INSTALLATION AND OPERATION MANUAL Gas-Fired Pool and Spa Heater Bronze ASME and Polymer Low NOx Heat Exchanger Models 207A, 266L, 267A, 337A, 399L, and 407A A S M E HLW ASME units only WARNING: If the information 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.
QUICK START GUIDE CLEARANCES WATER CHEMISTRY Space required: See page 11. Water chemistry requirements: See page 5. Minimum and service clearances: See page 7 for clearances table. Note that local codes prevail. POWER PIPING Pressure relief valve: See page 17 for recommended PRV orientation. Flow rates: See page 15 for flow rate values. GAS Supply voltage: See page 20 for acceptable input voltages. VENTING Materials: See pages 8, 10 and 12. D-2 Power Vent Kit: See page 12.
CONTENTS 1. WARNINGS.............................................................. 4 Pay Attention to These Terms.................................. 4 2. WATER CHEMISTRY.............................................. 5 Automatic Chlorinators and Chemical Feeders....... 5 3. BEFORE INSTALLATION....................................... 6 Receiving equipment............................................... 6 Rating and certifications........................................... 6 Elevation.............................
1. WARNINGS Pay Attention to These Terms A DANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. A WARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. A CAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
A CAUTION: 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.
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. THE MODEL AND SERIAL NO. CAN ALSO BE FOUND INSIDE THE BEZEL ABOVE THE DISPLAY 3. BEFORE INSTALLATION Receiving equipment The manufacturer recommends that this manual be reviewed thoroughly before installing the pool/spa heater.
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.
Description a. b. c. d. e. f. g. h. Location Back Right 3-1/2" (89 mm) thick Left masonry walls without Vent ventilated air space Indoor Top Outdoor Top Back Right 1/2" (13 mm)insulation Left board over 1" (25 mm) glass fiber or mineral Vent wool batts Indoor Top Outdoor Top Back 0.
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 12 for details. Minimum allowable space is shown on the nameplate.
Florida and Texas Building Code: Wind Speed = 150 mph 3 sec gust Exposure = C Model B in. (mm) 207A 20 (508) 266L/267A 23 (584) 337A 26 (660) 399L/407A 29 (737) B 31-13/16" (792 mm) F10649 28" (709 mm) 2" x 6" x 1/8" Pallet Anchor Bracket (4 Total) (Kit# 011636) 3" (76 mm) Min. Conc. Pad by others 1/4" x 1-3/4" 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) HOT Min.
Specifications and Dimensions Amp Draw B 120 VAC, 1 Ph, 60 Hz 240 VAC, 1 Ph, 60 Hz 6 3 CL FLUE D C J* 4-3/8" (111 mm) INDOOR DRAFTHOOD 31-13/16" (792 mm) 20-1/2" (521 mm) 10" (254 mm) 8-7/8" (225 mm) (6-5/8" ASME) (168 mm ASME) 34" (867 mm) STACKLESS OUTDOOR TOP 26-1/2" (673 mm) ELECTRICAL CONNECTION 7-3/4" (197 mm) A GAS CONNECTION Figure 8. 28" (711 mm) F10647 Front View Figure 9.
Vent Piping A WARNING: 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. When properly installed outdoors, only the outdoor stackless top, provided, is required.
2' MIN (0.6 m) 8' (2.4 m) OR LESS VENT CAP 2' MIN (0.6 m) 5' MIN (1.5 m) VENT PIPE A CAUTION: 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.
Gas Pressure Adjustment Locations Gas Pressure Adjustment F10638-1 Figure 15. Polymer Headers Water Flow Figure 14. Honeywell VR8340 Pipe Sizing for Gas Connection The capacities shown below are based on using SCH 40 black iron pipe. For capacities using other materials, consult local codes. Maximum Equivalent Pipe Length (ft) (m) Natural Gas 1000 BTU/FT3 0.60 Specific Gravity @ 0.5 in. WC Pressure Drop Model 3/4" 207A 25 (7.6) 266L/267A 15 (4.6) 1" 1-1/4" 90 (27.4) 360 (109.
Flow GPM (lpm) Bronze Headers (ASME Models) Pressure Drop Ft. of Head (m of Head) 207A 267A 337A 407A 20 (75) 8.2 30 (113) 9.5 9.5 40 (151) 9.7 9.7 11 13.4 50 (189) 10 9.8 12.2 13.4 60 (227) 11 10.4 13.7 13.5 70 (265) 11.5 10.9 14.3 14 80 (303) 12.6 12 15.5 15 90 (340) 14 13 16.2 16.2 100 (378) 15 14.2 17.5 16.7 Table L. Bronze Heat Exchanger Pressure Drop - ASME Models (UG Closed) NOTE: Table capacity is based on Schedule 40 black iron pipe.
UG/BYPASS ASSY A CAUTION: STOP the pool pump before attempting to remove ProTek Shield Assembly. 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. UNITHERM GOVERNOR Follow the steps below to replace the ProTek Shield Assy: F10642-2 1. Shut off the pool pump and bleed pressure from the system.
FROM HEATER TO HEATER FULL PORT BALL VALVE OR GLOBE VALVE FROM POOL/SPA TO POOL/SPA BYPASS VALVE F10663 PRESSURE RELIEF VALVE Figure 25. Pressure Relief Valve Bronze Header (ASME Models) Do not use gate valve. Figure 23. Auxiliary Bypass Valve Auxiliary Bypass Valve Adjustment To set bypass - With clean filter, adjustment is made by feeling the inlet and outlet pipes at the heater. Outlet pipes should be slightly warmer than inlet and comfortable to the touch.
Plumbing Diagram Water Connection ISOLATION VALVE THIS DIAGRAM IS A RECOMMENDATION AND IS NOT INTENDED TO REPACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER Figure 29. Single Pool Heater Installation 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 30.
Heat Exchanger Reversal Procedure for Residential Models 1. Remove right and left side access panels. See Figure 26. 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 27. 5. Reconnect high limit, AGS, water pressure switch wires, and ProTek Shield bonding wire. 6. Insert the temperature sensor into the compression fitting, so that the sensor is flush with the top of the fitting.
Electrical Power Draw L1 A CAUTION: 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. SUPPLY SIDE RETURN or NEUTRAL GROUND HOT BLACK The Electronic Intermittent Ignition Device automatically lights the pilot and main burners upon a call for heat.
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7. CONTROLS MANUAL RESET ROLL-OUT SWITCH CONTROL BEZEL PRESSURE SWITCH TEMP SENSOR HL1 - HIGH LIMIT HL2 - HIGH LIMIT NOTE: Caution must be used to not damage controls or wiring. KNURLED SCREW UNITHERM GOVERNOR F10647-3 GAS VALVE Figure 36. Knurled Screw Location PILOT AIR PRESSURE SWITCH PROTEK SHIELD ASSY F10639-3 Figure 34.
Mode Button Service Menu and Fault History The Mode button is used to select POOL or SPA operation. It allows the user to turn the heater off electronically. The LCD remains energized and displays OFF, while continues to show the actual water temperature. 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.
Program Button Fahrenheit or Celsius 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) as shown in Figure 39. Press and hold the button for 5-7 seconds until SET FACTORY DEFAULTS appears on the display. Release the program button. Refer to step one above to access the program screen. Press the MODE button until FAHRENHEIT or CELSIUS appears on the digital display.
Status and Diagnostics The digital models are programmed to display a variety of status and diagnostic messages, depending on the operating conditions. No Demand Table M. Vent/Field Sw #1 Vent spill switch/field switch #1 open. Hi Limit 1 Fault High limit 1 open. Hi Limit 2 Fault High limit 2 open. Call for heat established, flame present. Rollout Sw Open Rollout switch open. Spark operating. Flow/Field SW #2 Field-supplied flow switch/field switch #2 open.
Remote Control Installation and Operation A CAUTION: Before installing remote controls to the 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 45. 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.
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 (eg. 102°F (39°C) for Spa). 3.
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 15 to 20 minutes prior to shutting down the pool pump. The fireman’s switch connection is located on the 14pin header connected to the digital control board.
Flame Roll-Out Safety Switch Pilot Safety Heaters are equipped with a thermal cutoff device to prevent flame roll-out in the event the heat exchanger becomes blocked. It is a “manual reset” type roll-out switch that must be reset by a service technician after any over-temperature conditions have been fixed. Excessive restriction in the heat exchanger flue passage may cause the switch to disable the heater.
Gas Valve Removal Combustion Blower Removal 1. Shut off gas supply to the heater. Remove gas piping to gas valve inlet. 1. Remove the (2) screws that secure the blower box to the burner tray. 2. Remove burner tray, following above procedure. 2. Remove (2) screws that mount the blower box to the base of the heater. 3. Disconnect, pilot tubing from gas valve. 4. Remove (2) screws that mount anti-rotation bracket to the burner tray. 5. Turn vertical gas pipe from manifold slightly and unscrew gas valve.
Unitherm Governor (U.G.) Replacement Extension Pieces (2) Auger Wire Brush with Carbide Tip 1. Shut water, gas and electricity off, close valves and relieve pressure. 2. Drain heat exchanger. Figure 56. Tube Cleaning Kit 3. Remove retainer plug located next to the outlet pipe connection on polymer header models. Desooting Procedure A WARNING: Soot Is Combustible. Exercise Extreme Care. Soot will clog areas between fins and cause eventual tube failure.
8. OPERATING INSTRUCTIONS Visual Inspection Before Start-Up Flames can be observed through the opening below the plenum. Flame color is blue and evenly spread on the top surface of the burner. At least every three months a visual inspection should be made of the burners. Burners Water Pressure Switch Keep heater area clear and free from combustibles, flammable liquids and chemicals. Do not obstruct the flow of combustion and ventilation air.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES ALL 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.
9. MAINTENANCE AND CARE A WARNING: 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 top of heater and drafthood for soot, a sticky black substance around finned tubes and “V” baffles, and open flue gas passageways. Any visible soot should be cleaned for proper operation. A CAUTION: Soot may be combustible. Wet sooted surfaces completely prior to cleaning. Do not use steel wire brush. 2.
10. 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.
Digital - Flow Chart A WARNING: 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? (24 V NOMINAL) YES SPARK ACROSS IGNITER/SENSOR GAP? YES NOTE: Before troubleshooting, familiarize yourself with the start-up and check-out procedure.
Control Logic - Flow Chart Power On Is the water temperature displayed? NO YES “Remote” and Water Temperature displayed (a remote control is controlling the heater) Push MODE switch to select "Pool" or "Spa" Note: Disconnect the remote by turning the remote function off. See page 28 for instructions.
11. 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.
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2-S 1-C 9-C 27-HM 6-C 6-HM 26-HM 8-HP 5-HM 1-M 18-M INLET 2-HM 7-HM 1-M OUTLET 4-S 18-HP 28-HM 17-HP 6-M 20-HP 4-HM 3-HM FOR UNITS WITH ASME BRONZE HEADERS FROM 12/2019 (PROTEK SHIELD NOT AVAILABLE ON ASME HEATERS UNTIL END Q3 2020) 2-S 13-HM 1-M 5-HM 6-M (OPTIONAL) 6-C 14-HM 16-HM 9-S 19-HM 6-HM 15-HM 2-C 21-HM 2-HM 3-C 7-HM 3-HM 17-HM 4-HM 4-S 19-HM 20-HM 12-HM 18-HM 9-HM FOR UNITS WITH ASME CAST IRON HEADERS PRIOR TO 12/2019 40 11-HM 10-HM 8-HM
3-M (OPTIONAL) 19-HP 19-HP 1-M 6-M (OPTIONAL) 11-HP 6-C 8-HP 1-M 19-HP 6-C 11-HP 1-C 1-C 12-HP 8-HP 18-HP 26-HM 16-HP 23-M 15-HP 18-HP OUTLET 23-M 14-HP 17-HP 2-HP 13-HP 13-HP OUTLET 18-HP 24-M 2-HP INLET 22-M 27-HM 24-M 12-HP 16-HP 10-HP 14-HP 17-HP 17-HP INLET 29-HM 20-HP PROTEK ADPTER AND POLYMER UNITS PRIOR TO 10/2019 FOR U N IT S WITH POLYMER HEADERS FROM 10/ 2019 1-P 19-M 2-P 6-P 26-HM 20-M 27-HM 22-M 24-M 4-P 21-M 24-M 23-M 24-M 23-M IID LOW NOx PILOT
CALL OUT DESCRIPTION 207A 266L/267A 337A 399L/407A BB BURNER TRAY*** 1-B Burner Tray w/Burners (0-5000) 010343F 010344F 010345F 010346F Burner Tray w/o Burner (0-5000) 010084F 010085F 010086F 010087F 2-B Burner Hold Down Kit 010254F 010255F 010256F 010257F 3-B Burner 017045F/3 017045F/4 017045F/5 017045F/6 4-B Burner Orifice Nat. #26 (0-5000)* 351632/3 351632/4 351632/5 351632/6 Burner Orifice Nat. #27 (above 5000 ft.
CALL OUT DESCRIPTION 207A 267A 337A 407A HM HEAT EXCHANGER - METAL 1-HM Heat Exchanger Assy Copper ASME Units manufactured from 12/2019 (Bronze) 017983F 017984F 017985F 017986F Units manufactured prior to 12/2019 (Cast Iron) 010051F 016193F 010053F 010054F Heat Exchanger Assy Cupronickel ASME Units manufactured from 12/2019 (Bronze) 017987F 017988F 017989F 017990F Units manufactured prior to 12/2019 (Cast Iron) 010360F 010361F 010362F 010363F 2-HM Inlet/Outlet Header ASME Complete Units manufactured from 7/
CALL OUT J 1-J 2-J 3-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 18-M 19-M 20-M 21-M 15-M 25-M P 1-P 2-P 3-P 4-P 5-P 6-P 44 DESCRIPTION CONTROL BOX Transformer 120/240/24V Rocker Switch Relay Low Nox MISCELLANEOUS COMPONENTS Pressure Switch 1.75 PSI Pressure Switch 1.75 PSI Complete Kit (Units manufactured 12/2019 to 6/2020) Pressure Switch 11 PSI Special-See Water Pressure Switch Adj.
CALL OUT R 1-R 2-R 3-R S 1-S 2-S 3-S 14-S 4-S 5-S 6-S 7-S 8-S 9-S 10-S 11-S 12-S 13-S 1-V 2-V 4-V 3-V V DESCRIPTION REFRACTORY Refractory Common (Left & Right) Refractory Uncommon (Front and Rear) Refractory Retainer Kit SHEETMETAL Jacket Top (Louvered) Flue Collector (Units with Polymer Header) Flue Collector (Units with Metal Header) Door Assy.
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NOTES 47
