51300004201B

IN GROUND POOL/SPA GAS HEATERS

INSTALLATION & OPERATIONS MANUAL
FOR YOUR SAFETY: CONTENTS Pg
WARNING: If the information in these
instructions is not followed exactly, a fire GETTING STARTED 2
or explosion may result causing property INSTALLATION 10
damage, injury, or death.
LOCATING THE HEATER 11
• Do not store or use gasoline or other ALTITUDE OF INSTALLATION 13
flammable vapors or liquids in the vicinity AIR SUPPLY 14
of this or any other appliance.
FLUE GAS VENTING 15
WHAT TO DO IF YOU SMELL GAS: GAS SUPPLY 19
• Do not try to light any appliance. WATER PIPING 21
• Do not touch any electrical switch; do not
ELECTRICAL CONNECTIONS 24
use any phone in your building.
• Immediately call your gas supplier from a CHECK-OUT & START-UP 25
neighbor’s phone. Follow the gas supplier’s CONTROL SETUP 26
instructions. If you cannot reach your gas GAS TESTING 28
supplier, call the fire department.
WATER TESTING 31
• Installation and service must be performed
by a qualified installer, service agency or MAINTENANCE & SERVICE 31
the gas supplier. WATER CHEMISTRY 31
WINTERIZATION 32
This product must be installed and serviced by
authorized personnel, qualified in pool/spa heater COMPONENT SERVICE 32
installation. Improper installation and/or operation TROUBLESHOOTING 39
can create carbon monoxide gas and flue gases PARTS 49
that can cause serious injury, property damage,
or death.

SAVE THESE
INSTRUCTIONS

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GETTING STARTED
WHAT TO EXPECT WHEN OPERATING YOUR POOL HEATER
This flow chart provides guidance to protect pool users and product by maintaining good water quality.

INSTALLATION
Verify that product installation was performed
to local codes and according to this manual.

INITIAL USE OR SPRING STARTUP

Check all pool / spa water piping. Do not connect product to water piping.

IMPORTANT FOR POOL USER HEALTH AND PRODUCT PERFORMANCE

 Verify Chlorine or Bromine level every 2-3 days
 Verify PH level every week
 Verify Alkalinity level every 3-4 weeks (2 weeks if using an Automatic
Chlorine or Bromine Feeder)
 Verify Water Hardness and Total Dissolved Solids (TDS) every month (it is
recommended that a pool professional perform this testing)

DISCONNECT
IS POOL/SPA IN
NO WATER PIPING TO
CHEMICAL BALANCE?
PRODUCT

PRODUCT

CONNECT WATER PIPING TO PRODUCT, BYPASS TO OPEN POSITION OPEN

POOL/SPA
SET BYPASS TO
IS HEATING/COOLING OPEN POSITION,
NO WATER DIVERTED
NEEDED WITHIN 1 WEEK?
FROM PRODUCT

PRODUCT
BYPASS TO CLOSED POSITION, WATER DIRECTED TO PRODUCT
CLOSED
TURN ON ELECTRIC POWER AND GAS AS REQUIRED.
POOL/SPA
START PRODUCT. PROGRAM REQUIRED WATER
TEMPERATURE ON PRODUCT CONTROL PANEL.

ENJOY YOUR POOL/SPA

TURN OFF ELECTRIC

IS HEATING/COOLING
NEEDED FOR REST OF YEAR?
NO POWER AND GAS AS
REQUIRED

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PLEASE READ BEFORE PROCEEDING

Basic safety precautions should always be followed, including the following:

Failure to follow instructions can cause death and/or severe injury.

This is the safety-alert symbol. When you see this symbol on your equipment
or in this manual, look for one of the following signal words and be alert to the
potential for personal injury.

WARNING warns about hazards that could cause death and/or severe
injury or major property damage and if ignored presents a potential hazard.

CAUTION warns about hazards that could cause minor or moderate

personal injury and/or property damage and if ignored presents a potential
hazard. It can also make consumers aware of actions that are unpredictable
and unsafe.

NOTICE indicates special instructions that are important but not related to
hazards.

See product rating plate for manufactures information.

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HEATER CONSTRUCTION

Figure1: Sub-Assemblies

Top Flue Cover

Rain Shield
Assembly

Heat Exchanger
Water Pressure
Assembly
Switch
Water
Upper Side
Temperature
Panels
Switches

Drain Plug or
Relief Valve

Gas
Control

Combustion Lower Side

Blower Control Bezel Panels
and Control
Boards

Front Access Panel

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Table1: SPECIFICATIONS
Features:
 120 or 240VAC, 60Hz, 1-phase, 5.5A maximum current
 Forced draft combustion with silicon nitride hot surface ignition
 Cupronickel water tubes standard
 Integral low loss bypass, maximum water flow for all models is 125 GPM
Model Gas Input Minimum Thermal Heater Heater
Natural or Propane Water Flow Efficiency Width Weight
*xxx* btu/hr gpm % in. lbs.
150 150,000 20 82.7 19 135
200 199,900 20 83 22 140
250 250,000 25 84 25 165
300 300,000 25 82.7 26 175
350 350,000 30 83 31 195
400 399,900 30 84 34 195
500 500,000 40 83 40 245
250ASME 250,000 25 84 28 195
400ASME 400,000 30 84 36.5 225
500ASME 500,000 40 83 40.5 260
GAS REQUIREMENTS

OPERATING PRESSURES Natural Gas (inwc) Propane Gas (inwc)

Gas Manifold Pressure* 1.8 - 2.2 6.8 - 7.0
Gas Inlet Pressure, Minimum 4.5 10.0
Gas Inlet Pressure Maximum 10.5 13.0
GAS ORIFICE DRILL SIZES #25 #43
GAS ORIFICE DRILL SIZES (500kbtu/hr) #22 2.3mm
*Pressure range for allowable heating value variation.

Heater Width 22.2

22.2 22.2
2.2 2.2

22.2

2.2
2.2

22.2
22.2

22.2

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Wiring Connection Diagram

WARNING - Risk of Electric Shock Before working on any electrical equipment, turn off power supply to the
equipment.
WARNING - Risk of Electric Shock. All electrical wiring MUST conform to applicable local codes, regulations,
and the National Electric Code (NEC). Hazardous voltage can cause death, shock, burn, and/or serious property
damage. To reduce the risk of electric shock, do NOT use an extension cord to connect unit to electric supply. Provide
a properly located electrical receptacle. To reduce the risk of electric shock replace damaged wiring immediately.
Locate conduit to prevent abuse from lawn mowers, hedge trimmers and other equipment. Do NOT ground to a gas
supply line.
Figure2: Wiring Diagram

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Table2: CERTIFICATION AND COMPLIANCE

CERTIFICATION CODES AND STANDARDS USA CANADA

DESIGN CERTIFIED CSA CSA
DESIGN COMPLIANT ANSI Z21.56 CSA 4.7
NFPA 54/ANSI Z223.1
INSTALLATION COMPLIANT GAS CAN/CSA-B149.1-2
NFPA 58
ANSI/NFPA 70 CSA C22.1 – Canadian
INSTALLATION COMPLIANT ELECTRIC
NEC Electrical Code, Part I
EMISSIONS SCAQMD 1146.2
SHIPPING COMPLIANT ISTA 3B ISTA 3B

CONFORMANCE WITH CODES: The heater shall be installed in accordance with all local and state codes and with
the requirements of the authority having jurisdiction of the installing site. The heater installation must conform to the
latest edition of the above listed installation codes.

SAFETY INFORMATION

WARNING – Read, Understand, and Follow all instructions in this manual and on the equipment.
Failure to follow instructions can cause severe injury and/or death.

WARNING – Suction Entrapment Hazard.

Suction in suction outlets and/or suction outlet covers which are damaged, broken, cracked, missing, or unsecured
can cause severe injury or death due to the following entrapment hazards:

Hair Entrapment- Hair can become entangled in suction outlet cover.

Limb Entrapment- A limb inserted into an opening of a suction outlet sump or suction outlet cover that is damaged,
broken, cracked, missing, or not securely attached can result in a mechanical bind or swelling of the limb.
Body Suction Entrapment- A negative pressure applied to a large portion of the body or limbs can result in an
entrapment.
Evisceration/ Disembowelment - A negative pressure applied directly to the intestines through an unprotected
suction outlet sump or suction outlet cover which is damaged, broken, cracked, missing, or unsecured can result in
evisceration/disembowelment.
Mechanical Entrapment- There is potential for jewelry, swimsuit, hair decorations, finger, toe or knuckle to be caught
in an opening of a suction outlet cover resulting in mechanical entrapment.

WARNING - To Reduce the risk of Entrapment Hazards:

o When outlets are small enough to be blocked by a person, a minimum of two functioning suction outlets per pump
must be installed. Suction outlets in the same plane (i.e. floor or wall), must be installed a minimum of three feet (3’)
[1 meter] apart, as measured from near point to near point.
o Dual suction fittings shall be placed in such locations and distances to avoid “dual blockage” by a user.
o Dual suction fittings shall not be located on seating areas or on the backrest for such seating areas.
o The maximum system flow rate shall not exceed the flow rating as listed in TABLE1: SPECIFICATIONS.
o Never use Pool or Spa if any suction outlet component is damaged, broken, cracked, missing, or not securely
attached.
o Replace damaged, broken, cracked, missing, or not securely attached suction outlet components immediately.
o Install two or more suction outlets per pump in accordance with latest ASME, APSP Standards and CPSC
guidelines. Follow all applicable National, State, and Local codes.
o Installation of a vacuum release or vent system, which relieves entrapping suction, is recommended.

WARNING – Failure to remove pressure test plugs and/or plugs used in winterization of the pool/spa from the
suction outlets can result in an increase potential for suction entrapment as described above.

WARNING – Failure to keep suction outlet components clear of debris, such as leaves, dirt, hair, paper and other
material can result in an increase potential for suction entrapment as described above.

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WARNING – Suction outlet components have a finite life, the cover/grate should be inspected frequently and
replaced at least every seven years or if found to be damaged, broken, cracked, missing, or not securely attached.

CAUTION – Components such as the filtration system, pumps and heater must be positioned so as to prevent their
being used as means of access to the pool by young children. To reduce risk of injury, do not permit children to use or
climb on this product. Closely supervise children at all times. Components such as the filtration system, pumps, and heaters
must be positioned to prevent children from using them as a means of access to the pool.

