In extreme cases it may be necessary to do steam cleaning at the local car wash. DO NOT WIRE BRUSH.
Combustion Chamber Removal
To remove combustion chamber, you must first have removed the heat exchanger.

F10670
Figure 67. Well Assembly Unitherm Governor (U.G.) Replacement
Unitherm Governor (U.G.) Replacement
1. Shut water, gas and electricity off, close valves and relieve pressure.
2. Drain heat exchanger. 3. Remove retainer plug located next to the outlet pipe
connection on polymer header models. 4. Unsnap old U.G. to remove from retainer plug. Snap
in new U.G. 5. Reinstall retainer plug, taking care to lubricate
gasket with a non-petroleum based grease such as AquaLube.

UG PLUG

UNITHERM GOVERNOR

GASKET

F10723
Figure 66. Refractory Panels

F10725

AWARNING: 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.

Figure 68. Unitherm Governor – Polymer
To test the operation of the Unitherm Governor – Polymer, place in hot water (over 110°F [43°C]) and watch for movement against spring. If there is no movement, replace unit.
UG/BYPASS ASSY

Immersion Well Replacement (Millivolt)
1. Shut off water to heater and drain heat exchanger. 2. Remove access panel on water connection side. 3. Remove old immersion well with bushing and sleeve. 4. Install replacement well in header.
NOTE: Installation in polymer header should be hand tight plus 1/2 turn.

UNITHERM GOVERNOR
F10642-2
Figure 69. Unitherm Governor/Bypass Valve Assy ­ ASME
NOTE: The U.G. on bronze header models (ASME) can only be replaced by replacing the entire Unitherm Governor/Bypass Valve Assembly.

35

9. OPERATING INSTRUCTIONS
Before Start-Up
Burners
Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not obstruct the flow of combustion and ventilation air.
Water
Water must be flowing through the heater during operation. Ensure that the system is filled with water and that the pump is operating.

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. 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.
4″ MAX (102 mm)

Start-Up Procedures
Your pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available with millivolt or electronic ignition. ASME- certified units typically used in commercial applications, are also available. This manual provides installation, operation, maintenance, and service information for these heaters.
TEMP ADJUST BUTTONS MODE BUTTON

Figure 71. Main Burner Flame Figure 72. Millivolt Pilot Burner Flame

TEMP

MODE

LCD DISPLAY

ON OFF

Figure 70. Heater Control Toggle Switch
If your heater has been installed correctly, operating the heater is an easy task. The upper front panel of the heater contains the control center that allows you to turn the heater On or Off and adjust the temperature settings for the pool or spa. The temperature range is factory set from 65°F (18°C) to 104°F (40°C). See Figure 70 for location of toggle switch to turn the heater On and Off.
See Section 8 for additional details about the use of the controls in the Control Adjustments subsection.

Water Pressure Switch
A water pressure switch is provided in the heater to shut off the burners in the event that water supply 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 switch should be checked and adjusted for proper operation by a qualified service person at the time of installation and periodically checked thereafter. Refer to “Water Pressure Switch Adjustment” on page 32 of this manual.

After Start-Up
Feel the inlet and outlet pipes. Outlet pipe should be only slightly warmer than the inlet. It should not be hot.
AWARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control to the appliance.

F10671
Figure 73. Water Pressure Switch
AWARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the heater. Such damage is not covered under warranty.

36

OPERATING INSTRUCTIONS AND SHUTOFF PROCEDURES MILLIVOLT SYSTEM
(MANUALLY-LIGHTED PILOT)

FOR YOUR SAFETY READ BEFORE LIGHTING

A. This appliance has a pilot which must be lit by hand. When lighting the pilot, follow these instructions exactly.
B. BEFORE LIGHTING, smell all around the appliance area for gas. Be sure to smell near 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 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.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above. 2. Set the thermostat to the lowest setting. 3. Turn On/Off switch to the “OFF” position. 4. Remove heater door panel. 5. Push in gas control knob slightly and turn clockwise
to “OFF”.

NOTE: Knob cannot be turned from “PILOT” to “OFF” unless knob is pushed in slightly. Do not force.
6. Wait 5 minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.
7. Locate pilot mounted in the right-side panel of the burner tray. HONEYWELL MILLIVOLT GAS VALVE
ROBERTSHAW MILLIVOLT GAS VALVE

8. Turn gas control knob counter-clockwise

to

“PILOT”.

9. Place flame to end of pilot tube. Push in control knob all the way and hold to light pilot. Continue to hold control knob in for about one minute after the pilot has lighted, release knob and it will pop up. Pilot should remain lighted. If it goes out, repeat steps 5 through 9. If knob does not pop up when released, stop and immediately call your service technician or gas supplier.

10. Stand to the side of the heater and turn the gas

control knob counter-clockwise

to “ON”.

11. Replace heater door panel.

12. Turn On/OFF switch to the “ON ” position.

13. Set thermostat to the desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting. 2. Turn On/Off switch to the “OFF” setting. 3. Remove heater door panel.

