STA-RITE SR200LP, Service Manual

Page 1: ...400HD Section 1 Design and Function Section 2 Installation Section 3 Operation Section 4 Component Description Section 5 Repair Parts List Section 6 Glossary Section 7 Troubleshooting S5066 Rev 8 20 04 NOTICE See the inside of the front cover to determine if a heater is single voltage 115VAC built prior to 4 27 04 or dual voltage 120 240 VAC built 4 27 04 or after ...

Page 2: ... e e e C C C Co o o on n n nttt tr r r ro o o olll l B B B Bo o o ox x x x Note12 PinPlugatleft rear of box Dual voltage units 120 240VAC havebeenmanufacturedsinceApril 27 2004 S S S Siii in n n ng g g glll le e e e V V V Vo o o olll lttt ta a a ag g g ge e e e C C C Co o o on n n nttt tr r r ro o o olll l B B B Bo o o ox x x x Singlevoltage units 120VAC only weremanufactured prior toApril 27 2004...

Page 3: ...f this book for the control electricity Take all normal precautions for the voltage involved including precautions needed when working with electricity around a spark ignitible fuel Installationmustcomplywithalllocalbuilding codes that apply InstallationmustcomplywithNationalElectrical Code NEC ANSI NFPA70 orCanadian Electrical Code CEC Standard CSA22 1 require ments asapplicable andalllocalelectr...

Page 4: ... lV V V Va a a alll lv v v ve e e e 5 5 5 5 theC C C Co o o om m m mb b b bu u u us s s sttt tiii io o o on n n nA A A Aiii ir r r rB B B Blll lo o o ow w w we e e er r r r 6 6 6 6 andthe W W W Wiii ir r r riii in n n ng g g g H H H Ha a a ar r r rn n n ne e e es s s ss s s s notshown Figure 1 2 Heater Systems TheB B B Bu u u ur r r rn n n ne e e er r r rS S S Sy y y ys s s sttt te e e em m m m in...

Page 5: ...ter control system OFF Press Switches off the heater TEMP Press Raises the pool or spa temperature setting TEMP Press Lowers the pool or spa temperature setting INDICATOR LIGHT Light ON indicates POOL ON Heater is on The pool water temperature is controlling heater operation SPA ON Heater is on The spa water temperature is controlling heater operation HEATING The thermostat is calling for heat Ste...

Page 6: ... o o on n n n C C C Co o o on n n nttt tr r r ro o o olll l M M M Mo o o od d d du u u ulll le e e e 9 In20secondsthe H H H Ho o o ottt t S S S Su u u ur r r rfff fa a a ac c c ce e e e III Ig g g gn n n niii ittt te e e er r r r H H H HS S S SIII I elementheatstoignitiontemperature The C C C Co o o om m m mb b b biii in n n na a a attt tiii io o o on n n n G G G Ga a a as s s s C C C Co o o on n ...

Page 7: ... C C C Ch h h ha a a am m m mb b b be e e er r r r aroundthecircumferenceofthe F F F Flll la a a am m m me e e eh h h ho o o olll ld d d de e e er r r r Combustioncontinuesuntilthepre setwatertemperatureisreached 6 TheH H H He e e ea a a attt t E E E Ex x x xc c c ch h h ha a a an n n ng g g ge e e er r r r tubessurroundingthe Burner Flameholderextractheatfromthehotflue gasesand heatthewaterflowin...

Page 8: ...ger andreturnedtotheManifoldAdapter 6 TheT T T Th h h he e e er r r rm m m ma a a alll lR R R Re e e eg g g gu u u ulll la a a attt to o o or r r r controlstheflowofwater outoftheHeatExchangertomaintainawaterout lettemperatureabove120 F 49 C 7 ThewaterflowsfromtheO O O Ou u u uttt tlll le e e ettt t tothepoolorspa 1 6 1 3 5 6 7 4 2 Primary Heating Coils Secondary Heating Coils Inlet Cold Water Out...

Page 9: ...ePad _________________________________________________ _________________________________________________ Respondtothefollowingstatements Thisheaterhasapilotlightthatmustbelitbyhand Yes_____ No_____ TheServiceSystemlightindicatesafaultintheheater oritscontrols Yes_____ No_____ Ifanysafetylocksopenduringoperation theBurner andBlowerimmediatelyshutoff Yes_____ No_____ TheThermalRegulatorcontrolsthefl...

Page 10: ...nformation G G G Ga a a as s s s C C C Co o o on n n nn n n ne e e ec c c cttt tiii io o o on n n ns s s s HeaterModelsSR200NA SRC200NA SR333NA SRC333NA SR400NA SR400HD andSRC400NA leavethefactoryequippedtousenaturalgas Heater ModelsSR200LP SRC200LP SR333LP SRC333LP SR400LP and SRC400LP leave the factoryequippedto useliquidpropane LP gas In the field refertothe nameplateontheheaterforthetypeofgast...

Page 11: ...ular pool or spa 2 2 Cool Water In From Spa 2735 1296 From Filter Outlet to Heater Inlet Warm Water Out to Pool or Spa Sanitizer Corrosion Resistant Positive Seal Check Valve To Filter Inlet Cool Water In From Pool To Spa To Pool SYSTEM 3 Modular Media Filter Typical Installation Figure 2 1 Typical Installation Table 2 A Maximum Pool Size in Sq Ft for a Given Model Heater and a Given Temperature R...

Page 12: ... unroofedareathatis protected fromdrainageorrun off Installtheheaterinanareawhereleavesorother debriswillnotcollectonoraroundtheheater Donot installtheheaterwherewater includingrain sprin klers orrunoff willfalldirectlyontotheheaterjacket 2 3 1 Min 4 Min 4 Min 4 Min 3 Minimum clearance if horizontal distance to exhaust opening is less than 10 feet Forced Air Inlet Installation Procedures Figure 2 ...