WARNING – Hazardous Pressure. Pool and spa water heating and circulation systems operate under
hazardous pressure during start up, normal operation, and after pump shut off. Stand clear of circulation system
equipment during pump start up. Failure to follow safety and operation instructions could result in violent
separation of the pump housing and cover, and/or filter housing and clamp due to pressure in the system, which
could cause death, severe personal injury and/or property damage. Before servicing pool and spa water circulation
system, all system and pump controls must be in off position and filter manual air relief valve must be in open
position. Before starting system pump, all system valves must be set in a position to allow system water to return
back to the pool. Do not change filter control valve position while system pump is running. Before starting system
pump, fully open filter manual air relief valve. Do not close filter manual air relief valve until a steady stream of
water (not air or air and water) is discharged.

WARNING – Separation Hazard. Failure to follow safety and operation instructions could result in violent
separation of pump and/or filter components. Strainer cover must be properly secured to pump housing with
strainer cover lock ring. Before servicing pool and spa circulation system, filters manual air relief valve must be in
open position. Do not operate pool and spa circulation system if a system component is not assembled properly,
damaged, or missing. Do not operate pool and spa circulation system unless filter manual air relief valve body is in
locked position in filter upper body. Never operate or test the circulation system at more than 50 PSI. Do not
purge the system with compressed air. Purging the system with compressed air can cause components to
explode, with risk of severe injury or death to anyone nearby. Use only a low pressure (below 5 PSI), high volume
blower when air purging the pump, filter, or piping.

WARNING – Risk of Electric Shock. All electrical wiring MUST be in conformance with applicable local
codes, regulations, and the National Electric Code (NEC). Hazardous voltage can shock, burn, and cause death or
serious property damage. To reduce the risk of electric shock, do NOT use an extension cord to connect unit to
electric supply. Provide a properly located electrical receptacle. Before working on any electrical equipment, turn
off power supply to the equipment. To reduce the risk of electric shock replace damaged wiring immediately.
Locate conduit to prevent abuse from lawn mowers, hedge trimmers and other equipment. Do NOT ground to a
gas supply line.

WARNING – Risk of Electric Shock. Failure to ground all electrical equipment can cause serious or fatal electrical shock
hazard. Electrically ground all electrical equipment before connecting to electrical power supply.

WARNING – Risk of Electric Shock. Failure to bond all electrical equipment to pool structure will increase risk for
electrocution and could result in injury or death. To reduce the risk of electric shock, see installation instructions and consult a
professional electrician on how to bond all electrical equipment. Also, contact a licensed electrician for information on local
electrical codes for bonding requirements.
Notes to electrician: Use a solid copper conductor, size 8 or larger. Run a continuous wire from external bonding lug to
2 2
reinforcing rod or mesh. Connect a No. 8 AWG (8.4 mm ) [No. 6 AWG (13.3 mm ) for Canada] solid copper bonding wire to the
pressure wire connector provided on the electrical equipment and to all metal parts of swimming pool, spa, or hot tub, and
metal piping (except gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool, spa, or hot tub.
IMPORTANT - Reference NEC codes for all wiring standards including, but not limited to, grounding, bonding and other
general wiring procedures.

WARNING – Risk of Electric Shock. The electrical equipment must be connected only to a supply circuit that is protected
by a ground-fault circuit-interrupter (GFCI). Such a GFCI should be provided by the installer and should be tested on a routine
basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push reset button. Power should be restored.
If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts power to the electrical equipment
without the test button being pushed, a ground current is flowing, indicating the possibility of an electrical shock. Do not use this
electrical equipment. Disconnect the electrical equipment and have the problem corrected by a qualified service representative
before using.

CAUTION – These heaters are intended for use with permanently-installed pools and may be used with hot tubs and spas
if so marked. Do not use with storable pools. A permanently-installed pool is constructed in or on the ground or in a building
such that it cannot be readily disassembled for storage. A storable pool is constructed so that it is capable of being readily
disassembled for storage and reassembled to its original integrity.

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WARNING – Risk of Hyperthermia. To avoid hyperthermia the following “Safety Rules for Hot Tubs” are recommended by
the U.S. Consumer Product Safety Commission.
1. Spa or hot tub water temperatures should never exceed 104°F [40°C]. A temperature of 100°F [38°C] is considered
safe for a healthy adult. Special caution is suggested for young children. Prolonged immersion in hot water can
induce hyperthermia.
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 above 100°F [38°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 adhere 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 taking medications, which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants, should
not use spas or hot tubs.
6. If the pool/spa is used for therapy, it should be done with the advice of a physician. Always stir pool/ spa water before
entering the pool/spa to mix in any hot surface layer of water that might exceed healthful temperature limits and cause
injury. Do not tamper with controls because scalding can result if safety controls are not in proper working order.
7. Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure problems should
obtain a physician’s advice before using spas or hot tubs.
8. Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above normal body
temperature of 98.6°F [37°C]. The symptoms of Hyperthermia include: drowsiness, lethargy, dizziness, fainting,
and an increase in the internal temperature of the body.
The effects of Hyperthermia include:
 Unawareness of impending danger.
 Failure to perceive heat.
 Failure to recognize the need to leave the spa.
 Physical inability to exit the spa.
 Fetal damage in pregnant women.
 Unconsciousness resulting in danger of drowning.

DEFINITIONS:
Suction Outlet: The Suction Outlet is a fitting, fitting assembly, cover/grate and related components that provide a means for
water to exit the pool and return into the pump circulating system. This fitting may also be referred to as the “Main
Drain”
Bypass Valves: A valve or series of valves that direct the pool water to flow or not flow through the heater.
CSA: Canadian Standards Association
CGA: Canadian Gas Association
ANSI: American Nation Standards Institute
NFPA: National Fire Protection Association
NEC: National Electric Code
SCAQMD: South Coast Air Quality Management District
ISTA: International Safe Transit Association
Pressure measurement units:
Inches of Mercury (inHg) is typically used with atmospheric pressure measurements.
Pounds per square inch (PSI) is typically used with water “pressure”, “suction” or system measurements.
Inches of Water (inwc) is typically used with gas or air pressure measurements
(1.0 inHg = .49 PSI = 13.5inwc)

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INSTALLATION:
This manual contains instructions for installation, operation, maintenance, troubleshooting, and parts lists for the proper operation of
the swimming pool/spa/hot tub heaters. It is strongly recommended that the installer read the manual before installing the
swimming pool/spa/hot tub heater. If after reviewing the manual any questions remain unanswered, contact tech services or local
representative. Following heater installation, the installer should leave all manuals with the consumer for future reference.

NOTICE: The installation instructions are intended for the use of a qualified technician, specifically trained and experienced
in the installation of this type of heating equipment. Some states or provinces require that installer be licensed. If this is the
case in the state or province where heater is located, the contractor must be properly certified.

THE USE OF A POOL COVER IS RECOMMENDED. A pool cover reduces heat loss, conserves chemicals, lowers the
load on filter systems and may provide a valuable safety feature

EQUIPMENT INSPECTION: On receipt of the heater, inspect the heater carton(s) for damage. If any carton(s) is damaged,
note it when signing for it. Remove the heater from the carton(s) inspect it and advise the carrier of any damages at once.

NOTICE: Do not drop the heater from a pickup truck tailgate to the ground. This may damage the heater.

UNCRATING THE HEATER: Follow these steps to

remove the shipping carton from the heater: 3. To access the four (4) internal screws (see figure4), open
the front access panel by removing the single top screw.
1. Remove the corrugated carton from the heater. The
Then remove the two (2) screws and brackets which hold
carton, top pad, bottom pad, and the four corner posts can
the heater base pan to the pallet shown in Figure3. Next
be recycled.
open the rear access panel by removing the four (4)
2. There are four (4) external screws (see figure3) used to
screws holding this panel. Then remove the two (2)
secure the heater to the wood pallet. All four must be
screws and brackets which hold the heater base pan to
removed to separate the heater from the pallet.
the pallet as shown in Figure3.
Figure3: External Shipping Screw Locations 4. Lift the heater clear of the corrugated bottom pad and off
of the pallet. Discard bottom corrugated tray and pallet
appropriately.
Front shipping
screws and Figure4: Internal Shipping Screw Locations
brackets Front
shipping
screws

Rear shipping
screws and
Rear
brackets
shipping
screws

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SPRINKLER HEADS: The heater is designed to handle the wettest weather conditions that are typical of rain and high
humidity. Sprinkler heads force high-pressure water into the unit from the side at an odd angle. Make sure there are no sprinkler
heads near the heater that will spray on or into the unit. Many sprinkler systems are connected to a well system, whose water is
high in minerals, Sulphur, salt and other aggressive contaminates, that will leave a buildup on the unit and electronics causing
corrosion and shortens life.

NOTICE: Damage from sprinkler interaction is not covered under the warranty agreement. Make sure that sprinklers are
placed at a sufficient distance away so that normal wind will not carry the mist to the Heater.
NOTICE: If located in an oceanfront area, the Heater should be placed out of direct spray of sand and salt. This will clog,
damage, and corrode the unit. You may also consider protecting the unit by creating a physical barrier outside of the minimum
clearances between the unit and the prevailing beachfront wind. Damage caused by sand or salt spray is not covered by the
warranty.

LOCATING THE HEATER:

Locate the pool/spa heater in an area where leakage of the heat exchanger or connections will not 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
drain outlet, be installed under the heater. The pan must not restrict airflow. This heater must be installed at least (5) feet from the
inside wall of a pool (in-ground or above-ground)/spa/hot tub unless separated from the pool/spa/hot tub by a solid barrier. The
heater must be installed such that the location of the exhaust gas vent assembly outlet relative to adjacent public walkways,
adjacent buildings, openable windows, and building openings complies with the National Fuel Gas Code (ANSI Z223.1/NFPA 54)
and/or CAN/CGA B149 installation codes.
1. Level surface for proper rain water draining and removal.
2. Suitable electrical supply line. See rating plate on the heater for electrical specifications. A junction box is not needed at the
heater; connections are made inside the unit electrical compartment. Minimum wire size to be selected per NEC.
3. Electric disconnect switch that will interrupt all power to the unit. This switch MUST be within line of sight of the heater.
4. The heater does not require additional vent piping when installed outdoors.
5. Do not install in a location where growing shrubs may in time obstruct a heater’s combustion air and venting areas.
6. Do not install this appliance under an overhang less than 72in from the top of the appliance. The area under the overhang must
be open on (3) sides.
7. Do not install the heater where water spray from ground level can contact the heater. The water could reach the controls
causing electrical damage.
8. Do not install under a deck.
9. Do not install within 24in of any outdoor HVAC equipment.
10. Do not install where water may run-off a roof into the heater. A gutter may be needed to protect the heater.
CAUTION: Make sure the heater is not located where large amounts of water may run-off from the roof into the unit. Sharp
sloping roofs without gutters will allow massive amounts of rainwater, mixed with debris from the roof to be forced through the
unit. Failure to follow the instructions may result in property damage and void warranty.
11. Any enclosure around the heater must provide a combustion air vent large enough to accommodate input ratings of all gas
appliances in the enclosure. See AIR SUPPLY section for more detail
12. For minimum exhaust vent clearances for all building openings, including but not limited to vented eaves, doors, windows, or
gravity inlets, see Figure5. In Canada, the heater must be installed with the top of the vent at least 10 feet (3m) below, or
to either side of, any opening into a building.