4. Push the gas control knob slightly and turn clockwise to “OFF”. Do not force
5. Replace heater door panel.

37

OPERATING INSTRUCTIONS AND SHUTOFF PROCEDURES ELECTRONIC IGNITION DIGITAL MODELS (AUTOMATICALLY-LIGHTED PILOT)
FOR YOUR SAFETY READ BEFORE LIGHTING

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 near 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 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.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. Remove heater door panel.

6. For

Honeywell

valve:

Turn

gas

control knob clockwise

to “OFF”.

For Robertshaw valve: Models 266-406: Turn

gas control knob clockwise

to “OFF”. Model

206 Push in and move gas control lever counter-

clockwise

to “OFF” position.

7. 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.

8. Turn gas control knob counter-clockwise to “ON”. (Honeywell VR8340 and Robertshaw 7000).

9. Replace heater door panel.

10. Turn on all electrical power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier. HONEYWELL VR8340 GAS VALVE IID
GAS INLET
ROBERTSHAW 7000 GAS VALVE IID
ROBERTSHAW 7200 GAS CONTROL LEVER SHOWN IN “OFF” POSITION
GAS INLET

O OF

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat at the lowest setting.
2. Turn off all the electrical power to the appliance if service is to be performed.
3. Remove heater door panel.

4. For Honeywell VR8340 and Robertshaw 7000 gas

valve.

Turn gas control knob clockwise

to “OFF”.

Make sure knob rests against stop.

5. Replace heater door panel.

38

10. MAINTENANCE AND CARE Cold Weather Operation

AWARNING: Check the heater for possible rodent
nests after long periods of non-use.
To be followed one month after start-up and then semiannually.
1. Inspect the top of the 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 operation.
ACAUTION: 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 (if equipped).
4. Make visual check of the burner and pilot flames. Yellow flame means restriction of the air openings. Lifting or blowing flame indicates high gas pressure. Low flame means low gas pressure. Should the latter occur, shut the heater off and contact your gas supplier or qualified service agency. See Figure 71 and Figure 72.
5. On indoor heaters, clean room intake openings to ensure adequate flow of combustion and ventilation air.
ACAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the heater. Such damage is not covered under warranty.
6. Keep area around heater clear and free from combustible materials, gasoline and other flammable and corrosive vapors and liquids.
If Heater Will Not Fire:
If you have no electrical power, it may be that your “circuit breaker” has tripped. Try re-setting it.
If you have electrical power but the heater will not fire check the following or see “TROUBLESHOOTING” on page 40.
1. The time clock must be in the “ON” position.
2. Your pump strainer basket may be full. If so remove debris.
3. Your filter may be dirty. If so, backwash or clean filter. (To tell if your filter is dirty, look to see if the filter pressure is higher than usual).
4. The pump may have lost its prime and be running dry. Check the pressure 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 its normal flow rate.

Important Freeze Information
MODERATE CLIMATE: Heater operation can continue during short-term cold spells. When temperatures are between 0°F (-18°C) and 32°F (0°C), flow (continuous pump operation) must be maintained.
ACAUTION: 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 with water temperatures below 50°F (10°C), operate the heater continuously until higher temperatures are reached. Operating the heater for prolonged periods with pool water below 50°F (10°C) can seriously damage the heater, and is not covered by the warranty. For cold climate areas, please follow the winterizing procedures listed below.
Winterizing the Pool and Spa Heater
Heaters installed outdoors in freezing climate areas may be shut down for the winter. Observe the following procedure for winterizing the heater:
1. Turn off gas valve, manual gas valve, and electrical supply to the heater.
2. Remove the ProTek ShieldTM Assembly (if attached). Remove the heat exchanger inspection panel on the side opposite water piping to gain access to the drain plug on the return header. Open drain plug on return header. See Figure 74 and Figure 75.

O RING DRAIN PLUG

F10672

Figure 74. Return Header Drain Plug – Residential (“P” Prefix Model)

DRAIN PLUG

F10673

Figure 75. Return Header Drain Valve – Commercial (“B” Prefix Model)

39

11. TROUBLESHOOTING

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 these instructions.

Problem

Possible Cause

Corrective Action

Harmonics, or whining noise

U.G. inoperative……………………………….. Check movement by putting in hot water (110°F [43°C] or higher)

*Debris or restriction in system…………… Locate the restriction and remove. Flush system and clean

*Debris in gas line…………………………….. Remove debris or blow out gas line

Low flow………………………………………….. Scale forming in heat exchanger – clean heat exchanger and check pool pH and total alkalinity

When the above listed recommendations do not generate acceptable results, the following service kits are recommended:

1st recommendation: 105F UG Service Kit

2nd recommendation: Coil Service Kit

Used on Models

018759F

019104F

206-207

018759F

019203F

266-268

018758F

019204F

336-337

018758F

019205F

406-408

Heater going on and off continuously

Dirty filter ………………………………………… Low water level in pool ………………………

Clean or replace filter Raise water level

External bypass setting out of adjustment ………………………………………. Adjust bypass

*Pressure switch out of adjustment …….. Adjust pressure switch

Liming or scale forming in exchanger

Pool water……………………………………….. Bypassing too much water …………………

See Water Chemistry on 5 Inspect bypass for movement, if no movement, replace

U.G. not functioning………………………….. Replace if no movement when heated

Sooting

High flow rates………………………………….