Page 13: ...fthejacket canbeturnedtoanyofsixpositionsforconvenient access to the Operating Controlpanelasfollows 1 Unboltandseparatethejackethalves 2 Pullthehairpinclips seeFigure 2 4 3 Depressplasticclipsonthecontrolpanelassembly andliftpaneloff of support plate see Figure 2 4 4 Turnthecontrolpaneltothedesiredpositionand snapitinplace 5 Makesurethattheoperatingcontrols can be adjustedwithouthavingtoleanovert...

Page 14: ...cle H H H He e e ea a a attt te e e er r r r C C C Clll le e e ea a a ar r r ra a a an n n nc c c ce e e es s s s III In n n nd d d do o o oo o o or r r r U U U U S S S S o o o or r r r O O O Ou u u uttt td d d do o o oo o o or r r r S S S Sh h h he e e elll lttt te e e er r r r C C C Ca a a an n n na a a ad d d da a a a Thefollowingclearancesmustbemaintainedfrom combustiblesurfaces T T T TO O O O...

Page 15: ...tfromtheheatertoallowexhaustcondensateto drainandmusthaveacondensatedrainasdescribedin theventinginstallationinstructions O O O Ou u u uttt td d d do o o oo o o or r r rV V V Ve e e en n n nttt tC C C Co o o ov v v ve e e er r r rR R R Re e e em m m mo o o ov v v va a a alll l Theheaterissuppliedfromthefactorywithabuilt in stacklessoutdoorventforoutdoorinstallation Remove theoutdoorVentCoverforenc...

Page 16: ...ermination andwhichhavethreeorlesselbowsinthesystem For ventingsystemswhichdonotmeettheseconditions consulttheNationalFuelGasCode ANSIZ223 1 U S and CSA B149 1 Canada 2 7 Heater Venting Negative Pressure Combustion Chamber Flue Collar 4 x 8 Metal Flue Collar Vent Body 2855 0597 RTV Clean the Interior Surface Vent Pipe Clean and RTV This Surface Table 2 E Permitted Minimum and Maximum Vent Heights ...

Page 17: ...al Fuel Gas Code requirements carefully during assembly and installation 4 Installventpipesothatitcanexpandandcontract freelyasthetemperaturechanges Supportthevent pipe accordingtoapplicablecodesandthevent manufacturer sinstructions Pipesupportmust allowtheventpipefreemovementoutandback fromsidetoside orupanddownasnecessary withoutputtingastrainontheheaterorventbody Slopehorizontalpiperunsupfromth...

Page 18: ...o 21 12 8 Ft Vent must be at least eight 8 feet away from nearest verti cal surface Vents extending five 5 feet or more above the roof must be braced or guyed Consult your local code officials for detailed information 6 Minimum Clearance to Combustible Materials Listed Termination Cap Storm Collar Flashing Firestop Vent Body Metal Flue Collar Class B Double Wall Metal Vent Pipe See Table 4 For Min...

Page 19: ... nn n n ne e e ec c c cttt tiii in n n ng g g g S S S Sp p p pe e e ec c c ciii ia a a alll l G G G Ga a a as s s s V V V Ve e e en n n nttt t ttt to o o o ttt th h h he e e eH H H He e e ea a a attt te e e er r r r M M M Me e e ettt ta a a alll llll liii ic c c c 1 Order anApplianceAdapter Kit Sta Rite Part No 77707 0086 for Saf T Vent or Saf TVent CI Sta Rite Part No 77707 0087 for Z Vent 2 Remo...

Page 20: ...ondensatemight collect Plumb condensate drains to a drain throughhardpipingorhigh temperature tubing suchassiliconerubber or EPDM rubber do not usevinylorotherlowtemperaturetubing Follow drainmanufacturer sinstallationinstructions 5 Use Listed firestops for floor and ceiling penetra tions UseListedthimbleforwallpenetrations Use a Listed roofflashing roofjack orroofthimblefor allroofpenetrations Do...

Page 21: ...y active vent such as a factory built or masonry chimney Figure 2 11 Typical Special Gas Vent Pipe Installation Horizontal Positive Pressure Table 2 H Maximum Vent Length F F F Fiii in n n na a a alll l III In n n ns s s sttt ta a a alll llll la a a attt tiii io o o on n n n C C C Ch h h he e e ec c c ck k k k Checkthathorizontalventpiperunsslopeuniformlyat least 1 4 perfoot 2cm meter tocondensate...

Page 22: ...erenoughgas atnomi naldiameter to supply heater 2 13 Installation Procedures Manual Shut off Valve Sediment Trap Union At least 4 1 Dia and up 18 24 of 3 4 Gas Line Figure 2 12 Raise gas line above Air Orifice at least 4 centerline to reduce risk of water in the gas line in case of a heat exchanger leak Table 2 K Recommended Pipe Sizes Natural Gas Recommended Pipe Sizes for Natural Gas 1 000 Btu f...

Page 23: ...werjacket To reduceabrasionwheretheflexibleconduitenters thejunctionbox installaninsulatingbushingorits equivalentontheconduit 6 T T T Th h h he e e efff fiii illl lttt te e e er r r rp p p pu u u um m m mp p p pm m m mu u u us s s sttt tr r r ru u u un n n nc c c co o o on n n nttt tiii in n n nu u u uo o o ou u u us s s slll ly y y yw w w wh h h he e e en n n nttt th h h he e e e h h h he e e ea...