OUTDOOR AND INDOOR INSTALLATION AND SERVICE Table3: Installation Required Clearances (in.)
CLEARANCES: For both outdoors and indoors installations,
the installation clearances from combustible materials and Outdoor Indoor
Heater Panel
service clearances shown in Table3 and Figure5 must be Clearance Clearance
maintained. Do not install heater in a closet or enclosed space Top Unobstructed 36
(consult NFGC) Front 18 18
Back* 6 6
*If the heater is to be installed with vinyl siding at back,
increase the clearance in Table3 to 12 inches to avoid potential Water Side Connection 12 12
discoloration of siding Opposite Water Side
6 6
Connection

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EQUIPMENT PAD: Place the heater on a level surface such as concrete or a fabricated slab (pad). This allows proper
drainage of condensation and rainwater from the base of the unit. If possible, the pad should be placed at the same level or slightly
higher than the filter system equipment pad.
FLOORING: This heater may be installed on either non-combustible flooring or combustible flooring that does not reduce the
bottom clearance of the heater. Ultralite™ or equivalent concrete-over-foam HVAC pads are acceptable.
Figure5: Outdoor Minimum Clearances

Free
from rain
4 ft. 4 ft. run off or
minimum minimum blockage
from
3 ft. 4 ft. above
minimum minimum
Force Air
Inlet 10 ft. minimum

ANCHORING: The heater is equipped for installation of factory supplied tie-down brackets when required by local codes.
Follow all relevant Local, State and National requirements regarding wind load anchoring. The brackets are shipped in the
consumer kit. You will need the following to complete the installation:
Tie-down brackets (FACTORY-SUPPLIED, qty = 4)
Sheet metal screws (FACTORY-SUPPLIED, qty = 4)
Concrete tapping screws (FIELD-SUPPLIED, Tapcons®, qty = 4, stainless steel, size to be ¼”diameter with a minimum
length of 1-1/2”)
Fender washers (FIELD SUPPLIED, stainless steel, qty = 4, size to be at least 1-1/2”)
INSTALLING TIE-DOWN BRACKETS:
1. Locate the tie-down brackets and the sheet metal screws.
2. Obtain the Tapcons®. Be sure the overall length of the concrete tapping screw is at least1-1/2”.
3. Remove the front (1 screw) and rear access panel (4 screws).
4. Position the heater on the pad so that all Tapcons® can “bite” into the pad. Observe local codes regarding pad construction,
some jurisdictions specify a minimum thickness for concrete pads.
5. Position the tie-down brackets into the slots in the front of the heater base pan so they are positioned as shown in Figure6. Install
the sheet metal screws through the holes in the bracket to secure the bracket to the heater base pan.
6. Install the Tapcons® through the inner set of holes in the tie-down brackets into the pad (see figure7).
7. Repeat Steps 6 & 7 at the rear of the heater.
8. Tie down is completed when (4) brackets are secured to the heater and the pad. Re-install the access panels in locations (front
and rear), front shown

Figure6: Tie-Down Installation Locations Figure7: Use 2nd Hole for Ground Mount of
Tie-Down Brackets with 2 Holes

Install supplied screws at these locations.

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GAS CONVERSION:
Where permitted by local codes, the factory-installed gas train may be changed from natural gas to propane or from propane to
natural gas, using the appropriate conversion kits. Gas conversions are to be performed only by a qualified service agency. Detailed
instructions are included with each kit.

ALTITUDE OF INSTALLATION:
Heaters may be installed at any altitude up to 10,100 ft. above sea level, provided the appropriate modification(s) are performed.
The altitudes which require modification vary depending on the model. Parts necessary to convert the heater for outdoor installation
at altitudes up to 7,700 ft. (minimum) are included with the heater.

WARNING: Failure to comply with the appliance and vent package installation instructions and service instructions in
this manual may result in equipment damage, fire, asphyxiation, or carbon monoxide poisoning. Exposure to products of
incomplete combustion (carbon monoxide) can cause cancer and birth defects or other reproductive harm.

Conversion is accomplished by replacement of the blower air inlet plate, and for indoor applications, installation of the appropriate
vent pressure switch. The blower air inlet plates are clearly marked with the compatible heater model(s), vent configuration(s), and
altitude range(s). Care should be taken to verify the correct plate and vent pressure switch is being used to ensure proper heater
performance. The vent pressure switch will be provided with the indoor adapter kit, or if you have an older indoor adapter kit, order
p/n FDXLVPS1931 for the high-altitude indoor vent pressure switch. Table4 lists the maximum altitudes for which each model is
designed with: a) no modifications, b) the included conversion plate installed, and c) the accessory conversion kit FDXLHAK1930
installed (sold separately).

Table4 High Altitude Conversions in (ft.)

Model Outdoor Installation Indoor Installation *
No Included Kit No Included Kit
Modifications Conversion FDXLHAK1930 Modifications Conversion Plate FDXLHAK1930
to Heater Plate Installed Installed to Heater Installed Installed

150FDN 7,700 N/A 10,100 10,100 N/A N/A

150FDP 7,700 N/A 10,100 2,000 10,100 N/A
200FDN 10,100 N/A N/A 10,100 N/A N/A
200FDP 5,400 10,100 N/A 2,000 10,100 N/A
250FDN 5,400 10,100 N/A 2,000 10,100 N/A
250FDP 2,000 7,700 10,100 2,000 7,700 10,100
300FDN 10,1001 N/A N/A 10,100 N/A N/A
300FDP 2,000 10,100 N/A 2,000 10,100 N/A
350FDN 2,000 10,100 N/A 2,000 10,100 N/A
350FDP 2,000 7,700 10,100 2,000 7,700 10,100
400FDN 10,100 N/A N/A 10,100 N/A N/A
400FDP 2,000 7,700 10,100 2,000 7,700 10,100
500FDN 10,100 N/A N/A 10,100 N/A N/A
500FDP 5,400 7,700 10,100 5,400 7,700 10,100
* All indoor installations at altitudes above 2,000 require a vent pressure switch to be installed in addition to the blower inlet plate.
The vent pressure switch is included with the appropriate indoor vent kit (UHXNEGVT1xxx or UHXPOSHZ1xxxx), or the high-
altitude vent pressure switch kit FDXLVPS1931.

USE ONLY GENUINE REPLACEMENT PARTS 13

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High-Altitude Conversion Procedure:

1. Identify the altitude of the installation site. This may be done using a GPS device, or by looking up the altitude for the geographic
location. Altitudes for all locations in the United States and Canada may be found using the zip/postal code database at
www.zip-codes.com. If the altitude for the installation site is greater than 10,100 ft., the heater may not be installed. Note that if
installing outdoors, some heaters may be compatible with your altitude without modification. Table4 lists the altitude ranges for
heaters without modification. All indoor heaters installed above 2,000 ft. require the appropriate vent pressure switch, see indoor
installation kit instructions.
2. Select the appropriate blower air inlet plate to use based on the heater model, vent configuration (outdoor or indoor), and altitude
needed. Extra plate(s) are included with the heater, packaged in the plastic bag with this manual. Each plate has a label which
identifies which model(s), vent configuration(s), and altitude range(s) for which it is designed. Table4 lists the maximum
installation altitudes using the included conversion plate(s). If installing above 7,700 ft., the high-altitude kit FDXLHAK1930 (sold
separately) may be necessary.
3. If installing indoors, select the appropriate high-altitude indoor vent pressure switch from the indoor adapter kit or from the
FDXLVPS1931 kit. Each switch has a label which identifies which model(s) and altitude range(s) for which it is designed.
4. If connected, turn pump, main gas valve, and heater power off, remove heater front access door.
5. Remove the 4 #10 hex head screws that fasten the blower air inlet plate to the blower, and remove the blower air plate and
discard. Save the 4 screws as they will be needed to install the new plate. See Figure29: Blower
6. Install the appropriate blower plate from the kit using the 4 screws. It may be helpful to drive the screws in and out of the plate
outside of the heater first to “thread” the holes before installing it in the heater.
7. If the installation is configured for indoor venting, a special high-altitude vent pressure switch must be installed. Follow the
instructions provided in listed vent kits (see Tables 6 and 9), and use the appropriate blower air inlet plate and vent pressure
switch for your altitude.
8. Re-install heater front door, if connected, turn pump, main gas valve, and heater power back on.
9. Activate heater and check for proper operation.
AIR SUPPLY:
Indoor installations and outdoor shelters (confined spaces) must be provided with adequate combustion and ventilation air openings
to assure proper heater operation. These openings must be sized according to the requirements stated in paragraphs below (ALL
AIR SUPPLY FROM INSIDE THE BUILDING or ALL AIR SUPPLY FROM OUTDOORS whichever applies to the installation). These
air openings must never be obstructed when heater is in operation. These confined spaces shall be provided with 2 permanent
openings, one commencing within 12 inches of the bottom and one commencing within 12 inches of the top of the enclosure. The
openings shall communicate directly or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the
outdoors. Ducts shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall not be less than 3 inches. When air blowers are used in spa/hot tub installations and are
located in proximity to the heater, caution must be observed to ensure sufficient combustion air is available to the heater for proper
combustion. A separate blower air duct is recommended. Table 3 indoor clearances apply.
ALL AIR SUPPLY FROM INSIDE THE BUILDING: The
Table5 Combustion and Ventilation Air
confined space shall be provided with 2 permanent openings
Requirements (sq. in.)*
communicating directly with an additional room(s) of sufficient
volume so that the combined volume of all spaces meets the Free Area per Total Input Combustion Ventilation
criteria for an unconfined space (a space whose volume is not Total Btu (Btu/hr) Air Free Area Air Free Area
Requirement Required Required
less than 50 cubic feet per 1,000 btu/hr of total input all gas
1 sq. in. per 150,000 150 150
utilization equipment installed in the combined space shall).
200,000 200 200
Each opening shall have a minimum free area of 1 square inch 1,000 Btu/hr 250,000 250 250
per 1,000 btu/hr of the total input, but not less than 100 square (Indoor Air) 300,000 300 300
350,000 350 350
inches. See Table5 and Figure8.
400,000 400 400
ALL AIR SUPPLY FROM OUTDOORS: When communicating 500,000 500 500
1 sq. in. per 150,000 75 75
with the outdoors through horizontal ducts, each opening shall 200,000 100 100
2,000 Btu/hr
have a minimum free area of 1 square inch per 2,000 btu/hr of 250,000 125 125
(Outdoor Air thru 300,000 150 150
total input See Table5 and Figure9B. When communicating Horz duct) 350,000 175 175
with the outdoors (either directly or through vertical ducts), 400,000 200 200
each opening shall have a minimum free area of 1 square inch 500,000 250 250
per 4,000 btu/hr of total input rating of all equipment in the 1 sq. in. per 150,000 37.5 37.5
4,000 Btu/hr 200,000 50 50
enclosure. See Table5 and Figure9A. When installing a heater 250,000 62.5 62.5
(Outdoor Air
below ground (in a pit, for use with Natural Gas only), direct or thru Vert 300,000 75 75
combustion and ventilation air openings must be provided as 350,000 87.5 87.5
duct ) 400,000 100 100
shown in Figure10. 500,000 125 125
*For detailed methods of providing combustion and ventilation air, see
latest edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54).