Reduce by adding manual bypass valve Adjust manual bypass valve until heater outlet water temp is between 105°F and 110°F (40°C and 43°C)

U.G. inoperative……………………………….. Check movement by putting in hot water (110°F [43°C] or higher). If no movement, replace

*Air starvation ………………………………….. Refer to installation instructions

*Improper venting …………………………….. Follow recommended installation instructions

*Insects or debris clogging burner intake ports……………………………………………….. Clean burners

Pilot outage or “Weak Flame” signal

Low gas pressure …………………………….. Restricted/dirty pilot …………………………..

Adjust gas pressure Clean pilot

Weak pilot generator ………………………… Replace pilot

Yellow lazy flame

Low gas pressure …………………………….. Adjust gas pressure

*Insects or debris clogging burner intake ports……………………………………………….. Clean burners

Outer jacket very hot (paint blistered)

*Broken refractory caused by shipping damage or improper combustion………… Replace refractory panels

Excessive sooting of heat exchanger ….. Determine cause of sooting and correct

• Indicates symptom which usually occurs on initial start-up.

40

TROUBLESHOOTING (CONT:)

Problem Takes too long to heat pool or spa
Leaking at well Leaking at heat exchanger Gasket brittle and leaking (overheated)

Possible Cause Under-sized heater ……………………………
Filter not running long enough……………. Dirty filter ………………………………………… Gas line or meter undersized …………….. Overacid …………………………………………. Overacid …………………………………………. Heater running after pump shuts off ……. Refractory damage …………………………… Sooted heater …………………………………..

Corrective Action
Calculate heating capacity of heater Htr. output (BTUH) 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

41

Millivolt – Flow Chart

Light pilot

If pilot burner remains lit

Jump across both “TH” wires on gas valves

If main burner fires, If main burner does not

remove jumper

fire, remove jumper

Replace gas valve

If pilot burner goes out when main burner lights or when gas valve knob
is released
Remove both “TH” wires from gas valve.
Relight pilot

If pilot burner does not light
Check gas supply, gas line size, gas pressure. Also check for insects or debris in pilot output

Jump across pressure switch terminals

If main burner fires, remove jumper

If main burner does not fire, remove jumper

Clean filter

Jump across thermostat

If pilot burner stays on
Problem is a wire or component short to cabinet or low gas
pressure

If burner does not remain lit, attach millivolt meter and read pilot output
If above 500mV, replace gas valve

Check for adequate water flow from filter
Replace pressure switch

If main burner fires, remove jumper
Replace thermostat

If main burner does NOT fire…
Jump across each high limit and remove
jumper

Replace high limit that caused heater to fire

If below 500mV, check gas pressure. Also check for insects or debris in
the pilot burner
If output is still low, replace pilot generator

1 Raw Output (700mV± 100) Pilot generator disconnected from valve (knob must be held down to keep pilot on). White ­ Negative Red + Positive
2 Pilot Load (500mV± 100) Pilot generator connected to valve-Power applied to pilot solenoid. TP (Thermopile-Robertshaw) PP (Power Pile-Honeywell) TH TP ­ Common TH PP ­ Common
3 Main Valve Load (200mV± 100) Control/Limit circuit closed (All switches “ON”) TP (Thermopile-Robertshaw) PP (Power Pile-Honeywell) TH TP ­ Common TH PP ­ Common
42

Digital – Flow Chart

AWARNING: HIGH VOLTAGE
For qualified technicians ONLY
NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater.

START TURN GAS SUPPLY OFF.
TURN THERMOSTAT (CONTROLLER) TO CALL-
FOR-HEAT POWER TO PC BOARD? NO
(24 V NOMINAL) YES
SPARK ACROSS IGNITER/SENSOR GAP? NO
YES
TURN GAS SUPPLY ON PILOT BURNER LIGHTS? NO
YES

NOTE: Before troubleshooting, familiarize yourself with the start-up and check-out procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Make sure that the line voltage is NOT 208 VAC.

Pull ignition lead and check spark at PC board. Spark Okay?

YES

NO Replace the PC board.

· Check ignition cable, ground wiring, ceramic insulator and gap, and correct. · Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.

· Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked.
· Check electrical connections between PC board and pilot operator on gas control. · Check for 24 VAC across PV-MV/PV terminals on PC board. If voltage is okay,
replace gas control; if not, replace PC board. NOTE: If PC board goes into lockout, reset system. Lockout is used on L.P.G. models.

MAIN BURNER LIGHTS? NO YES

· Check for 24 VAC across MV-MV/PV terminals. If no voltage, replace module. · Check electrical connections between PC board and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.

SYSTEM RUNS UNTIL CALL-FOR-HEAT ENDS? NO
YES
CALL-FOR-HEAT ENDS SYSTEM SHUTS OFF? NO
YES TROUBLESHOOTING
ENDS

NOTE: IF PC board goes into lockout, reset system.
· Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the time of checkout.
· Check that pilot flame covers flame rod and is steady and blue. · If checks are okay, replace PC board.
· Check for proper thermostat (controller) operation. · Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.

43

Control Logic – Flow Chart – Digital

Power On

Is the water

temperature displayed?

NO

YES

· Check On/Off switch (under lid on control panel) · 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 switch to select “Pool” or “Spa”

Push Temp arrow to scroll to desired temperature

Water temperature and set

NO

temperature

displayed?

YES

“Heating” will display briefly

“Spark”

Flame icon displayed

and flashing?

OR

Water temp displayed?

(pilot lit and rectified)

NO

YES

“Remote” and Water Temperature displayed (a remote control is controlling the heater)
Note: Disconnect the remote by turning the remote function off. See page 30 for instructions.

NO

Is a fault code displayed and flashing?
YES

Diagnostic Readouts

“Sensor Failure,” “Sensor Open” or “Sensor Short” Temperature sensor out of range (replace sensor)

Sensor Failure Inspect thermistor, wires, and connector at Terminal P1 Check resistance value of the thermistor. Reference to chart below. Replace thermistor if not within 10% of values shown below. If okay, replace Circuit Board.
Sensor resistance at various temperatures Temp Degrees F 40 50 60 70 80 90 100 106
Temp Degrees C 4 10 15 21 27 32 38 41
Resistance (k) 261.1 199.0 153.1 118.8 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” “Hi Limit 2 Fault”

High limit switch. Verify water flow. Inspect internal Thermostat (Unitherm Governor) and bypass valve. Press manual button on HL1 fault on bronze (ASME) models.

“Rollout Sw Open”

Rollout Sensor – Check for blocked heat exchanger and soot. Press manual reset button.

“Clock/Fireman Sw”

Fireman or Remote switch connected to safety loop is in the OFF mode.

“Vent/Field Sw #1”

Vent switch open. Check connections to the board. If extractor installed, troubleshoot extractor.

“Ignition Lockout” “Ignition Failure”

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 rod. Ignition failure. Verify gas to the heater. Verify valve operation (gas present at tube fitting).

Heater Fired?
YES
END 44

NO

Verify power at MV on P-4 Terminal on digital circuit board.

Verify power to valve MV voltage. (Replace valve.)

12. REPLACEMENT PARTS
NOTE: To supply you with the correct part, it is important that you supply the heater model number, serial number and type of gas when applicable. 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
45

13. QR CODES
View this Installation Manual on your smart device. This QR Code will take you to the most current version of the manual. Previous versions of manuals can be found in the document library at Raypak.com. P/N: 241236 Manual Atmospheric 206A-406A P/N: 241243 Manual D-2 Power Vent
46

14. ILLUSTRATED PARTS LIST

3-V 1-S

14-M

13-S

1-V

4-V

2-S

2-V

6-HP

5-HP

15-HP

3-HP

8-C

7-HP 4-HP

3-R

14-M 6-S

4-S

17-HM

8-S

11 – S

10-M 9-M

5-C 3-M

7-C 4-C

7-HP 2-HP 6-HP 12-S
20-HP 7-S

4-M 2-M
13-M 12-M
3-S
14-S

11 – M 2-J
1-G

25-M 18-M
2-B 5-M

1-B 5-B 4-B 10-S

5-S 16-M 3-B

2-R 4-S
1-R 16-M 1-J 15-S

47

5-HM 1-M
7-HM 3-HM

2-S 6-HM
4-HM 4-S

6-C 8-HP
21-M
2-HM 1-M

6-C
8-HP 27-HM 26-HM

1-C 9-C
31-HM

INLET

17-HP

OUTLET 18-HP

20-HP

28-HM 6-M

FOR UNITS WITH ASME BRONZE HEADERS FROM 12/2019 (PROTEK SHIELD AVAILABLE ON ASME HEATERS AFTER END OF Q3 2020)

1-M
3-C 7-HM 3-HM 17-HM

5-HM

2-S 6-HM

6-C 14-HM 13-HM
2-HM

16-HM

9-S

15-HM

6-M (OPTIONAL)
2-C

4-HM

12-HM

10-HM

4-S

8-HM

11-HM

18-HM

9-HM

UNITS WITH ASME CAST IRON HEADERS, DISCONTINUED 12/2019

30-HM

INLET PROTEK SHIELD ADAPTER KIT

48

6-M (OPTIONAL)
1-M

18-HP

8-HP

11-HP 6-C

19-HP

10-HP 16-HP
12-HP

INLET OUTLET
17-HP 20-HP

2-HP 13-HP 14-HP

FOR UNITS WITH POLYMER HEADERS FROM 10/2019

6-M (OPTIONAL)
6-C

19-HP

1-M

19-HP

11-HP 1-C

8-HP

12-HP

26-HM

22-M 27-HM

24-M 23-M
INLET

24-M

2-HP

13-HP

OUTLET 18-HP 23-M 17-HP

15-HP 14-HP

16-HP 10-HP
18-HP
17-HP

29-HM
PROTEK ADPTER AND POLYMER UNITS PRIOR TO 10/2019

1-P

2-P

8-P

5-P

7-P

6-P

9-P

3-P
9-P HONEYWELL MILLIVOLT PILOT

HONEYWELL IID ATMOSPHERIC PILOT

19-M

26-HM 27-HM

20-M 22-M

24-M

24-M 23-M

21-M
24-M 23-M

INLET

OUTLET

22-M

29-HM PROTEK ADAPTER AND TEXAS CODE OPTION PRIOR TO 12/2019
49

CALL OUT B
1-B
2-B 3-B 4-B
5-B C
1-C 2-C 3-C 4-C
7-C 8-C 5-C 6-C 9-C
G 1-G
HP 1-HP
2-HP
3-HP 4-HP
5-HP
6-HP 7-HP 8-HP 9-HP 10-HP 11-HP 12-HP 13-HP 14-HP 15-HP 16-HP 17-HP 18-HP 19-HP 20-HP

DESCRIPTION

BURNER TRAY – SPECIFY ELEVATION*

Polymer Cu HX, or

Burner Tray w/Burners Nat (sea level)*

ASME HX (Cu or Cupro)

Burner Tray w/Gas Valve Nat Millivolt (sea level)*

NAT #50 ORIFICE

Burner Tray w/Gas Valve Nat IID (sea level)*

Polymer Cu HX, or

Burner Tray w/Burners Pro (sea level)*

ASME HX (Cu or Cupro)

Burner Tray w/Gas Valve Pro Millivolt (sea level)*

PRO #57 ORIFICE

Burner Tray w/Gas Valve Pro IID (sea level)*

Polymer Cupro HX NAT #51 ORIFICE

Burner Tray w/Burners Nat (sea level) Burner Tray w/Gas Valve Nat Millivolt (sea level) Burner Tray w/Gas Valve Nat IID (sea level)*

Polymer Cupro HX PRO #58 ORIFICE

Burner Tray w/Burners Pro (sea level) Burner Tray w/Gas Valve Nat IID (sea level) Burner Tray w/Gas Valve Pro IID (sea level)*

Burner Spacer/Hold Down Kit

Burner

Burner Orifice (TO BE ORDERED BASED ON RATING PLATE AND ELEVATION)

Natural Gas

Burner Orifice #50* (0-1999 ft elevation)

Burner Orifice #51* (2000-5999 ft elevation)

Burner Orifice #52* (6000-8999 ft elevation)

Burner Orifice #53* (9000 + ft elevation)

Propane Gas

Burner Orifice #57* (0-1999 ft elevation)

Burner Orifice #58* (2000-2999 ft elevation)

Burner Orifice #59* (3000-4999 ft elevation)

Burner Orifice #60* (5000-6999 ft elevation)

Burner Orifice #61* (7000-7999 ft elevation)

Burner Tray w/o Manifold w/o burners

CONTROLS

High Limit Auto Reset 135°F Deg Surface Mount

AGS 135°F (Auto Gas Shut-Off) – Red Epoxy – prior to 12/2019

High Limit 140°F – Black Epoxy – prior to 12/2019

P.C. Board/Control

LCD Display

Units manufactured from 5/2011

Fuse 5 AMP

Thermostat Control MV Units Mechanical

Temperature Sensor IID Units

High Limit Auto Reset 150°F Surface Mount (ASME Only)

GAS VALVE

Combination Valve – Nat. MV

Combination Valve – Pro. MV

Combination Valve – Nat. IID

Combination Valve – Pro. IID

HEAT EXCHANGER – POLYMER (RESIDENTIAL ONLY)

Heat Exchanger Assy Copper ***

Units manufactured from 10/2019

Units manufactured prior to 10/2019

Heat Exchanger Assy Cupronickel ***

Units manufactured from 10/2019

Units manufactured from 7/2013 thru 9/2019

Units manufactured prior to 7/2013

Inlet/Outlet Header Complete

Units manufactured from 10/2019

Units manufactured prior to 10/2019

Inlet/Outlet Header (Includes 6-HP)

Units manufactured from 10/2019

Units manufactured prior to 10/2019

Return Header (Includes 6-HP)

Tube Bundle Copper ** & ***

Tube Bundle Cupronickel ** & ***

Units manufactured from 7/2013

Units manufactured prior to 7/2013

Baffle (Copper Heat Exchanger)

Baffle (Cupronickel Heat Exchanger)

Units manufactured from 6/2013

Units manufactured prior to 6/2013

Flange Nut Kit

O Ring Gasket (2)

Sensor Adapter Digital Electronic

Sensor Well Millivolt

Bypass Kit

Bypass Valve

Bypass Dam / Shaft

Bypass Spring (All Sizes Included)

Unitherm Governor

Unitherm Governor Plug

Drain Plug

Inlet/Outlet Header Dam

2″ CPVC Connector & Nut (2)

O Ring (2)

Inlet/Outlet Header Baffle w/Header Dam ProTek ShieldTM Assembly

206A
010391F 010399F 010407F 019206F 010403F 010411F 019210F 019214F 019218F 019222F 019226F 019230F 010415F 301210/13

266/266A
010392F 010400F 010408F 019207F 010404F 010412F 019211F 019215F 019219F 019223F 019227F 019231F 010416F 301210/18

336A
010393F 010401F 010409F 019208F 010405F 010413F 019212F 019216F 019220F 019224F 019228F 019232F 010417F 301210/22

399/406A
010394F 010402F 010410F 019209F 010406F 010414F 019213F 019217F 019221F 019225F 019229F 019233F 010418F 301210/27

350079F/13 350080F/13 350081F/13 350347F/13
350083F/13 350087F/13 350350F/13 350351F/13 350352F/13
010421F
006725F 600892B 600893B 013464F
013640F 013733F 003346F 009577F 018304F
003898F 003899F 003900F 004306F

350079F/18 350080F/18 350081F/18 350347F/18
350083F/18 350087F/18 350350F/18 350351F/18 350352F/18
010422F
006725F 600892B 600893B 013464F
013640F 013733F 003346F 009577F 018304F
003898F 003899F 003900F 004306F

350079F/22 350080F/22 350081F/22 350347F/22
350083F/22 350087F/22 350350F/22 350351F/22 350352F/22
010423F
006725F 600892B 600893B 013464F
013640F 013733F 003346F 009577F 018304F
003898F 003899F 003900F 004306F

350079F/27 350080F/27 350081F/27 350347F/27
350083F/27 350087F/27 350350F/27 350351F/27 350352F/27
010424F
006725F 600892B 600893B 013464F
013640F 013733F 003346F 009577F 018304F
003898F 003899F 003900F 004306F

017994F 010043F

017995F 010044F

017996F 010045F

017997F 010046F

017998F 014926F 010356F

017999F 014927F 010357F

018000F 014928F 010358F

018001F 014929F 010359F

017959F 006827F

017959F 006827F

017959F 006827F

017959F 006827F

017965F 014648F 015095F 010059F

017965F 014648F 015095F 010060F

017965F 014648F 015095F 010061F

017965F 014648F 015095F 010062F

014930F 010364F 010038F

014931F 010365F 005261F

014932F 010366F 010040F

014933F 010367F 010041F

014934F 010038F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F
N/A Use 19-HP 006723F 006724F 006826F
017960F

014935F

014936F

005261F

010040F

008259F

008259F

006713F

006713F

006714F

006714F

006805F

006805F

006715F

006715F

006716F

006716F

006717F

006717F

006718F

006718F

006719F

006719F

006720F

006720F

006721F

006721F

N/A Use 19-HP N/A Use 19-HP

006723F

006723F

006724F

006724F

006826F

006826F

017960F

017960F

014937F 010041F 008259F 006713F 006714F 006805F 006715F 006716F 006717F 006718F 006719F 006720F 006721F
N/A Use 19-HP 006723F 006724F 006826F
017960F

*FOR INSTALLATION AT OVER 2,000 FEET ABOVE SEA LEVEL, DERATE 4% PER I,000 FEET ABOVE SEA LEVEL. Refer to the heater’s rating plate.

**WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.
***WARNING: Copper and Cupronickel heat exchangers and tube bundles are not interchangeable. Units with suffix “C” must use copper replacement parts and units with suffix “X” must use Cupronickel replacement parts.
50

CALL OUT HM
1-HM
2-HM
15-HM 16-HM
3-HM
4-HM
5-HM 6-HM
7-HM 8-HM
9-HM 18-HM 10-HM
11-HM
12-HM 13-HM 14-HM 17-HM 19-HM 26-HM 27-HM 28-HM 29-HM 30-HM 31-HM
J 1-J 2-J
M 1-M
2-M 3-M
4-M 5-M 6-M 7-M 8-M
9-M 10-M
11-M
12-M
13-M 14-M 15-M
16-M 17-M
19-M 20-M
21-M 22-M
23-M 24-M
18-M 25-M

DESCRIPTION HEAT EXCHANGER – METAL (ASME-CERTIFIED, FOR COMMERCIAL USE) Heat Exchanger Assy.Copper ASME
Units manufactured from 12/2019 (Bronze) Units manufactured prior to 12/2019 (Cast Iron) Heat Exchanger Assy.Cupronickel ASME Units manufactured from 12/2019 (Bronze) Units manufactured prior to 12/2019 (Cast Iron) Inlet/Outlet Header ASME Complete Units manufactured from 7/2020 (Bronze) Units manufactured from 12/2019 (Bronze) Units manufactured prior to 12/2019 (Cast Iron) Inlet/Outlet Header ASME (Header Only) Units manufactured from 7/2020 (Bronze) Units manufactured from 12/2019 (Bronze) Units manufactured prior to 12/2019 (Cast Iron) Inlet & Outlet Flange – prior to 12/2019 Flange Gasket 1 1/2″ Connections – prior to 12/2019 Flange Gasket 2″ Connections – prior to 12/2019 Return Header ASME Units manufactured from 7/2020 (Bronze) Units manufactured from 12/2019 (Bronze) Units manufactured prior to 12/2019 (Cast Iron) Tube Bundle Copper ASME Units manufactured from 12/2019 Units manufactured prior to 12/2019 Tube Bundle Cupronickel ASME Units manufactured from 12/2019 Units manufactured prior to 12/2019 Baffle Stud Bolt Kit Units manufactured from 12/2019 Units manufactured prior to 12/2019 Header Gasket (9) Unitherm Governor U.G. Retainer Spring U.G. Plug Bypass Valve Bypass Spring Units with Plastic Bypass Valve (Units manufactured from 3/5/17 to 12/19) Units with Bronze Bypass Valve (Units manufactured prior to 3/5/17) Drain Valve Sensor Well Well Retaining Clip Rear Drain Plug & Cover Adapter CPVC 2″ Adapter – ProTek Shield (Includes 27-HM) from end of Q3 2020 Nut – ProTek Shield Adapter – 2-Pc from end of Q3 2020 U.G./Bypass Assembly (Units manufactured from 12/2019) ProTek Shield Assembly from end of Q3 2020 ProTek Shield Adapter Assembly – from end of Q3 2020 Bypass O-Ring (Units manufactured from 12/2019) CONTROL BOX Transformer 120/240/24V Rocker Switch MISCELLANEOUS COMPONENTS Pressure Switch 1.75 PSI Pressure Switch 1.75 PSI Complete Kit (Units manufactured from 12/2019 to 6/2020) Pressure Switch 11 PSI Special-See Water Pressure Switch Adj. Thermostat Knob Thermostat Shaft MV Knobstop Thermal Fuse PRV Deliming Kit Wire/Harness Millivolt Wire/Harness IID Control Bezel MV (Includes Dial Decal) Dial Decal MV Control Bezel (Includes Switch Decal) Units manufactured from 5/2011 Units manufactured prior to 5/2011 Switch/Decal-Membrane Units manufactured from 5/2011 Units manufactured prior to 5/2011 Control Bezel Cover Gasket Insulation (Swaybrace & Jacket Top) Touch-up Paint Green Dark Gray Cool Dark Gray Warm Dark Gray Tie Down Bracket (Optional) Texas Code Option (ASME Only) – Units manufactured prior to 12/2019 Flanged Connection (Not Shown) NPT Connection (Not Shown) Flow Switch Flow Switch Paddle T & P Gauge 2″ CPVC Connector (Outlet Plumbing) NPT Connection Flanged Connection 2″ CPVC Connector & Nut (2) O Ring (2) PC Board Shield (Optional) Gas Line Finish Flange

206A
017983F 010051F
017987F 010360F
018740F 017961F 006730F
018739F 017966F 012319F 003766F 062236B 800080B
018738F 017973F 006731F
017974F 010055F
017978F 010368F 010038F
017982F 007870F 800014B 062234B 013792F 013738F 016194F
016196F 013794F 013793F 003765F 300203 005264F 005393F 018006F 018007F 017958F 018766F 018006F 016230F
006736F 009493F
006737F 018297F 009133F 009499F 800307 006886F 005899F 017957F 052871F 010386F 009490F 009489F 009858F
013491F 009491F
013492F 009492F 009487F 010350F
750125 750126 750256 750258 011636
015889F 015890F 007142F 010026F 014647F
013795F 015883F 006723F 006724F 015557F 016160F

266/266A

336A

399/406A

017984F 016193F
017988F 010361F
018740F 017961F 006730F
018739F 017966F 012319F 003766F 062236B 800080B
018738F 017973F 006731F
017975F 006733F
017979F 010369F 005261F
017982F 007870F 800014B 062234B 013792F 013738F 016194F
016196F 013794F 013793F 003765F 300203 005264F 005393F 018006F 018007F 017958F 018766F 018006F 016230F
006736F 009493F
006737F 018297F 009133F 009499F 800307 006886F 005899F 017957F 052871F 010386F 009490F 009489F 009858F
013491F 009491F
013492F 009492F 009487F 010350F
750125 750126 750256 750258 011636
015889F 015890F 007142F 010026F 014647F
013795F 015883F 006723F 006724F 015557F 016160F

017985F 010053F
017989F 010362F
018741F 017992F 006730F
018739F 017966F 012319F 003766F 062236B 800080B
018738F 017973F 006731F
017976F 010057F
017980F 010370F 010040F
017982F 007870F 800014B 062234B 013792F 013738F 016194F
016196F 013794F 013793F 003765F 300203 005264F 005393F 018006F 018007F 017962F 018766F 018006F 016230F
006736F 009493F
006737F 018297F 009133F 009499F 800307 006886F 005899F 017957F 052871F 010386F 009490F 009489F 009858F
013491F 009491F
013492F 009492F 009487F 010350F
750125 750126 750256 750258 011636
015889F 015890F 007142F 010026F 014647F
013795F 015883F 006723F 006724F 015557F 016160F

017986F 010054F
017990F 010363F
018741F 017992F 006730F
018739F 017966F 012319F 003766F 062236B 800080B
018738F 017973F 006731F
017977F 010058F
017981F 010371F 010041F
017982F 007870F 800014B 062234B 013792F 013738F 016194F
016196F 013794F 013793F 003765F 300203 005264F 005393F 018006F 018007F 017962F 018766F 018006F 016230F
006736F 009493F
006737F 018297F 009133F 009499F 800307 006886F 005899F 017957F 052871F 010386F 009490F 009489F 009858F
013491F 009491F
013492F 009492F 009487F 010350F
750125 750126 750256 750258 011636
015889F 015890F 007142F 010026F 014647F
013795F 015883F 006723F 006724F 015557F 016160F

*WARNING: The Hydraulic conditions or water chemistry that caused the tube bundle to fail have very likely also damaged the bypass valve and Unitherm Governor. We recommend you replace the Unitherm Governor and inspect the bypass assembly. Failure to do so could cause premature failure of this replacement part.

51

CALL OUT

DESCRIPTION

P

PILOT

1-P

Pilot Nat. MV

Pilot Pro. MV

3-P

Pilot Orifice Nat. MV

Pilot Orifice Pro. MV

5-P

Pilot Generator MV

2-P

Pilot Nat & Pro IID

4-P

Pilot Orifice Nat. IID .020

Pilot Orifice Pro. IID .012

6-P

Pilot MTG Bracket MV

7-P

Pilot Mounting Bracket IID

8-P

Lighter Tube (MV Units Only)

9-P

Pilot Tube

10-P

Hi Tension Wire IID with Pilot Electrode

11-P

Pilot Shield

R

REFRACTORY

1-R

Refractory Common Lt & Rt

2-R

Refractory Uncommon (Front & Rear)

3-R

Refractory Retainer Kit

S

SHEET METAL

1-S

Jacket Top (Louvered)

2-S

Flue Collector (Units with Polymer Header)

Flue Collector (Units with Metal Header)

3-S

Door Assy

Raypak

Cool Dark & Warm Dark Gray

Green

Rheem

Cool Dark & Warm Dark Gray

Green

Ruud

Cool Dark & Warm Dark Gray (Units mfd after 9/2012)

Warm Dark Gray (Units manufactured prior to 9/2012)

Green

Jacuzzi

14-S

Screw & Retainer

4-S

Access Panel Set (3 Pcs Units with Polymer Header)

Access Panel Set – ASME

Access Panel Set (3 Pcs. for BR Header) – from 12/2019

Access Panel Set (3 Pcs. for CI Header) – prior to 12/2019

5-S

Jacket Side Panel Right

6-S

Jacket Side Panel Left

7-S

Jacket Rear Panel (2 Pcs.)

8-S

Poolstat Cover/Lock

9-S

High Limit Cover – prior to 12/2019

10-S

Base Heat Shield – prior to 10/2019

11-S

Up Front Control Panel

Green

Cool Dark Gray

Warm Dark Gray

12-S

High Limit Shield

13-S

Weather Shield

15-S

Base Riser (Canada only)

V

VENTING

1-V

Indoor Stack Kit (Includes inner adapter panel)

Outdoor Stack Kit (Includes inner adapter panel)

2-V

Stack Adapter

4-V

Outer Stack Adapter

3-V

“Pagoda” Top

Cool Dark Gray

Green

Atmospheric CONVERSION KITS*

Gas Conversions

Nat. to Pro. MV Pilot

Pro. to Nat. MV Pilot

Nat. to Pro. IID Pilot

Pro. to Nat. IID Pilot

• Gas conversions are to be done only by a qualified agency. ** Conversion must be made with complete burner tray and gas valve (see item 1-B).

206A
600525B 600575B 003901F 003902F 600019B 002003F 003903F 004308F 010352F 306692 062996 004078F
N/A 010351F
010088F 010089F 010387F
010047F 010071F 010075F
013859F 010378F
013863F 010382F
013859F 013867F 010382F
N/A 006744F 010311F
017967F 010312F 010376F 010377F 010372F 009505 010319F 010320F
010321F 013887F 013891F 010342F 010325F 019444F
009838 009834 010330F 011461F
013883F 010334
004690B 010419F

266/266A
600525B 600575B 003901F 003902F 600019B 002003F 003903F 004308F 010352F 306692 062996 004078F
N/A 010351F
010088F 010090F 010388F
010048F 010072F 010076F

336A
600525B 600575B 003901F 003902F 600019B 002003F 003903F 004308F 010352F 306692 062996 004078F
N/A 010351F
010088F 010091F 010389F
010049F 010073F 010077F

013860F 010379F
013864F 010383F
013860F 013868F 010383F 016698F 006744F 010311F
017967F 010312F 010376F 010377F 010373F 009505 010319F 010320F
010322F 013888F 013892F 010342F 010326F 019444F
009839 009835 010331F 011462F
013884F 010335

013861F 010380F
013865F 010384F
013861F 013869F 010384F
N/A 006744F 010311F
017967F 010312F 010376F 010377F 010374F 009505 010319F 010320F
010323F 013889F 013893F 010342F 010327F 019444F
009840 009836 010332F 011463F
013885F 010336

004690B 010419F

004692B 010420F

399/406A
600525B 600575B 003901F 003902F 600019B 002003F 003903F 004308F 010352F 306692 062996 004078F
N/A 010351F
010088F 010092F 010390F
010050F 010074F 010078F
013862F 010381F
013866F 010385F
013862F 013870F 010385F 016699F 006744F 010311F
017967F 010312F 010376F 010377F 010375F 009505 010319F 010320F
010324F 013890F 013894F 010342F 010328F 019444F
009841 009837 010333F 011464F
013886F 010337
004692B 010420F

52

NOTES
Raypak, Inc. 2151 Eastman Avenue, Oxnard, CA 93030 805-278-5300 www.raypak.com 53

References

• Raypak – Raypak Pool & Spa, Residential and Commercial Hydronic Products –
• Raypak – Raypak Pool & Spa, Residential and Commercial Hydronic Products –

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