Page 24: ...d as follows 1 Turnheateroff 2 Unboltandremoveupperjackethalves 3 Depress clips and removecontrolboard assembly dome 4 PushtheMaximumTemperatureSetPointbutton onthebackofthecontrolboard SeeFigure 2 15 Thefollowingsequenceshouldhappen A TheunitwillcomeonandthePOOLONlight willcomeon B Press the appropriateTEMP orTEMP pad onTOP ofthepanel tosetmaximumpool temperature 2 15 Heater Electrical Connection...

Page 25: ... a alll lv v v ve e e e SeeFigure 2 16 Heaters are notsuppliedwithapressurereliefvalve althoughCanadiancodeandsomelocalU S codesmay requirethem Ifrequired install a 3 4 PressureRelief ValvecomplyingwiththeANSI ASMEBoilerand PressureVesselCode Thereliefpressureofthevalve MUST NOT EXCEED 50 PSI A3 4 inchNPTconnectionisprovidedinthemanifold forinstallationofapressurereliefvalve Therelief valvemustbei...

Page 26: ...n n n ns s s s Theheaterisdesignedtobeconnecteddirectly to 2 inchPVCpipe usingtheintegralunionsprovided Thelowthermalmassoftheheaterpreventsoverheat ingofthepipingifthepump stops Thereisnoneed foraheatsink Improper operation of chemical feeders can cause severe damage to the heater which is not covered by the warranty Install the chemical feeder downstream of the heater Equip the chemical feeder w...

Page 27: ... alll llll la a a attt tiii io o o on n n n Above2 000feetelevation deratetheheater4 per 1 000feetofelevation a a a ab b b bo o o ov v v ve e e e s s s se e e ea a a a lll le e e ev v v ve e e elll l That is at 3 000 feetelevation deratetheheater12 at5 000feeteleva tion deratetheheater20 Iflocalauthoritiesallowit theSta Riteheateronlyrequires to be derated 1 7 per 1 000feetabovesealevel 2 18 Heate...

Page 28: ...hemanifold N N N NO O O OT T T TE E E E Water trapped in the heater can cause freeze damage Allowingtheheatertofreezevoidsthe warranty Toreturntheheatertoserviceafterwinterizing 1 Closedraincockandfittings 2 Beforestartingtheheater circulatewaterthrough theheaterforseveralminutesuntilallairnoises stop See also PRE OPERATION CHECKLIST Page3 1 and ROUTINEMAINTENANCEAND PROFESSIONALSERVICING Page 4 1...

Page 29: ...et indoorinstallationsonly ___16 Doestheinstallationmeetallcoderequirements Section Review LP gasisheavierthanair Yes_____ No_____ Theheaterissuppliedwithanintegralventingsystem for selectoneofthefollowing ____ Indoorheaterinstallation ____ Outdoorheaterinstallation ____ Both indoorandoutdoorinstallation Respondtothefollowingstatements Adrafthoodisrequiredforindoorheaterinstallation Yes_____ No___...

Page 30: ...___ No_____ Therecommendedminimumclearanceforindoor heaterservicingrequirementsis12inchesor1foot 34 M Yes_____ No_____ Whichofthefollowingoutdoorheaterinstallation guidelinesisincorrect ____ Allowa6 inch 15cm clearanceabovethe heater ____ Locatetheheateronalevelsurface ____ Donotinstalltheheaterunderadeckor overhang ____ Locatetheheaterinanareawhereleavesor otherdebriswillnotcollectonoraroundit Th...

Page 31: ...ombustionandventilation areunobstructed Removeanydebrisinoraround heater Checkthatallwaterconnectionsaretight Makesurethatheaterandsurroundingarea are freefromcombustibles flammableliquids and chemicals Runthepool spacirculatingpumpforseveralmin utestoclearallairfromthesystem Cold Weather Operation Theheatermaybeoperatedinthewintertime provid edairtemperatures remainabovefreezingandthe watertemper...

Page 32: ...elow Turning Off Gas to the Heater Iftheheaterwillnotoperate usethefollowingproce duretoturnoffthegassupplytotheheater 1 PresstheOFFbuttonontheMembranePad 2 Turnoffallelectricpowertotheheater 3 RemoveJacketCover C C C CA A A AU U U UT T T TIII IO O O ON N N N Heaterpartsmaybehotafteroperation 4 TurntheGasControlKnobclockwisetothered line press slightly thenturntheknobtotheOFF position orthrowON OF...

Page 33: ...gthevalvelever 4 Water PressureSwitch TesttheWater Pressure Switch whichturnsofftheHeaterifthewaterflow isinterrupted a LowerthetemperaturesettingontheOperating ControlPaneltoturnofftheHeater b Wait15minutesaftertheBurnerisoffandthen turnoffthePump c RaisethetemperatureontheOperatingControl PaneltoturnontheBurner d Wait1minute TheBurnershouldnotcomeon If theBurnerorBlowerdoescomeonatthispoint theW...

Page 34: ...uitboardtotouchtheindex plate Donotforce any plugs they are polarized If they areright theywillassembleeasily Besureallplugsare connectedtothecorrect sockets TogainaccesstotheControlBoard 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 UnboltandremovetheheaterUpperLeftand UpperRightJacketCovers 3 RemovetheProtectivecover 4 TheOperatingControlAssemblyismountedtothe topoftheheaterassemblyo...

Page 35: ...ed d d du u u ur r r re e e e 1 Turnoffallpowertotheheater 2 UnboltandremovetheUpperLeftandUpperRight Jackets 3 Disconnecttheelectricalconnectiontothe Transformer 4 RemoveTransformerandreplacewithanewone 5 Reversesteps1through4abovetocomplete installation 4 3 PR ES S TA B VE NT PIL OT OF F O N O N Transformer 2685 1096 Transformer S S S Sa a a afff fe e e ettt ty y y y P P P Pr r r re e e ec c c c...

Page 36: ...splaysE02 ToreplacetheThermistor 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 Iftheheaterisbelowthepoolwaterlevel closeiso lationvalvestoavoiddrainingthepool 3 RemovetheDrainPlugundertheManifoldtodrain theheater 4 Unboltandremoveupperleftandupperrightjack etstoexposetheOperatingControlAssemblyand theManifoldSwitchCover 5 RemovetheOperatingControlAssembly See Page 4 2 6 DisconnecttheTh...

Page 37: ...pperRight Jackets fromtheheater 3 OpentheControlBoxcoverbylooseningthescrew onthetoprightsideofthecover 4 DisconnectallwirestotheIgnitionControlModule 5 RemovetheIgnitionControlModuleandreplace it withanewone 6 ReconnectallwirestotheIgnitionControlModule accordingtotheconnectiondiagram Page4 31 7 Replaceallcoversandrestartheater 4 5 PR ES S TA B VE NT PIL OT OFF OFF O N O N Ignition Control Module...

Page 38: ...su u u ur r r re e e e S S S Sw w w wiii ittt tc c c ch h h h S S S Se e e ettt tttt tiii in n n ng g g gs s s s Fordeck levelheaterinstallations thePressureSwitch is factory set at 3 psi 20 6 kPa If the pool water level is 1 2 feet 3 6 M below or 1 5 feet 3 1 6 M above thePressureSwitchlevel resettheswitchsothatitis openwhenthepumpisoffandclosedwhenthepump isrunning Turnthestar wheelontheswitchcl...

Page 39: ... r r ro o o oc c c ce e e ed d d du u u ur r r re e e e ToreplacetheHighLimitSwitch 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 UnboltandremoveUpperLeftandUpperRight Jackets fromtheheatertoreachswitchcoverbolt 3 Iftheheaterisbelowthepoolwaterlevel closeiso lationvalvestoavoiddrainingthepool 4 RemovetheDrainPlugundertheManifoldtodrain theheater 5 RemovetheSwitchCover 6 DisconnecttheHi...

Page 40: ... oc c c ce e e ed d d du u u ur r r re e e e ToreplacetheAGSSwitch 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 UnboltandremoveUpperLeftandUpperRight Jackets fromheatertoreachswitchcoverbolt 3 Iftheheaterisbelowthewaterlevelofthepool closeisolationvalvestoavoiddrainingthepool 4 RemovetheDrainPlugundertheManifoldtodrain theheater 5 RemovetheSwitchCover 6 DisconnecttheAGSwires fromtheSw...

Page 41: ...ficientairflow TheAFS is factory set and isnonadjustable S S S Se e e er r r rv v v viii ic c c ciii in n n ng g g g P P P Pr r r ro o o oc c c ce e e ed d d du u u ur r r re e e e ToreplacetheAFS 1 Turnoffthepumpandallelectricalpowertothe heater 2 DisconnecttheplastictubingfromtheAFSfittings 3 Disconnectthewires fromtheAFS 4 RemovethescrewsfasteningtheAFStotheControl Box 5 ToReplacetheAFS reverse...

Page 42: ...k k F F F Flll lu u u ue e e e S S S Sw w w wiii ittt tc c c ch h h h Thisswitchissealedinplace Donotremoveordisturbit Ifyouarereplacing thisswitchwithaprobeorsensor removethewires fromtheswitchandrunthemtotheprobe sensor S S S Sttt ta a a ac c c ck k k k F F F Flll lu u u ue e e e S S S Se e e en n n ns s s so o o or r r r ReachintotheExhaustElbow unscrewthelocknutontheSensorandremoveit Unscrewth...

Page 43: ...finpoolmode or SpaOnkey ifinspamode ThenewControlBoard willthenshowthecurrentStackFluetemperature Releasethekeytoallowthedisplaytoreturntowater temperature TheoldControlBoardwillnotdisplaythe StackFluetemperature N N N NO O O OT T T TE E E E Allowtheheatertofireforfiveminutesbefore makingthischeck toallowtheStackFluetimetogetto operatingtemperature 4 11 S 1 SET MAX Set Max im um s To gg le C or F ...

Page 44: ...n n niii im m m mu u u um m m m iii in n n nW W W W C C C C SR200 3 3 SR333 2 8 SR400 2 2 S S S Se e e er r r rv v v viii ic c c ciii in n n ng g g g P P P Pr r r ro o o oc c c ce e e ed d d du u u ur r r re e e e N N N NO O O OT T T TE E E E Theairandgasmixtures are preciselymatched forthespecificmodelandshouldnotbealtered except as described under Gas Orifice Page 4 17 ReplacingtheCombustionAirB...

Page 45: ...r riii ifff fiii ic c c ce e e e a a a an n n nd d d d G G G Gr r r riii illl llll le e e e TheAirOrificeattachestotheMixingTubeinlet It preciselymetersthecombustionairgoingintothe CombustionAirBlower IftheAirOrificebecomes plugged or damaged replaceitwithagenuine Sta Ritepart Donotmodifyitortrytouseadifferent orifice grille See Page 5 3 for part numbers 4 13 PR ES S TA B VE NT PIL OT OFF OFF O N ...

Page 46: ...hsidesoftheCombinationGas ControlValvedisconnected slidetheCombination GasControlValveoutofitssupportbracket 7 ReplacetheCombinationGasControlValve by reversingSteps1 5above 8 Test for gas leaks with a soapy water solution N N N NO O O OT T T TE E E E WhenreconnectingtheCombinationGas Valvetothegassupply piping useathreadsealant approvedforusewithnaturalgasandLP gas such as RECTORSEAL 4 14 Combina...

Page 47: ...controlvalvethatisfactorysetwithamanifoldpres sureof 2 wc Installationorservicemustbeper formedbyaqualifiedinstaller service agency orthe gas supplier Ifthiscontrolvalveisreplaced it must be replacedwithanidenticalcontrol TheCombinationGasValveincorporatesdualshut off valvesandanegative pressureregulator Forproper operation theregulated pressureattheoutletmanifold ofthevalvemustbe0 2 wc belowthere...

Page 48: ...ights verifythatthesupplypres sureiswithintherange4 to 14 wc If the supply pressure dropsbelowthisrangewhentheburner ignites the gas line capacity may be inadequate andshouldbeincreased See Page 2 13 11 Withtheburnerstillon opentheshut offonthe gauge The pressuregaugeshouldthen read 2 1 wc Sincethepressuretapisconnectedtothe lowsideofthegauge thepressure is actually nega tive Ifthepressureisoutsid...

Page 49: ...oohigh O2 toolow orhearinga high pitchedwhistle Indicationsthattoolittlegasisbeingburned mixture istoolean areasfollows 1 Delayedornoisyignition 2 Pronouncedexhaustodor However forashort timeafterinitialinstallation theremaybeanodor fromtheinsulationbinder whichisnormal 3 Rough rumblyBurnernoise Checktheair fuelratioforpropercombustionbymea suring the carbon dioxide CO2 or oxygen O2 levelin theexh...

Page 50: ...ingontheadjustmentorifice Verify thecorrectsizeoftheorificesincludedinyourkit seeinstructionsincludedwithkit 8 Inserttheadjustmentorificesquarelyinthegasline unionnexttothecombinationgasvalve 9 Swingthegasloopandunionhalfbackintoplace andtightenbothunionssecurely 10 Tightenthepipeclampholdingthegaslinetothe topcontrolsupport 11 Replacethetopjacket tightenbolts 12 Turnonheater Observeitforsmoothign...

Page 51: ...SItotest Resistance should be 40 75 Ωat roomtemperature Cracks in HSIwhichaffectperformancewillalterresistance levelbutmaybetoosmalltosee 6 Replace the HSI by reversingSteps1through4 above N N N NO O O OT T T TE E E E ReplacetheIgniterGasketwheneveryou replacetheHSI Tightentheigniterhold downnutsto 20inch lbs torque OvertighteningcancracktheHSI base 7 StarttheCombustionAirBlowerandcheckfor leakswi...

Page 52: ...erhasaslightlyoxidizedappearance innormaloperation However extensiveflakingor distortionoftheFlameholdercausedbyoverheat ingisnotnormal R R R Re e e ep p p plll la a a ac c c ciii in n n ng g g g ttt th h h he e e e F F F Flll la a a am m m me e e eh h h ho o o olll ld d d de e e er r r r 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 RemovetheCombustionAirBlower SeeReplacing theCombust...

Page 53: ... a a an n n nd d d dw w w wiii illl llll lc c c ca a a au u u us s s se e e ettt th h h he e e ep p p plll lu u u ug g g gttt to o o offf flll ly y y yiii ifff fn n n no o o ottt tr r r re e e es s s sttt tr r r ra a a aiii in n n ne e e ed d d d 7 RemovetheThermalRegulatoralongwiththe spring attached to it 8 RemovetheSwitchCoversonbothsidesofthe Manifold 9 DisconnectallwirestotheHighLimitThermost...

Page 54: ... R S S S SR R R RC C C C2 2 2 20 0 0 00 0 0 0 a a a an n n nd d d d S S S SR R R R S S S SR R R RC C C C4 4 4 40 0 0 00 0 0 0 F F F Fiii ig g g gu u u ur r r re e e e 4 4 4 4 3 3 3 3 1 Hand tightenalllongbolts thentightenindicated bolts enoughtoallowshortboltstoengage 2 Follow ManifoldTorque Procedure below S S S SR R R R S S S SR R R RC C C C3 3 3 33 3 3 33 3 3 3 1 Thesemodelsuselongboltsonly Tig...

Page 55: ...on Kit on hand in case the heating coil shifts during manifold installa tion and requires opening the combustion chamber cover to realign it Models SR200 SRC200 Short Bolt Placement 2 3 4 2 1 2 2 3 4 2 3 4 2 1 2 2 3 4 Models SR400 SRC400 Short Bolt Placement 2 3 4 2 1 2 2 3 4 2 1 2 Figure 4 3 Short bolt placement Models SR333 SRC333 use all long bolts Figure 4 4 Manifold Installation Torque sequen...

Page 56: ... p pr r r riii in n n ng g g g iii is s s s b b b be e e eh h h hiii in n n nd d d d ttt th h h he e e e p p p plll lu u u ug g g g a a a an n n nd d d d w w w wiii illl llll l c c c ca a a au u u us s s se e e e ttt th h h he e e e p p p plll lu u u ug g g g ttt to o o o fff flll ly y y y iii ifff f n n n no o o ottt t r r r re e e es s s sttt tr r r ra a a aiii in n n ne e e ed d d d 7 Removethe...

Page 57: ...p p pr r r riii in n n ng g g g iii is s s s b b b be e e eh h h hiii in n n nd d d d ttt th h h he e e e p p p plll lu u u ug g g g a a a an n n nd d d d w w w wiii illl llll l c c c ca a a au u u us s s se e e e ttt th h h he e e e p p p plll lu u u ug g g g ttt to o o o fff flll ly y y y iii ifff f n n n no o o ottt t r r r re e e es s s sttt tr r r ra a a aiii in n n ne e e ed d d d 5 Removeth...

Page 58: ... n nd d d d ttt th h h he e e e p p p plll lu u u ug g g g a a a an n n nd d d d w w w wiii illl llll l c c c ca a a au u u us s s se e e e ttt th h h he e e e p p p plll lu u u ug g g g ttt to o o o fff flll ly y y y iii ifff f n n n no o o ottt t r r r re e e es s s sttt tr r r ra a a aiii in n n ne e e ed d d d 7 RemovetheThermalRegulatoralongwiththe spring attached to it 8 RemovetheInlet Outle...

Page 59: ...videworkingclearance 5 RemovetheInlet OutletManifold See Inlet Outlet Manifold Page 4 23 6 RemovetheSwitchCoveronthesideofthe ManifoldAdapter 7 DisconnectallwirestotheHighLimitThermostat AGSSwitchandThermistor 8 LoosenthecompressionfittingtothePressure Switchandremovethetube 9 UnscrewtheboltsthatattachtheManifoldAdapter tothetubesheet removetheManifoldAdapter 10 ToreplacetheManifoldAdapter reverse...

Page 60: ...ard facingsurfacesoftheHeat Exchangercanbedonewithaflashlightandmirror ForacompleteinspectionoftheHeatExchanger removeitfromtheunit IfanyoneoftheHeat Exchanger tubes is damaged replacetheentire Heat Exchanger RepairingindividualHeatExchangerTubes requires special tools and proceduresandshouldnotbe attempted ToAccess the Heat Exchanger 1 Turnoffthefilterpumpandallelectricalpowerto theheater Closeth...

Page 61: ... 3 15 01 Withthesepartsremoved the Heat Exchanger can be lifted fromthechamber 12 Replace the Heat Exchanger by reversingsteps1 through11above N N N NO O O OT T T TE E E E Whenre installingtheCombustion ChamberCover apply a bead of RTV106around thecoverflangebeforere assembly Torquethenuts to 20 30 in lbs Allow24hoursfortheRTVtocure beforefiringtheheaterforanextendedlengthof time N N N NO O O OT T...

Page 62: ...otsurface igniter HSI After approximately20seconds when theHSIhasreachedoperatingtemperature the VALterminaloftheburnercontrollerisenergized and24VACissuppliedtopin5ofJ1 andout throughpin1ofJ3 throughtheAGSswitchtopin2 ofJ3 outthroughpin3ofJ3 throughtheStackFlue Switch ES2 safetyswitchjumpertopin4ofJ3 and outthroughpin5ofJ3tothegascontrol thereby openingtheCombustionGasControlValve 5 IfanyofthePS ...

Page 63: ...ED THEY MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT LADDER DIAGRAM L1 L2 120 240 VAC 120 240 VAC IGNITER L1 S1 S2 L2 F1 F2 BLOWER GND GND CLASS II TRANSFORMER 24 VAC 24 VAC 24V OPERATING CONTROL 24 VAC LOGIC TH IND AIR FLOW SWITCH HI LIMIT SWITCH WATER PRESSURE SWITCH COM NO AGS SWITCH VAL GAS VALVE THERMISTOR SENSOR STACK FLUE SENSOR NOTES 1 AND TH L1 L2 F1 F2 S1 24 VAC S2 GND IND VAL ARE ...

Page 64: ... L1 L2 BM FL F1 L2 S2 TH IND VAL GND GND GND GND BLOWER 120VAC 120VAC HOT 120VAC IGNITER MOT TRANS TRANS GROUND GND NEUTRAL NEU JUNCTION BOX F I R E M A N S S W I T C H Replace jumper with leads to Fireman s Switch field installed 24VAC SEC PRIM 120VAC Y W Y W Y R Y O Y BL BK GY GY BK BK W W BK W W W W G G Y Y Y Y BK BK Y W W W R R BL BL O O O O PR PR Y R Y BL Y O Y W Y Y Y Y Y Y Y Y Y BR BR 3661 ...

Page 65: ...IGNITION CONTROL MODULE DIAGNOSTIC INDICATOR F1 F2 24 VAC S1 240 S1 120 L1 L1 L1 L2 L2 BM FL F1 L2 S2 TH IND VALGND GND GND BLOWER 120 240 Volt Line 2 120VAC IGNITER TRANS Line 1 Ground JUNCTION BOX F I R E M A N S S W I T C H Replace jumper with leads to 24V Fireman s Switch field installed 24VAC SEC Y W Y W Y R Y O Y BL O W BK BK O GY GY BK BK R Y W BK BL Y W BK BL GY GY GY GY BK BK W R R W G Y ...

Page 66: ...ut only the two ties shown This should give you 1 Main Bundle 3 Small Sub Bundles 1 Yellow Jumper 2 Be sure you have bushings for the Control Box Holes 3 Follow the sequence shown on the next three pages for a trouble free installation 3106 1097 S S S Se e e ee e e e iii in n n ns s s siii id d d de e e e o o o offf f C C C Co o o on n n nttt tr r r ro o o olll l B B B Bo o o ox x x x C C C Co o o...

Page 67: ...T H V A L G N D FENWAL FC1 FC2 DIAGNOSTIC INDICATOR LED MODE ON CONTROL FAULT CAUTION HI VOLTAGE DISCONNECT WIRING BEFORE SERVICING Step 1 Ground 1 Green GND IGM 4 Grey IGN Black L1 White L2 Grey IGN Terminal Board 1 Black HOT Terminal Board 1 Black L1 Ground 1 Green GND Igniter 2 Grey IGN To Junction Box Terminal Board 1 White L2 Terminal Board 1 White NEU Terminal Board 1 Yellow FUSE F I R E M A...

Page 68: ...6 Single Voltage Wiring Harness Connection Instructions S1 120 L1 L2 S2 24 VAC I N D F 1 F 2 T H V A L G N D FENWAL FC1 FC2 DIAGNOSTIC INDICATOR LED MODE ON CONTROL FAULT CAUTION HI VOLTAGE DISCONNECT WIRING BEFORE SERVICING Step 2 IGM 1 Yellow w Red Stripe VAL IGM 2 Yellow w White Stripe GND Terminal Board 2 Yellow FUSE Water Pressure Switch 2 Purple WP Thermistor 2 Brown TM AGS Switch 2 Red AGS ...

Page 69: ... 1 Black TRANS Ground 1 Green GND Terminal Board 1 White TRANS Terminal Board 1 White BM F I R E M A N S S W I T C H HOT 3665 0200 J1 5 J3 6 J5 2 J7 4 J2 8 2 Jumpered From Membrane Pad Blower 3 White BM Black BM Green BM S1 SET MAX J6 J7 J2 J1 J3 J5 J9 Control Board 3 3 3 3 B B B Blll lo o o ow w w we e e er r r rM M M Mo o o ottt to o o or r r rB B B Bu u u un n n nd d d dlll le e e e A ConnectBl...

Page 70: ...N NO O O OT T T TE E E E YoumustpurchasetheappropriateAppliance AdapterKitforyourventinginstallation Donottryto saveandreusethe ApplianceAdapter you areremov ingfromtheheater R R R Re e e ettt tr r r ro o o offf fiii ittt t P P P Pr r r ro o o oc c c ce e e ed d d du u u ur r r re e e e 1 Turnoffthefilterpumpandallelectricalpowerto theheater 2 Allowtheheatertocoolforatleasthalfanhour before procee...

Page 71: ...theFlueCollarwiththeElbow sdetentmark alignedwiththecenterlineoftheStackFlueSwitch Drill two 5 32 holesintotheCombustionChamber FlueCollarthroughthepre drilledholesonoppo site sides of the Elbow Figure4 7 Theseholeswill take 10sheetmetalscrewstomechanicallylock theElbowtotheCombustionChamberFlueCollar Don tinstallthescrews yet 13 TheWelded Metal ElbowAssembly ispre drilled Figure4 8 totake 10sheet...

Page 72: ...liconeRTVmaysqueezeoutfromunderthe lipoftheElbowAssembly If so pack it back aroundthebottomedgeoftheelbowtoensure a good seal especially at the frontandbackofthe joint IfnoSiliconeRTVhasbeensqueezedout applyadditionalRTVaroundtheoutsideofthe jointandpackitintomakeagoodseal 20 ConnecttheStackFlueSwitchwirestothenew Probe Donotremovethestackflueswitch itis sealedtotheCombustionChamberFlueCollarto pr...

Page 73: ...NO O O OT T T TE E E E Youhaveabout1 2hourofworkingtime after spreadingtheRTV Afterthejointstartsto cure waitonehourbefore testing 7 ConnecttheStackFlueSwitchwirestothenew Probe Do not removethestackflueswitch itis sealedtotheCombustionChamberFlueCollarto preventcarbonmonoxide fluegasleaks 8 Afteronehour fireheaterfornotmorethanone minutetotestforexhaustleaks Resealanyleaks thatarefound 9 Reinstal...

Page 74: ...sswitchismarkedred S S S Se e e er r r rv v v viii ic c c ciii in n n ng g g gttt th h h he e e eB B B Bu u u ur r r rn n n ne e e er r r rS S S Sy y y ys s s sttt te e e em m m m Thegasorificemeterstheflowofgastotheburner Indicationsthattoolittlegasbeingburnedinclude select all that apply ____ Rough rumblyburnernoise ____ Theindicatorlightison ____ Ahigh pitchedwhistle ____ Pronouncedexhaustodor ...

Page 75: ...byopeningtoallowexcessflow to bypass the Heat Exchanger d Thiscomponentsurroundstheflameholderto extract heat fromthecombustiongases e Thiscomponentprovidesplumbingconnections andhousestheThermalGovernorandtheInternal Bypass Valve Respondtothefollowingstatements Yes or No TheManifoldAdaptershouldberemovedforroutine cleaning Yes____ No____ WhenreinstallingtheManifoldAdapter theO ringson theHeatExch...

Page 76: ...r complete Burner System parts breakdown Key Nos 5 through 9 See Pages 31 and 32 For complete Water System parts breakdown Key Nos 10 through 12 See Page 33 Repair Parts Forcomplete Electrical System parts breakdown KeyNos 1through4 See Page 5 5 Forcomplete Burner System parts breakdown KeyNos 5through9 See Pages 5 2 and 5 3 Forcomplete Water System parts breakdown KeyNos 10through13 See Page 5 4 ...

Page 77: ...5 16 19 20 21 22 23 24 1 2 3 4 2 5 6 7 8 10 9 12 13 14 11 18 17 25 26 2692 1196 PRE SS TAB VEN T PIL OT OF F O N Repair Parts Burner System For Heater mounting bolts and clamps purchase separately Bolt Down Bracket Kit Part No 42001 0085S ...

Page 78: ...apter Plate 1 42001 0090 42001 0090 42001 0090 Flameholder Kit Includes Key Nos 11 12 13 14 77707 0202 77707 0203 77707 0204 11 Flameholder Adapter Plate Gasket 1 42001 0084 42001 0084 42001 0084 12 Flameholder Assembly 1 42001 0202 42001 0203 42001 0204 13 Flameholder Combustion Chamber Gasket 1 42001 0065 42001 0065 42001 0065 14 Flameholder Insulation Cap 1 42001 0075 42001 0075 42001 0075 Flam...

Page 79: ... 0013 42002 0014 42002 0022 7 Manifold Bypass Valve Kit 1 77707 0001 77707 0001 77707 0001 8 Water Pressure Switch 1 42001 0060S 42001 0060S 42001 0060S 9 Manifold Body with Safeties Incl Key Nos 10 11 1 77707 0205 77707 0205 77707 0205 9 Manifold Body Only Incl O Ring Kit 1 77707 0206 77707 0206 77707 0206 10 5 16 Flat Washer 10 U43 41SS U43 41SS U43 41SS 11 5 16 18x2 3 4 Hex Capscrew 10 37007 02...

Page 80: ...78 38AT 9 High Limit Switch 1 42001 0063S 42001 0063S 42001 0063S 10 Thermistor 1 42001 0053S 42001 0053S 42001 0053S 11 Terminal Board 1 42001 0056S 42001 0056S 42001 0056S 12 Fireman s Switch Fuse 1 25A 1 1 4 1 32850 0099 32850 0099 32850 0099 13 Ignition Control Module 1 42001 0052S 42001 0052S 42001 0052S 14 Transformer 1 42001 0057S 42001 0057S 42001 0057S 15 Air Flow Switch 1 42001 0059S 420...

Page 81: ...t 0 03m3 of gas when the products of combustion are cooled to the initial temperature of the gas and air when the water vapor formed during the combustion is condensed and all corrections to standard conditions have been made This value for natural gas is approxi mately 1 000 BTU per cubic foot For Liquefied Petroleum Gas Propane it is about 2 500 BTU per cubic foot Heating Value Low The same as t...

Page 82: ...the line voltage to your heater Single volt age heaters operate on 120VAC ONLY Dual volt age heaters will operate on either 120 Volts AC or 240 Volts AC 2 Remove the covers and check for a 12 pin plug in the back of the control box A If the control box does not take a plug the heater is a single voltage heater and will operate on 120VAC ONLY B If the control box does take a plug the heater is dual...

Page 83: ...te good operation or can show problems See Page 4 11 for more information YES Start here for directions to specific Troubleshooting Chart Initial Troubleshooting Hazardous voltage Can shock burn or kill Disconnect power before servicing any components Fire and Explosion hazard Do not jumper switch terminals to remedy a failed safety switch Is green POOL or SPA LED on Is red SERVICE SYSTEM LED on I...

Page 84: ... connects to Pin 3 on Transformer Black to Pin 2 Orange to Pin 1 240V check Pin1 to Pin 3 120V check Pin 2 to Pin 3 Jumper Fireman s Switch at Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on Leaving jumper in place check for 24 VAC between Fireman s Switch terminals and ground Jumper pins 9 and 8 on J6 of Control Board Does SPA LED come on Jumper pins ...

Page 85: ...um flow requirement see Page 2 12 Minimum Flow Requirements Model Flow 200 20 GPM 76 LPM 333 30 GPM 114 LPM 400 40 GPM 151 LPM Is red SERVICE HEATER LED on YES YES NO YES NO NO Start Is red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above the minimum requirement Check that water pressure is within the adjustment range of the Pressure Switch 0 5 psig Ve...

Page 86: ...er call for heat SEE NOTE 1 Turn off power to heater for 5 seconds and turn back on Make sure tempera ture setting is above water temperature Wait one minute Does heater fire and stay on Did Blower come on Verify that gas is flow ing to burner during ignition try Observe gas meter for move ment during ignition try wait for about 30 seconds after calling for heat Check for 24 VAC between TH and GND...

Page 87: ...read some voltage between 0 and 240 VAC Exactly what reading you get will depend on the meter but with a good ICM the reading won t be 0 VAC or 240 VAC but somewhere in between IMPORTANT READ ME FIRST Gas flows during ignition try but burner does not fire NO check fuse at terminal board NO YES Go back to chart HEATER WILL NOT FIRE C Page 7 5 Check voltage across igniter leads OK Replace Ignition C...

Page 88: ... Air Flow Switch AFS If problem persists replace Blower Replace Blower Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board YES YES NO NO NO YES YES NO AFS on Does Blower operate THERMISTOR on Verify Thermistor wiring If OK replace Thermistor Disconnect Blower and check for line voltage between pins 1 and 3 of B...

Page 89: ...et power to Heater and retry Heater should fire Does the Digital Temerature Display show Error Code E05 or E06 Change Low Level Board Programming to SF0 See Page 4 11 Were you able to change the device code SF1 to SF0 Check Heat Exchanger Coil for liming or low flow A Is the Stack Flue Switch or Sensor correctly connected to the wiring harness B Is the Membrane Pad connected to the correct pins on...

Page 90: ...AdjustCO2 to8 9 fornaturalgas 9 2 10 5 forpropane Burnerpulsateson Exhaustventistoolong Reducelengthofexhaustventand or surges especially on numberofelbows ignition Combustionappears Flamecurrentisnot Checkforwetordamagedigniterwith normal butflamedoes being sensed lowresistance to ground Replacewith notstaylit newigniter Verifyburnerflameholderisproperly grounded ReplaceIgnitionControlModule Heat...

Page 91: ...LEDisnoton Green POOL or SPA LEDdoesnotcomeon after depressing POOL or SPA buttononmem brane pad 120VACisbeingsuppliedtotheHeater AcheckoftheTransformersecondaryshowsno24V Acheckofthe HOT and NEUTRAL terminalsof theTerminalBoardshows120VAC is present AcheckoftheprimaryoftheTransformershows 120VAC is present a BlownFuse b DefectiveMembranePad c DefectiveTransformer d DefectiveControlBoard Thefollow...