14 USE ONLY GENUINE REPLACEMENT PARTS

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Figure8: Air from Inside Building Installation Figure10: Air Below-Ground

1 square inch per 1,000 btu/hr of the total input (Pit for Natural Gas only Installations)
Table3 Indoor Clearance Apply 1 square inch per 4,000 btu/hr of total input
Table3 Indoor Clearance Apply
Vent Cap

Vent Cap
Ventilation
Ground Combustion
Air
Rise 1in/ft. Air

Drip Rise 1in/ft.

Ventilation
Tee
Air
Drip
Gas Shut Tee
Off Combustion
Air Gas Shut Off

Sediment Trap Level Floor/Slab

Figure9: Air from Outside Building Installation Sediment Trap Level Floor/Slab
A)1 square inch per B)1 square inch per
4,000 btu/hr of 2,000 btu/hr of
total input total input

FLUE GAS VENTING:

For installation outdoors, no additional venting is required for operation. Ensure top of unit remains unobstructed.

INDOOR INSTALLATION WITH NEGATIVE (CATI) OR POSITIVE (CATIII) PRESSURE VENTING SYSTEMS: The heater is
designed such that it may be vented using either a negative-pressure or a positive-pressure venting system. The appropriate
system of venting for a particular site will depend on many factors such as vent termination needs (horizontal/vertical), clearance of
vent termination, length of vent and the cost of venting system. Table6 (CATI) and Table9 (CATIII) list the required indoor venting
kits available for each system. Multiple forced- or induced-draft units should never be vented using common venting or vent
terminations. Never common vent this heater with other gas-burning appliances.

NEGATIVE PRESSURE (VERTICAL ONLY, CATI) VENTING:

NEGATIVE PRESSURE CATI VENT SIZING: Size the vent pipe according to the venting Tables in the National Fuel Gas Code
(ANSI Z223.1/NFPA 54) for a Category I gas appliance using single-wall or double-wall (Type B) gas vent. Vent pipe diameter
should not be less than the size of the vent pipe adapter on the heater with the appropriate vent kit adapter installed (see Table6).
Single-wall vent may be used in conditioned spaces only. Clearance to combustible materials for single-wall vent is 9 inches.
Double-wall (Type B) vent may be used in conditioned spaces, but must be used in non-conditioned spaces. Clearance to
combustible materials for double-wall vent is 6 inches. Smaller clearances may be available; consult the National Fuel Gas Code.

USE ONLY GENUINE REPLACEMENT PARTS 15

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Table6 Negative-Pressure (CATI) Indoor Vent Kits with Vent Pipe & Terminal Specifications
Indoor Vent Kit Vent Vent Pipe Vent Pipe Vent
Models Description Termination
Part Number Dia(in) Application Material
Requirement
150 UHXNEGVT11506 6 Indoor Vent Vent pipe to be
200 UHXNEGVT12006
Single or
6 Adapter Kit, installed according to
250 UHXNEGVT12506
Double Wall,
6 Negative the venting Tables in Vertical
300 UHXNEGVT13008
Galvanized,
8 Pressure the National Fuel Only
350 UHXNEGVT13508 Non-Sealed
8 CATI, Vertical Gas Code (ANSI
400 UHXNEGVT14008 8 Vent Pipe
Venting Z223.1/NFPA 54) for
500 UHXNEGVT15008 8 Applications a Category I gas
appliance
CATI MECHANICAL DRAFT SYSTEMS: Vent systems requiring power venting must use mechanical draft systems listed in
accordance with UL378 Draft Equipment. Selection of power venter and required clearances from combustible materials must
follow draft equipment manufacture’s instructions, National Fuel Gas Code, local codes and the information in this manual.

NEGATIVE PRESSURE CATI VENT TERMINATION: Any vent extending through a roof or wall must be listed double-wall (Type B)
vent, and pass through an approved roof jack, or roof thimble. A listed vent cap must be used. Terminations for Gas vents with
listed 12in or less diameter size and located not less than 8ft from a vertical wall or similar building feature shall terminate per
Figure11 and Table7 using the roof pitch to find the minimum termination height value of H. Terminations for Gas vents with listed
12in or less diameter size located less than 8ft from a vertical wall or similar building feature shall terminate not less than 2ft above
the highest point where they pass through the roof and not less than 2ft above any portion of a building within 10ft horizontally

Figure11: Minimum Height from Roof Table7 Height Requirements for Negative
for Vent Cap Pressure (CATI) Vent Caps (see Figure11)
Lowest Discharge Min. Height H from Roof to
Listed Roof Slope Lowest Discharge Opening
Cap (ft.) (m)
Flat to 6/12 1.0 0.30
Over 6/12 to 7/12 1.25 0.38
Over 7/12 to 8/12 1.5 0.46
Over 8/12 to 9/12 2.0 0.61
Roof Slope at X/12
Over 9/12 to 10/12 2.5 0.76
Over 10/12 to 11/12 3.25 0.99
Min. Height (H) from Roof to Over 11/12 to 12/12 4.0 1.22
Lowest Discharge Opening Over 12/12 to 14/12 5.0 1.52
Over 14/12 to 16/12 6.0 1.83
Over 16/12 to 18/12 7.0 2.13
Over 18/12 to 20/12 7.5 2.27
Over 20/12 to 21/12 8.0 2.44

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POSITIVE PRESSURE (HORIZONTAL OR VERTICAL, CATIII) VENTING:

When installed according to the following instructions, heaters meet the criteria for category III venting.

VENT SIZING: Vent pipe diameter must match the vent pipe diameter on the heater (see Table9). The vent pipe must be single or
double-wall stainless steel sealed vent as listed in Table9. Double-wall vent must be used in non- conditioned spaces. The
maximum total length of vent pipe, and number of 90-degree elbows cannot exceed the limits specified in Table8.The venting
system must be installed in accordance with the vent manufacturer’s installation instructions and guidelines. The installer is urged to
visit the vent system manufacturer’s website (see below) and review the installation information found there.

Table8 Positive-Pressure (CATIII) Indoor Vent Maximum Vent Lengths

Using Specified Positive Pressure Indoor Vent Kits
Number of 90- degree Elbows Maximum Vent Pipe Length horizontal & vertical (ft.)
0 50
1 50
2 40
3 30

VENT TERMINATION: The vent system must terminate with a vent terminal approved for this pool heater. Termination may be
either horizontal or vertical. See Table9a for approved vent terminals and 9b for termination locations.

OBTAINING VENT PIPE AND TERMINATIONS: A variety of vent components, including terminals, elbows, and straight lengths,
are available for use with this appliance. Approved parts are listed in Table9 and in the service parts section in the back of this
manual. If you need more specialized fittings, you may order them directly from the manufacturer, or one of their authorized
dealers. To locate an authorized dealer for venting parts, contact the appropriate manufacturer at:

M&G DuraVent Inc. Selkirk Corporation

6 Jupiter Ln. Heatfab Division
Colonie, NY 12205 OR 130 Industrial Blvd
(800) 835-4429 Turners Falls, MA 01376
www.duravent.com (800) 772-0739
DuraVent FasNSeal (W2) www.heatfab.com
Heatfab Saf-T Vent EZ
Seal (CI Plus)

Notes for Table9 Positive-Pressure (CATIII) Indoor Vent Kits with Vent Pipe & Terminal Specifications
* For Heatfab single-wall vent pipe section length, “x” to be: 1, 2, 4, 5, or 7, where 1=6 inches, 2=12 inches, 4=18 inches, 5=24 inches, and
7=36 inches.
** For Heatfab double-wall vent pipe section length, “x” to be: 06, 09, 12, 18, 24, or 36, indicating the length of the vent pipe section in
inches.
† For DuraVent vent pipe section length, “x” to be: 6, 12, 18, 24, or 36, indicating the length of the vent pipe section in inches.
‡ For these horizontal terminals, the wall penetration is included from the vent manufacturer. On all others, it must be ordered separately.

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Table9 Positive-Pressure (CATIII) Indoor Vent Kits with Vent Pipe & Terminal Specifications
Heatfab Saf-T Vent EZ Seal (CI Plus) or
Vent DuraVent FasNSeal (W2)
Maximum
Heater Indoor Vent Kit Pipe Appliance Vent Pipe
Installation Vent Pipe Horizontal Vertical Vent
Model Part Number Altitude (ft.) Dia. Adapter Type
(in) Part Vent Terminal Terminal
Number Part Number Part Number
HeatfabP/N HeatfabP/N HeatfabP/N
Single-Wall
960x * 9614TERM 5600CI
150 UHXPOSHZ11506 Heatfab adapter
10,100 6
200 UHXPOSHZ12006 included in kit
HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA06Lx ** 9614TERM CCA06RC

HeatfabP/N HeatfabP/N HeatfabP/N

Single-Wall
960x * 5690CI ‡ 5600CI
Heatfab adapter
250 UHXPOSHZ12506 10,100 6
included in kit
HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA06Lx ** CCE06WP ‡ CCA06RC

DuraVentP/N DuraVentP/N DuraVentP/N

Single-Wall
UHXDVA004 FSVLx04 † FSTT4 FSRC4
(4” Duravent
adapter) DuraVentP/N DuraVentP/N DuraVentP/N
250- Double-Wall
FDN W2-x04 † FSTT4 W2-RC4
UHXPOSHZ12504 2,000 4
(NAT
ONLY) HeatfabP/N HeatfabP/N HeatfabP/N
Single-Wall
UHXHFA004 940x * 9414TERM 5400CI
(4” Heatfab
adapter) HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA04Lx ** 9414TERM CCA04RC

HeatfabP/N HeatfabP/N HeatfabP/N

Single-Wall
300 UHXPOSHZ13008 980x * 5890CI ‡ 5800CI
Heatfab adapter
350 UHXPOSHZ13508 10,100 8
included in kit
400 UHXPOSHZ14008 HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA08Lx ** CCE08WP ‡ CCA08RC

DuraVentP/N DuraVentP/N DuraVentP/N

Single-Wall
UHXDVA006 FSVLx06 † FSTT6 FSRC6
(6” Duravent
adapter) DuraVentP/N DuraVentP/N DuraVentP/N
Double-Wall
W2-x06 † FSTT6 W2-RC6
400 UHXPOSHZ14006 2,000 6
HeatfabP/N HeatfabP/N HeatfabP/N
Single-Wall
UHXHFA006 960x * 9614TERM 5600CI
(6” Heatfab
adapter) HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA06Lx ** 9614TERM CCA06RC

DuraVentP/N DuraVentP/N DuraVentP/N

Single-Wall
UHXDVA006 FSVLx06 † FSTT6 FSRC6
(6” Duravent
adapter) DuraVentP/N DuraVentP/N DuraVentP/N
Double-Wall
W2-x06 † FSTT6 W2-RC6
500 UHXPOSHZ15006 10,100 6
HeatfabP/N HeatfabP/N HeatfabP/N
Single-Wall
UHXHFA006 960x * 9614TERM 5600CI
(6” Heatfab
adapter) HeatfabP/N HeatfabP/N HeatfabP/N
Double-Wall
CCA06Lx ** 9614TERM CCA06RC

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 51300004201B

Table9b Positive-Pressure (CATIII) Vent Termination Clearances

DIM Clearance Description U.S. Installation (1) Canadian Installation (2)
Clearance above grade, veranda, porch, deck,
A balcony or anticipated snow level 12 in. (305 mm) 12 in. (305 mm). 18 in. (457 mm) above roof surface.
12 in. (305 mm) for appliances > 500,000 Btuh (15 36 in. (914 mm) for appliances > 100,000 Btuh (30
B Clearance to a window or door that may be opened kW) kW)
C Clearance to a permanently closed window
Vertical clearance to a ventilated soffit located
above the terminal within a horizontal distance of 2
D For clearances not specified in ANSI Z223.1/NFPA 54 or For clearances not specified in ANSI Z223.1/NFPA 54 or
feet (61 cm) from the centerline of the terminal
C A N / CSA B149.1, clearances shall be in accordance C A N / CSA B149.1, clearances shall be in accordance
E Clearance to an unventilated soffit with local installation codes and the requirements of with local installation codes and the requirements of
F Clearance to an outside corner the gas supplier the gas supplier
G Clearance to an inside corner
Clearance to each side of the centerline extended
above electrical meter or gas service regulator as- 3 ft. (.9 M) within 15 ft. (4.6 M) above the meter/ 3 ft. (.9 M) within 15 ft. (4.6 M) above the meter/
H regulator assembly regulator assembly
sembly
For clearances not specified in ANSI Z223.1/NFPA 54 or
C A N / CSA B149.1, clearances shall be in accordance
Clearance to service regulator vent outlet with local installation codes and the requirements of
I 3 ft. (.9 M)
the gas supplier
Clearance to non ---mechanical air supply inlet to 9 in. (229 mm) for appliances > 10,000 Btuh (3kW) and <= 12 in. (305 mm) for appliances > 10,000 Btuh(3kW)
building or the combustion air inlet to any other 50,000 Btuh (15 kW), 12 in. (305 mm) for appliances > and <= 100,000 Btuh (30 kW), 36 in. (914 mm) for
J
appliance 50,000 Btuh (15 kW) appliances > 100,000 Btuh (30 kW)
K Clearance to a mechanical air supply inlet 3 ft. (.9 M) 6 ft. (1.8 M)

For clearances not specified in ANSI Z223.1/NFPA 54 or

CAN/CSA B149.1, clearances shall be in accordance 7 ft. (2.1 M). A vent shall not terminate above a side-
Clearance above paved sidewalk or paved driveway with local installation codes and the requirements of walk or paved driveway that is located between two
L located on public property the gas supplier single family dwellings and serves both dwellings.

For clearances not specified in ANSI Z223.1/NFPA 54 or

C A N / CSA B149.1, clearances shall be in accordance 12 in. (305 mm). Permitted only if veranda, porch,
with local installation codes and the requirements of deck, or balcony is fully open on a minimum of two
M Clearance under a veranda, porch, deck, or balcony
the gas supplier sides beneath the floor.

N Clearance from a plumbing vent stack 3 ft. (.9 M) 3 ft. (.9 M)

(1) In accordance with the current ANSI Z223.1.NFPA 54, National Fuel Gas Code
(2) In accordance with the current C A N / CSA B 149.1, Natural Gas and Propane Installation Code.

WARNING:
1. The vent for this appliance shall not terminate:. Over public walkways; or Near soffit vents of crawl space vents or other areas where condensate or
vapor could create a nuisance or hazard or property damage; or Where condensate vapor could cause damage or could be detrimental to the operation of
regulators, relief valves, or other equipment.
2. When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of
the combustion products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat
exchangers.
3. Do not vent under a deck or large overhang. Recirculation could occur and cause performance or system problems.

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 51300004201B

GAS SUPPLY:
The heater is shipped from the factory with the gas connection located on the left side of the heater cabinet. The gas connection
can also be configured from the right. Insert the pipe to the gas valve through the grommet in the cabinet side (see Figure13.) A
union should be installed outside the heater cabinet for easy removal of the gas manifold assembly during service. A CSA certified
main gas shutoff valve must be installed outside the cabinet and within 6 feet of the heater. This valve must have an I.D. large
enough to supply the proper amount of gas volume to the heater. See Figure12. Reduction of gas supply pipe or tubing to the inlet
to the heater gas valve must be made at the valve only and must match the valve inlet size (3/4” or 1” NPT).If more than one
appliance is installed on the gas line, consult the local gas company or appropriate technical service for the proper gas line size.

CAUTION: Apply joint compound (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply joint
compound to the first two threads. Use joint compounds resistant to the action of liquefied petroleum gas. Do not
overtighten the gas inlet pipe or damage may result.

NOTICE: Use Only CSA approved flexible outdoor gas appliance connectors marked with BTUH capacity (which must be
equal to or greater than the heater rated input) and appropriate gas type (natural and/or LP).

Figure12: Gas Piping with Shut Off & Trap Figure13: Gas Entry and Junction Box Cover
6in Max

Gas Remote
Gas
Supply Union Control
Inlet
Wiring
Gas Valve

3in
Gas Sediment Supply
Heater Bonding
Shut Off trap Voltage
Cabinet Lug Wiring

NATURAL GAS: The gas meter must have the capacity to supply enough gas to the pool heater and any other gas appliances if
they are on the same pipeline (Example: 225 meter = 225,000 BTUH). If doubt exists as to the meter or regulation sizes, consult the
local gas utility for assistance. Natural gas must be “pipeline quality” supplied from a natural gas utility company.

NOTICE: Manufacturer is not responsible for heaters that are damaged if connected to a natural gas well.

PROPANE GAS: All propane gas tanks must be located outdoors and away from pool/spa structure and in accordance with the
standard for storage and handling of propane gas, ANSI/NFPA 58 (latest edition) and applicable local codes. If the propane gas
tank is installed underground, the discharge of the regulator vent must be above the highest probable water level. Propane tanks
must have sufficient capacity to provide adequate vaporization for the full capacity of the equipment at the lowest expected
temperatures. Consult a propane expert for accurate pipe and pressure sizing. Make sure that 1st and 2nd stage regulators are
large enough to handle the BTUH input listed for the heater(s) being used

NOTICE: Manufacturer is not responsible for heaters that soot due to improper gas line or propane tank sizing or regulation
control resulting in improper gas volume.

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GAS SUPPLY AND PIPING: To properly size the gas piping for the heater, refer to Tables 10, 11, 12, and 13, depending on natural
or propane gas, and single-stage or 2-stage regulation. Follow local gas codes for proper gas line material selection (copper, iron,
plastic, etc.). It is VERY IMPORTANT when installing a propane heater on a 2-stage regulation system to follow the gas line sizing
data in Tables 12 or 13 without exception

Table10 Natural Gas Pipe Sizing (dia. In), Low-Pressure, Single-Stage Regulation
btu/hr input 150,000 200,000 250,000 300,000 350,000 400,000 500,000
Gas Line Material Iron or Iron or Iron or Iron or Iron or Iron or Iron or
Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe
0 to 50 3/4 1 1 1-1/4 1-1/4 1-1/4 1-1/4
Distance from Gas
50 to 100 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2
Meter to Gas Valve
Inlet (ft.) 100 to 200 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 2
200 to 300 1-1/4 1-1/4 1-1/2 2 2 2 2
Based upon an inlet gas pressure of 0.5 psig or less at a pressure drop of 0.5 inwc

Table11 Propane Gas Pipe Sizing (dia. In), Low-Pressure, Single-Stage Regulation
btu/hr input 150,000 200,000 250,000 300,000 350,000 400,000 500,000
Gas Line Material Iron Tubing Iron Tubing Iron Tubing Iron Tubing Iron Tubing Iron Pipe Iron Pipe
btu/hr input Pipe Pipe Pipe Pipe Pipe
LineMaterial
0 to 50 3/4 7/8 3/4 7/8 1 1-1/8 1 1-1/8 1 1-1/8 1 1
Distance from
Tank 50 to 100 3/4 1-1/8 1 1-1/8 1 1-1/8 1 --- 1-1/4 --- 1-1/4 1-1/4
Regulator to
Gas Valve 100 to 200 1 1-1/8 1 --- 1-1/4 --- 1-1/4 --- 1-1/4 --- 1-1/4 1-1/4
Inlet (ft.)
200 to 300 1 --- 1-1/4 --- 1-1/4 --- 1-1/4 --- 1-1/4 --- 1-1/2 1-1/2

Based upon an inlet gas pressure of 11 inwc at a pressure drop of 0.5 inwc

Table12 Natural Gas Pipe Sizing (dia. In), High-Pressure, 2-Stage Regulation
btu/hr input 150,000 200,000 250,000 300,000 350,000 400,000 500,000
Gas Line Material Iron or Iron or Iron or Iron or Iron or Iron or Iron or
Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe Plastic Pipe
Distance of First 0 to 50 1/2 1/2 1/2 1/2 1/2 1/2 1/2
1st Stage then Stage * 50 to 100 1/2 1/2 1/2 1/2 3/4 3/4 3/4
2nd Stage to 100 to 150 1/2 1/2 1/2 3/4 3/4 3/4 3/4
Gas Valve
Second 0 to 10 3/4 3/4 3/4 3/4 3/4 3/4 1
Inlet (ft.)
Stage **

* Based upon an inlet gas pressure of 2 psig at a pressure drop of 1 psi

** Based upon an inlet gas pressure of 10 inwc at a pressure drop of 0.5 inwc

Table13 Propane Gas Pipe Sizing (dia. In), High-Pressure, 2-Stage Regulation
btu/hr input 150,000 200,000 250,000 300,000 350,000 400,000 500,000
Gas Line Material Iron Tubing Iron Tubing Iron Tubing Iron Tubing Iron Tubing Iron Tubing Iron Tubing
Pipe Pipe Pipe Pipe Pipe Pipe Pipe

Distance of First 0 to 50 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
1st Stage Stage + 50 to 100 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 5/8 1/2 5/8 1/2 5/8
then 2nd
100 to 150 1/2 1/2 1/2 1/2 1/2 1/2 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8
Stage to Gas
Second 0 to 10 1/2 5/8 1/2 5/8 1/2 3/4 3/4 3/4 3/4 7/8 3/4 7/8 3/4 1
Valve Inlet
Stage++
(ft.)
+ Based upon an inlet gas pressure of 10 psig at a pressure drop of 1 psi
+
+ Based upon an inlet gas pressure of 11 inwc at a pressure drop of 0.5 inwc

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WATER PIPING:
REVERSIBLE WATER CONNECTIONS: This heater is designed so that it can be installed with the water connections located on
either the right or left side. Heaters are factory-shipped with right-side water connections. To move the connections to the left side
follow the instructions below and reference Figures1 and 14 as needed. A trained service technician must perform these steps
before the heater is installed.

1. Before beginning, be aware that it is not necessary to 10. Lift and rotate the heat exchanger 180 degrees. Do not
remove the water header from the heat exchanger to flip. Use care when setting the heat exchanger in place
perform this manipulation. When this procedure is do not damage the white sealing gaskets or combustion
complete, the water inlet will be located at the BACK of chamber refractory.
the heater. The water outlet will be located at the FRONT. 11. Route the water temperature sensor wires into the
2. Remove screws and remove both of the upper plastic heater cabinet through the hole in the left-metal side
heater side panels (see Figure14). Note the wires that panel, and re-connect to the ignition control board.
pass through a hole in the heater side panel go through a 12. Re-connect the heater wire harness to the water
split-bushing, which will allow separation of the wires from pressure switch and temperature limit.
the panel without disconnecting them.
13. Reverse the above disassembly steps to reassemble the
3. Disconnect the 2 wires connecting the heater wire heater.
harness to the heat exchanger header. One is located on
the water pressure switch and one is located on the
temperature limit switch, both on the top of the header.
Pull these wires into the heater cabinet from the hole in Figure14: Screw Locations on Side of Unit
the right- hand metal side panel in the heater, and re-
route them out through the left-hand metal side panel in
the heater.
4. Remove countersunk screws on the heater top and
remove louvered exhaust panel on heater top (see
Figure1).
5. Remove the heater top flue cover by removing 3 screws
on each side of the heater (see Figure1).
6. Remove screws and remove rain shield assembly (see
Figure1). Note that there are screws which hold the rain
shield assembly to the heat exchanger tube sheets, which
also must be removed.
7. Remove the front access panel (see Figure1).
8. Disconnect water temperature sensor plug from the
ignition control board located inside the heater (see
Figure1).
9. Pull the water temperature sensor wires out of the heater
cabinet through the hole in the right-hand metal side
panel.

NOTICE: The heater is for use with pool and spa/hot tub water furnished by municipal water distribution systems only. Do not
use with mineral water, seawater (PPM>5000), or other non-poTable waters which invalidate the warranty. Do not install any
restriction in the water pipe between the heater outlet and the pool/spa with the exception of; three-way switching valve, in-line
chlorinator and/or chlorinator check valve.

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Figure15: Water Connections Figure16: Bypass Valve(s)

Polymer Header
Header
Outlet

Flow
Meter
Header Union
Gasket Fitting
Nut
Bronze Header (ASME)

Header
Inlet
Bypass
From Valve
Pool/SPA
Header pa
Gasket Fitting Bolts

WARNING: EXPLOSION HAZARD Blockage of water flow from heater return to pool may result in fire or
explosion causing property damage, personal injury, or loss of life.

The heater is equipped with CPVC flanged pipe nipples to accommodate water piping to and from the pool or spa. These pipe
nipples will accept piping by solvent welding (PVC glue). The fittings will accept either a 2”pipe, or a 2 1/2” pipe fitting, and seal to
the heater header with rubber gaskets. On plastic headers, the fittings are secured in place with supplied plastic union nuts, and on
bronze headers (ASME models), the fittings are secured in place with bolts. Assemble these parts to the heater prior to plumbing.
Tighten union nuts (or bolts) securely before gluing fittings to the ends of the pipe nipples. See Figure15. The CPVC flanged pipe
nipples must be installed on the heater inlet and outlet without modification. Pipe, fittings, valves, and any other element of the filter
system may be made of plastic materials, if acceptable to the authority having jurisdiction. Heat sinks, heat tapes, firemen switches,
and check valves are not required on the heater. However, if there is any chance of “back-siphoning” of hot water when the pump
stops running, it is suggested that a check valve be used on the heater outlet pipe down stream of bypass system. The built-in
bypass inside the header will maintain proper flow through the heat exchanger if the flow rate is within the range specified in the
specification in the Getting Started section. The minimum flow rate is to be calculated or measured with the in-floor cleaning system
in use, if the pool is so equipped, as well as any other jets or other demands on the water flow. If the normal pump and filter system
flow rate exceeds 125gpm then a manual bypass valve must be installed as shown in Figure16. Damage caused by flow rates
outside this range will void the manufacturer’s warranty. Bypass valve setting may be accomplished by temporarily installing a flow
meter on the outlet line of the heater. Then adjust the manual bypass valve until the flowrate through the heater is within the flow
rate range specified. Once the manual bypass valve is set, note the position and remove the valve handle to prevent accidental
adjustment.

CAUTION: Improperly adjusted manual bypass valves will result in damage to the heater if the flow rates are not
maintained under all operating conditions as specified in Table1: Specifications. The heat exchanger will fail and this
damage will not be covered under the manufacturer warranty.

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Figure17 illustrates a typical pool piping diagram and layout for the pool equipment. Figure18 illustrates a multiple heater installation
for very large pools with and without a manual bypass valve.

Figure17: Typical Plumbing to Pool or Spa Figure18: Multiple Heater System

INSTALLATION ABOVE POOL/SPA SURFACE: If the

heater is installed less than three (3) feet above the surface AUTOMATIC CHLORINATORS AND CHEMICAL
of the pool/spa water, install eyeball fittings or directional flow FEEDERS: If used, a chlorinator must be installed
fittings on the end of the return water line to the pool/spa to downstream from the heater in the pool return line and at a
create adequate back pressure at the heater to operate the lower elevation than the heater as shown in Figure20. Install
pressure safety switch when the pump is running. If the a separate positive seal corrosion resistant check valve
heater is installed more than three (3) feet above the surface between the heater outlet and the chlorinator to prevent
of the pool/spa water, install a loop as shown in Figure19 to highly concentrated sanitizer from back siphoning into the
prevent drainage of water in the heater during a filter change. heater. Back siphoning may occur when the pump is shut off
For installation above or below the pool/spa surface, refer to and a pressure differential is created.
START UP section for proper pressure switch setup.
Figure20: Automatic Chlorinator
Figure19:Installation Above Pool or Spa

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DRAIN VALVE INSTALLATION (ASME MODELS ONLY): If Figure21: Drain and relief valve locations
installing an ASME model heater, a 3/4” brass drain valve must be
installed. A drain valve is included separately with all ASME heaters.
Apply a suitable amount of pipe thread sealant or Teflon tape to the
threads and install as shown in Figure21.
PRESSURE RELIEF VALVE (ASME MODELS ONLY): If installing
an ASME model heater, a 3/4” pressure-relief valve having a
discharge capacity greater than or equal to the Btu/hr input of the
heater, and a pressure rating equal to or less than the working
pressure must be installed. See the rating plate located inside the
front access panel on the heater for the input rating and working
pressure. An appropriate pressure relief valve is included separately
with all ASME heaters. Apply appropriate pipe thread sealant or
Teflon tape to the threads and assemble as shown in Figure21.
Please note that the drain valve must be installed before the Pressure Drain
pressure relief valve. Install the pressure relief valve with the Valve
Relief Valve
discharge connection facing the ground. If necessary, connect a
pipe (of the same size as the valve outlet) to the outlet and run it to a
code appropriate place of discharge. Do not install any shut-off or
restriction in this pressure relief discharge line.
PRESSURE RELIEF VALVE (NON-ASME MODELS ONLY): Some local building codes require a pressure relief valve for non-
ASME pool/spa heaters. The plastic header has a 3/4” port which can be used for this purpose (see Figure21 for location of port). A
3/4” pressure relief valve having a discharge capacity greater than or equal to the Btu/hr input of the heater, and a pressure rating
equal to or less than the working pressure is recommended. See the rating plate located inside the front access panel on the heater
for the input rating and working pressure. If desired, you may order the pressure relief valve; order p/n CHXRLV1930. Remove the
factory-installed pipe plug, and install the pressure relief valve using an appropriate amount of pipe thread sealant or Teflon tape on
the threads. Install the pressure relief valve with the discharge connection facing the ground. If necessary, connect a pipe (of the
same size as the valve out- let) to the outlet and run it to a code appropriate place of discharge. Do not install any shutoff or
restriction in this pressure relief discharge line.

ELECTRICAL CONNECTIONS:
GENERAL INFORMATION: An external supply of power is required to operate the control system of the heater. The electrical
specifications for this heater are 120 or 240VAC, 60Hz, 1-phase, 5.5A maximum current. It is recommended that circuit protection
for the heater circuit be rated at 15 Amperes. The heater is shipped from the factory wired for use with 240VAC, 60 Hz field power
supply. To convert the heater to 120VAC, 60 Hz operation remove the 240VAC voltage selector jumper from the ignition control
board and replace it with the 120VAC jumper. These jumpers are tie-wrapped together and are located on the fuse board. See
Figure23 for location of the fuse board. All wiring connections to the heater must be made in accordance with the latest edition of
the National Electrical Code ANSI/NFPA 70, unless local code requirements specify otherwise. In Canada, follow CSA C22.1
Canadian Electrical Code, Part 1. The heater must be electrically grounded and bonded in accordance with local codes or, in the
absence of local codes, with National Electrical Code, ANSI/NFPA 70. Wiring connections must be made as shown in the wiring
diagram found inside the heater cabinet, and a copy is provided for convenience in the GETTING STARTED section at the
beginning of the manual. The heater must also have an independent ground and bond connection. There is a ground lug inside the
control box adjacent to the power connections per figure22 and a bonding lug on the side of the heater per figure13. Use a solid
copper conductor, size No. 8 AWG (8.4 mm2) solid copper bonding wire or larger for bonding conductor. Run a continuous wire
from external bonding lug to reinforcing rod or mesh. Connect to the grounding lug provided and to all metal parts of swimming pool
or spa, and to all electrical equipment, metal piping (except gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming
pool or spa. IMPORTANT - Reference NEC codes for all wiring standards including, but not limited to, grounding, bonding and other
general wiring procedures.
WARNING: Risk of Electric Shock Review all safety information provided in the GETTING STARTED section of
this manual prior to servicing. Always disconnect power circuit before servicing. This heater contains wiring that
arries high voltage. Contact with these wires could result in death or personal injury.

ELECTRICAL CONNECTIONS: The heater may be junction box or right side using the floating junction box. There
installed with the electrical service and optional remote control are (4) openings for electrical entry. The junction box must be
wiring entering the heater cabinet on either the left side used for field power wiring. Plug any unused openings with the

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supplied caps. The power connections are to be made to the Figure22a: Junction Box Connections
supplied wires inside the junction box (see Figure22a) using
field supplied wire nuts. All connections are to be stored within
junction box attached to side panel.
Fuse Board Connection
REMOTE CONTROL CONNECTION: Remote control can be
accomplished via a 2-wire or 3-wire connection (see
Figure22b). The 2-wire connection allows thermostat control
where the remote temperature is sensed and calls for heat
when needed. The 3- wire remote switches function between
“POOL” and “SPA”. The set point temperatures for “POOL”
and “SPA” operation are still controlled locally. The 3-wire
remote simply provides a convenient way to manage the
“POOL” or “SPA” mode selection. Remote wiring is
accomplished using the factory supplied remote wire harness.
Remote wiring must be run in a separate conduit from power
supply. Use 22 AWG wire for runs less than 30 feet. Use 20 Ground
AWG wire for runs over 30 feet. The maximum allowable run is
Connection
200 feet. N(120V) or
2-WIRE REMOTE CONTROL CONNECTION: Connect the
L2(240V)
appropriate wires from the remote control to the factory L(120V) or
harness ORANGE wire (“POOL”) and WHITE wire (“COM”). To
configure the heater for 2-wire remote thermostat control, use L1(240V)
the “MODE” key on the heater keypad to put the control into
“STANDBY” mode. Then simultaneously press and hold the “(
- )” and “MODE” keys for 3 seconds until the display shows the Figure22b: Remote Control Connections
code “bo” (bypass operation). Once in bypass operation, press
the ‘MODE’ button until ‘POOL’ or ‘SPA’ LED is illuminated.
The control is now ready to operate in 2-wire remote
thermostat control. The heater’s thermostat will only function Factory supplied
to limit the return water temperature to a maximum of 104°F.
remote wire
3-WIRE REMOTE CONTROL CONNECTION: Connect the
harness
appropriate wires from the remote control to the factory
harness ORANGE wire (“POOL”), WHITE wire (“COM”), and
RED wire (“SPA”). No control ‘MODE’ configuration setting is
needed, only connection of all three remote control wires. To
operate the heater with a remote 3-wire switch, the heater’s
control must be in “STANDBY” mode. The “STANDBY” LED
will be illuminated. When the remote switch is set to “Pool” the
“POOL” LED will be illuminated and the water temperature will
be displayed. When the remote switch is set to “Spa” the “SPA”
LED will be illuminated and the water temperature will be
displayed. The heater will use its internal thermostat to
regulate the water temperature to the set point of the mode
selected.

CHECK-OUT & START-UP:

GENERAL: The heater is equipped with a control system that automatically monitors the “Pool” and “Spa” temperature set points
and control devices. Then when heat is needed, turns on the combustion air blower, hot surface igniter and gas valve to light the
burners and monitor the flames. Figure23 provides a summary of heater components and their locations. Some of the following
procedures will require the heater to be operating. The Full lighting and shutdown instructions are included in this manual as well as
on the lighting and operating label affixed to the inside of the front access panel of the heater. Water must be flowing through the
heater during any operation. Check that the pump is operating and the system is filled with water and purged of all air prior to
starting the heater.

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Figure23: Location of Components

Fuse Board User Panel

Ignition Control Pressure Switches(2)

Gas Valve Transformer

Flame Sensor Combustion Blower

Ignitor Access Sight Glass

Gas Manifold Air Box

CONTROL SETUP
This pool heater is equipped with a digital thermostat which allows the user to select the desired water temperature (see figure24).
The heater will then function automatically to maintain the desired temperature. The heater has 4 modes of operation:

1. STANDBY: in this mode, the heater will not function to heat the water.
2. SPA: in this mode, the heater will automatically function to maintain the water temperature setting for SPA mode.
3. POOL: in this mode, the heater will automatically function to maintain the water temperature setting for POOL mode.
4. BYPASS OPERATION “bo” is displayed. In this mode the heater will respond to a remote call for heat for set point control and
monitor the local thermostat for high return water temperature (maximum of 104°F).

Use the MODE button to change STANDBY/POOL/SPA modes. The indicator lights will illuminate to show which mode is currently
active.

USER PANEL AND KEYPAD INPUTS: The control Figure24: User Panel
accepts user inputs via user panel (figure24).
1. When changing the mode from “STANDBY” to Indicator Lights
either “SPA” or “POOL” (see Figure24) there
may be up to a 10- second delay before the
heater starts operating. The control performs an
internal self-test and then verifies that the
blower vacuum switch contacts are open before
energizing the blower.
2. It is normal for the heater to encounter a 1- to 2-
second delay in responding to any user panel
input.
3. It is normal for the heater to encounter up to a
5-second delay when the user panel is used to
reset the control to clear an error code. Numeric Mode
4. The control will accept a mode change during Display Button
lockout after 5 seconds. The control will
continue to display the error code and remain in Indicator Lights

lockout until it is reset. At reset the control will Control and Selector Buttons
go to the last saved mode.

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NORMAL OPERATION FOR POOL & SPA MODES: The control continually compares the water temperature with the set point
and the high limit temperature. When the water temperature is more than 1°F below the set point a call for heat is generated and a
heating cycle is initiated.
1. The control checks for open contacts at the blower vacuum switch.
2. The control energizes the blower and the igniter. The igniter heat-up time is approximately 20 seconds. The blower is running a
pre-purge cycle during this time.
3. The control checks for closed contacts at the blower vacuum switch.
4. When the igniter reaches the proper temperature a 4-second trial for ignition begins. The control opens the gas valve and
monitors flame current. The igniter is turned off when flame is sensed or after 4 seconds.
5. The blower vacuum switch, temperature limit switches, vent pressure switch, water pressure switch, the water temperature
sensor, and the flame sensor are constantly monitored during a call for heat to assure the heater is operating properly.
6. When the thermostat is satisfied and the call for heat ends the control immediately de-energizes the gas valve.and flame
extinguishes.
7. The control operates the blower during a 30-second post-purge period.
FAHRENHEIT OR CELSIUS: The temperature can be displayed in Fahrenheit or Celsius. To change the display, use the “MODE”
button to place the heater in “STANDBY”. Then press and hold the “( + )” and “MODE” buttons until the display shows the °F/°C
selection. Press the “( - )” button to toggle between selections. To accept the selection, press the “MODE” button. If the user does
not act, the selection will be automatically accepted after 60 seconds.

TEMPERATURE ADJUSTMENT: This control allows the user to have 2 individual pre-set temperature settings, “SPA” and “Pool”.
To adjust the temperature while in “SPA” or “POOL” mode, use the ( + ) and ( - ) buttons. The numeric display will flash while the
temperature is being adjusted. When the numeric display is not flashing, the actual measured water temperature is being displayed.
The temperature settings for both “SPA” and “POOL” modes are initially set at the factory to 65°F. The minimum allowed settings for
“SPA” and “POOL” modes are both 65°F. The maximum allowed settings for “SPA” and “POOL” modes are adjustable up to 104°F
using the TEMPERATURE MAXIMUM SET POINT feature (see below).

TEMPERATURE MAXIMUM SET POINT: The digital thermostat in this pool heater allows the user to lock the maximum
temperature setting allowed. This feature is useful for preventing unauthorized users from manually adjusting the temperature
settings higher than desired. On a new heater, the maximum allowed temperature lock settings are initially set at the factory to 90°F
for “POOL” mode, and 104°F for “SPA” mode. To adjust these settings, use the following procedure:
1. Use the MODE button to put the heater in “STANDBY” mode.
2. Press and hold both the ( + ) and ( - ) buttons at the same time.
3. After 3 seconds, the thermostat enters maximum temperature lock adjustment mode.
4. The “SPA” indicator light illuminates and the numeric display shows the current “SPA” mode maximum temperature lock
setting. Both the “SPA” indicator light and the numeric display flashes rapidly when in adjustment mode.
5. Use the ( + ) and ( - ) buttons to set the desired maximum temperature lock setting. When finished, press the MODE button.
6. The “POOL” indicator light illuminates and the numeric display shows the current “POOL” mode maximum temperature lock
setting. Both the “POOL” indicator light and the numeric display flashes rapidly when in adjustment mode.
7. Use the ( + ) and ( - ) buttons to set the desired maximum temperature lock. When finished, press the MODE button.
8. The heater will return to “STANDBY” mode
FAILURE TO LIGHT – RETRY: If the first ignition attempt fails during a normal heating cycle the control will make two (2) additional
ignition attempts:
1. The control de-energizes the gas valve after the 4-second ignition trial ends.
2. The control operates the blower during a 30-second post-purge period.
3. The control monitors for open contacts at the blower vacuum switch.
4. The control performs a gas valve relay check.
5. A normal ignition sequence resumes with Item #2 in NORMAL OPERATION FOR POOL & SPA MODES (see above). If the
third ignition trial fails the control enters a safety lockout (or “hard” lockout) after the post purge period of the third failed trial.
6. The error code “IF” is displayed and the “SERVICE” indicator is illuminated.
a. The control automatically resets and clears the “IF” error code without any user intervention after60 minutes. If there is a
call for heat after reset, the control will make three (3) trials for ignition. If ignition is not established the control will again
enter safety lockout for 60 minutes. This cycle will continue until ignition is established or the call for heat is removed.
b. The user can reset the control and clear the “IF” error code by pressing the “MODE” button to move through “STANDBY”
and return to the previous mode (“POOL” or ”SPA”).

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LOSS OF FLAME – RECYCLE: If flame is established and then lost, the control will make ten (10) attempts at ignition. If flame is
lost within ten (10) seconds of ignition, the control will respond within 2 seconds. If flame is lost more than ten (10) seconds after
ignition the control will respond within 0.8 seconds.
1. The control de-energizes the gas valve and the blower.
2. The control monitors for open contacts at the blower vacuum switch.
3. The control performs a gas valve relay check.
4. A normal ignition sequence resumes with Item #2 in NORMAL OPERATION FOR POOL & SPA MODES (see above).
5. If the tenth ignition trial fails the control enters a safety lockout (or “hard” lockout) after the post- purge period of the tenth failed
trial.
6. The error code “IF” is displayed and the “SERVICE” indicator is illuminated.
a. The control automatically resets after 60 minutes. If there is a call for heat after reset the control will make three (3) trials
for ignition. If ignition is not established the control will again enter safety lockout for 60 minutes. If flame is established but
is lost the control will make ten (10) attempts at ignition. This cycle will continue until ignition is established or the call for
heat is removed.
b. The user can reset the control and clear the “IF” error code by pressing the “MODE” button to move through “STANDBY”
and return to the previous mode (“POOL” or ”SPA”).

AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation as
detailed in NORMAL OPERATION FOR POOL & SPA MODES (see above). The heater can be manually reset using the keypad by
cycling the mode button through “STANDBY” and back to the original operating mode (“SPA” or “POOL”).

GAS TESTING:
GAS LINE TESTING: The appliance and its gas connection must be leak tested before placing the appliance in operation. The
heater must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing
of the gas supply piping system at test pressure equal to or less than ½ psig (3.45 kPa). Gas supply line must be capped when not
connected. After pressure testing, reconnect the gas piping to the gas valve. Turn gas supply “ON” and test all pipe and tubing joints
for leaks. Use a soap and water solution.

WARNING: EXPLOSIVE HAZARD. The use of an open flame to check for gas leaks could cause an explosion
resulting in severe injury and/ or death. Shut off gas and fix even the smallest leak right away. Be sure to leak test
the heater gas manifold fittings using the above procedure once the heater is in operation.

GAS PRESSURE TESTING: The following gas pressure requirements are important for the operation of the burners in gas heaters.
Improper gas pressure or gas volume may create the following conditions:
1. Flame burns totally yellow.
2. Flame lift off burner.
3. Heat exchanger soot’s up. The gas pressure regulator on all heaters is preset at the factory, but the setting should be verified
by the installer to ensure proper operation.

NOTICE: If inlet gas pressure is inadequate, check for undersize piping between the gas meter and the heater or for a low-
capacity gas meter (see GAS SUPPLY section of this manual).

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Figure25: Lighting & Operating Instructions Label

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GAS PRESSURE TEST PROCEDURE: Follow the lighting instructions on the unit (or from Figure25). Refer to Figure23: Location
of Components for the location of the gas valve. See figure26 for pressure regulation adjustment for use in this procedure. Note
that even though the valves look different, the required pressure taps and regulation adjustment screws are present on every gas
valve.
1. Obtain the necessary equipment; Qty (2) manometers to NOTICE: If proper pressures cannot be achieved by
read pressure in inches of water column, Qty (2) 1/8”NPT adjusting the gas valve regulator, the installer must contact
pipe barbed fitting, silicon or EPDM hose to fit on barb
the gas supplier and request that the inlet pressure to the
fittings, 3/16” hex wrench, 7/16 open end wrench, and
medium flat screw driver. heater(s) be provided to within the gas pressure range listed.
2. Turn off gas supply to heater. Access the gas valve and
remove the 1/8” plugs from the gas valve inlet pressure
and manifold pressure taps and install the barb fittings 7. Remove the barb fittings and replace the original 1/8” pipe
into the tap openings. plugs. Turn on gas and water to heater and start the
3. Securely connect the hoses and manometers to the barb heater to check for gas leaks.
fittings. Make sure the manometers have ample range
and accuracy to properly read the gas inlet pressure and
manifold pressure per Table14. Table14: Required Gas & Air Pressures
4. Turn on gas and water to heater and start the heater (inwc)
following the lighting & operating instructions on the label
affixed inside the front access panel. If there is more than Measurement Natural Propane
one pool/spa heater connected to the gas supply line, turn
each of those appliances “ON” while testing the heater. Manifold
+1.8 to 2.2 +6.8 to 7.0
5. Take pressure readings with the heater(s) running, the Pressure*
pressure values should agree with those in Table14. If the Inlet Pressure,
pressures are within the stated ranges, then no further Minimum
+4.5 +10.0
adjustment is needed. If the manifold gas pressure does
not meet the values in Table14, the gas valve regulator Inlet Pressure,
must be adjusted. Maximum +10.5 +13.0
6. To adjust the gas valve regulator perform the following:
a. Remove the screw cap over the regulator adjustment Blower Vacuum,
-0.50 -0.50
screw (see Figure26). minimum
b. Turn the inner regulator adjustment screw clockwise Vent Pressure,
to increase pressure and counterclockwise to (Models150-400) +0.45 +0.45
decrease pressure as required. maximum
c. Replace the screw cap over the regulator adjustment Vent Pressure,
screw.
d. Cycle the heater on/off multiple times and repeat
(Model-500) +0.30 +0.30
measurements to ensure regulation springs are set. maximum
*Pressure range for allowable heating value variation.
WARNING: EXPLOSION HAZARD Do not remove the measurement tap screws with the valve in the “ON”
position and gas supplied to heater. No gas pressure must be present when the taps are open to atmosphere.
Removal of the taps screws or barb fittings with gas present could cause an explosion resulting in severe injury
and/or death.

WARNING: EXPLOSION HAZARD Gas pressures in excess of those listed in Table14 could cause a gas leak or
diaphragm rupture. Gas leakage could cause an explosion resulting in severe injury or death.

Figure26: Gas Valves Regulator

ON/OFF adjustment
switch Regulator Gas Inlet Tap
under cap
adjustment ON/OFF
under cap knob
Electric
terminals Electric
Gas Inlet Tap Gas Manifold Tap terminals

For all valves, adjust regulator pressure by removing the screw cap and turning the adjustment
screw clock wise for increase in pressure and counter clock wise for decrease in pressure

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WATER TESTING: 5. Check the function of the pressure switch by turning

WATER PRESSURE SWITCH TEST / ADJUSTMENT PROCEDURE: the filter pump on and off several times and confirming
The pressure switch is preset at the factory for most typical deck level that the heater turns off immediately when the pump is
installations. When the heater is located above or below the level of the turned off. Never allow the heater to operate with less
pool or spa, the pressure switch will require adjustment to compensate than the minimum rated water flow rate.
for the change in static pressure. The following procedure is
recommended when the switch needs adjustment and/or is replaced;
Figure27: Water Pressure Switch
1. Be sure the filter is clean before making any adjustment.
2. Turn “ON” the filter pump and ensure all air is out of the water lines,
and ensure water flow rate is at least the rated minimum (see
SPECIFICATION SECTION).
3. Turn “ON” the heater and adjust the temperature control to create a
Adjustment
call for heat.
4. For Installations with Heater above water level: If the heater does not Knob
light, adjust the pressure switch by turning the adjustment knob on
the pressure switch counter-clockwise until the heater lights. Turning
the adjustment knob counterclockwise decreases the pressure
needed to close the switch (see Figure27).
4. For Installations with Heater below water level: Turn the adjustment
knob on the pressure switch clockwise, until the heater turns off,
then turn the knob ¼ turn counter-clockwise, so that the heater turns
back on. Turning the adjustment knob clockwise increases the
pressure needed to close the switch
.
TWO-SPEED PUMP: In a few cases the pressure from a two-speed pump is below the 1-pound minimum required to operate the
water pressure switch on the heater. This is apparent when the pressure switch cannot be further adjusted. In these cases the
pump must be run at high speed to operate the heater. If the pump and piping arrangement are such that the required 1-pound
minimum pressure cannot be obtained, do not attempt to operate the heater. Correct the installation.

NOTICE: Heater installation, checkout, and start-up should now be completed. BE SURE to leave this manual with the
pool owner.

MAINTENANCE & SERVICE

PERIODIC INSPECTION: The heater is designed and built for long performance life when installed and operated according to the
manufacturer’s directions. Regular inspection by qualified service personnel is recommended to keep the heater working properly.
The following inspection points are suggested to help maximize heater life.
1. Periodically check the venting on outdoor heaters. The heater’s venting areas (the louvered top panel) must never be obstructed
in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air. Remember that
shrubs grow and in time may obstruct a heater’s venting areas.
2. Check the venting of indoor heaters for looseness and possible leaks. Keep all openings for combustion and ventilation air clear
and unobstructed.
3. Keep the entire pool heater area clean and free of all debris, combustible materials, gasoline, and other flammable vapors and
liquids. