INSTALLATION AND OPERATING INSTRUCTIONS

1 INSTALLATION AND OPERATING INSTRUCTIONSGAS-FIRED POOL AND SPA HEATERCATALOG NO. Effective: 02-01-06 Replaces: 12-16-05 P/N 241236 WARNING:If these INSTRUCTIONS are not followed exactly, a fire or explosion may resultcausing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of thisor any other appliance. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's INSTRUCTIONS . If you cannot reach your gas supplier, call the fire department. INSTALLATION and service must be performed by a qualified installer, service agency or thegas manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for Models206A, 266A, 336A and 406 ALow NOx Models207A, 267A, 337A and 407 AWATER CHEMISTRY(Corrosive water voids all warranties)For your health and the protection of your pool equipment, it is essential that yourwater be chemically balanced.

2 The following levels must be used as a guide for bal-anced Level(s)Fiberglass PoolsFiberglass SpasOther Pool & SpaTypesWater Temp. (Deg. F)68 to 8889 to 10468 to to to to Alkalinity (PPM)120 to 150120 to 15080 to 120 Calcium Hardness (PPM)200 to 300150 to 200200 to 400 Salt (PPM)6000 MAXIMUM6000 MAXIMUM6000 MAXIMUMFree Chlorine (PPM)*2 to 32 to 32 to 3 Total Dissolved Solids (PPM)3000 MAXIMUM3000 MAXIMUM3000 MAXIMUM* Free Chlorine MUST NOT EXCEED 5 PPM! Occasional chemical shock dosing of the pool or spa water should not damage theheater providing the water is balanced. Automatic chemical dosing devices and salt chlorinators are usually more efficientin heated water, unless controlled, they can lead to excessive chlorine level whichcan damage your heater. Further advice should be obtained from your pool or spa builder, accredited poolshop, or chemical supplier for the correct levels for your ONEOWNER'S OPERATING INSTRUCTIONS4 SECTION 1 START-UP PROCEDURES4 Before Start-Up5 Lighting INSTRUCTIONS & Shut-Off Procedures - Manually Lighted Pilots MV6 OPERATING Instruction & Shut-Off Procedures -Automatically Lighted Pilots IID7 After Start-Up7 SECTION 2 CAUTION8 SECTION 3 MAINTENANCE & CARE PROCEDURES8 Pool & Spa Water Chemistry8 Automatic Chlorinators & Chemical Feeders9 Cold Weather Operation9 Winterizing the Pool & Spa Heater10 PART TWOINSTALLATION & SERVICE INSTRUCTIONS10 SECTION 1 RECEIVING EQUIPMENT 11 SECTION 2 GENERAL SPECIFICATIONS11 SECTION 3 INSTALLATION INSTRUCTIONS11 Code Requirements12 Clearances12 Outdoor Heater Installation14 Florida Building Code 200115 Indoor Heater Installation15 Outdoor Stack/Indoor Stack16 Atmospheric Specifications and Dimensions17 Low NOx Specifications and Dimensions18 Combustion

3 And Ventilation Air18 Vent Piping19 Gas Supply Connections20 Gas Pressure Regulator20 Gas Pressure Adjustment Locations20 Pipe Sizing For Gas Connections 21 Plumbing For Water Connections21 Flow Rates22 Polymer Headers22 Cast Iron Headers22 Unitherm Governor Operation23 Internal Automatic Bypass Valve23 External Auxiliary Bypass Valve23 Auxiliary Bypass Valve Adjustment23 Pressure Relief Valve Installation24 Heat Exchanger Pressure Drop Tables25 Heat Exchanger Reversal Procedure26 Electrical Wiring26 Millivolt Models26 Digital Models27 Transformer Wiring28 Wiring Diagram - Millivolt (Mechanical Therm.)29 Wiring Diagram - Digital Models, Atmospheric30 Wiring Diagram - Digital Models, Low NOx31 SECTION 4 SERVICING INSTRUCTIONS31 General Location of Controls32 Control Panel Removal32 Control Adjustments - Digital Models32 Control Adjustments - Millivolt Models33 Digital Thermostat Controls33 Thermostat Control Operation35 Diagnostics35 Codes35 Reading a Fault36 Remote Control INSTALLATION and Operation36 Remote Operation36 Activating the Remote37 Remote Control Wiring372-Wire Remote Control373-Wire Remote Control38 Water Pressure Switch38 Flame Roll-Out Safety Switch38 High Limits38 Pilot Safety39 Burner Tray Removal (ATM)39 Gas Valve Removal (ATM)39 Main Burner and Orifice Removal (ATM)39 Pilot Removal and Cleaning39 Heat Exchanger Removal40 Tube Cleaning Procedure40 Desooting Procedure40 Combustion Chamber Removal40 Immersion Well Replacement40 Unitherm Governor ( )

4 Replacement41 Low NOx Pool Heaters41 Operation41 Start-Up Procedures41 Visual Inspection41 Electrical41 Flame Roll-Out Safety Switch42 Burner Tray Removal42 Gas Valve Removal42 Main Burner and Orifice Removal42 Pilot Removal42 Combustion Blower Removal43 SECTION 5 TROUBLESHOOTING44 Electrical - Standing Pilot Millivolt45 Electrical - Electronic Ignition (IID)46 Digital Control Logic - Flow Chart47 SECTION 6 REPLACEMENT PARTS48 Illustrated Parts List51 Part Numbers3 CONTENTS4 PART ONE OWNER'S OPERATING INSTRUCTIONSFOR YOUR SAFETY - READ BEFORE OPERATINGWARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAYRESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF 1 - START-UP PROCEDURESYour pool/spa heater has been designed for years of safe and reliable pool/spa water heating. It is available withmillivolt or electronic ignition. ASME-certified units, typically used in commercial applications, are also manual provides INSTALLATION , operation, maintenance, and service information for these your heater has been installed correctly, OPERATING the heater is an easy task.

5 The upper front panel of theheater contains the control center that allows you to turn the heater On or Off and adjust the temperature set-tings for the pool or spa. The temperature range is factory set from 65 F (18 C) to 104 F (40 C). See figureabove for location of toggle switch to turn the heater On and Off. Section 4 of this manual contains more detailsabout the use of the controls in the Control Adjustments subsection (page 31).ONOFFFig. # 9472 BEFORE START-UPBURNERSC lean main burners, combustion fan (if equipped) andair louvers of dust, lint and debris. Keep heater areaclear and free from combustibles, flammable liquidsand chemicals. Do not obstruct the flow of combustionand ventilation must be flowing through the heater during oper-ation. Ensure that system is filled with water and havepump :Propane gas is heavier than air and will settle on the ground. Since propane can accumulate inconfined areas, extra care should be exercised when lighting propane INSTRUCTIONS AND SHUT-OFF PROCEDURESMILLIVOLT SYSTEM(MANUALLY LIGHTED PILOT)A.

6 This appliance has a pilot that must be lit byhand. When lighting the pilot, follow theseinstructions BEFORE LIGHTING, smell all around theappliance area for gas. Be sure to smell nearthe floor because some gas is heavier than airand will settle on the 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 aneighbor's phone. Follow the gas supplier'sinstructions.*If you cannot reach your gas supplier, call the fire Use only your hand to push in or turn the gascontrol 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 orattempted repair may result in a fire or Do not use this appliance if any part has beenunder water. Immediately call a qualified serv-ice technician to inspect the appliance and toreplace any part of the control system and anygas control which has been under !

7 Read the safety information above. 2. Set the thermostat on the lowest Turn On/Off switch to the "Off" Remove heater door Push in gas control knob slightly and turnclockwise to "Off".NOTE: Knob cannot be turned from "Pilot" to Off"unless knob is pushed in slightly. Do Wait 5 minutes to clear out any gas. If youthen smell gas, STOP! Follow "B" in thesafety information above. If you don't smellgas, go to the next Locate pilot mounted on the right side panel ofthe burner INSTRUCTIONS8. Turn gas control knob counter-clockwiseto "Pilot"9. Place flame to end of pilot tube. Push incontrol knob all the way and hold to light to hold control knob in for about oneminute after the pilot is lighted, release knoband it will pop back up. Pilot should remainlighted. If it goes out, repeat steps 5 through knob does not pop up when released, stopand immediately call your service technician orgas Stand to the side of the heater and turn thegas control knob counter-clockwiseto "On".

8 11. Replace heater door Turn On/Off switch to the "On" Set thermostat to the desired Set the thermostat to the lowest Turn On/Off switch to the "Off" Remove heater door Push the gas control knob slightly and turnclockwise to "Off". Do not Replace heater door PROCEDUREFig.# 9265 Fig.# 9263 HONEYWELLMILLIVOLTGAS VALVEINVENSYS/ROBERTSHAWMILLIVOLTGAS VALVEHONEYWELL PILOTROBERTSHAW PILOTFig.# # :Propane gas is heavier than air and will settle on the ground. Since propane can accumulate inconfined areas, extra care should be exercised when lighting propane INSTRUCTIONS AND SHUT-OFF PROCEDURESELECTRONIC IGNITION SYSTEM(AUTOMATICALLY LIGHTED PILOT)A. This appliance is equipped with an ignitiondevice which automatically lights the pilot. Donot try to light the pilot by BEFORE OPERATING , smell all around theappliance area for gas. Be sure to smell nearthe floor because some gas is heavier than airand will settle on the TO DO IF YOU SMELL GAS:*Do not try to light any appliance.

9 *Do not touch any electric switch; do not useany phone in your building.*Immediately call your gas supplier from aneighbor's phone. Follow the gas supplier'sinstructions.*If you cannot reach your gas supplier, call thefire Use only your hand to push in or turn the gascontrol knob. Never use tools. If the knob willnot push in or turn by hand, do not try to repairit. Call a qualified service technician. Force orattempted repair may result in a fire or Do not use this appliance if any part has beenunder water. Immediately call a qualifiedservice technician to inspect the appliance andto replace any part of the control system andany gas control which has been under !Read the safety information Set the thermostat to the lowest Turn off all electrical power to the This appliance is equipped with an ignitiondevice which automatically lights the pilot.

10 Donot try to light the pilot by Remove heater door Honeywell valve:Turn gas control knobclockwise to "Off".For Robertshaw valve:Models 266-406:Turn gas control knob clockwise to"Off". Model 206: Push in and move gas con-trol lever counter-clockwise to "Off" Wait 5 minutes to clear out any gas. If youthen smell gas, STOP! Follow "B" in the safe-ty information above. If you don't smell gas, goto the next Turn gas control knob counter-clockwiseto "On". (Honeywell VR 8300 andRobertshaw 7000)9. Replace heater door Turn on all electrical power to the Set thermostat to desired If the appliance will not operate, follow theinstructions "To Turn Off Gas To Appliance"and call your service technician or INSTRUCTIONS1. Set the thermostat at the lowest Turn off all the electrical power to the appli-ance if service is to be Remove heater door Honeywell VR 8300 and Robertshaw7000 gas gas control knob clockwiseto "Off".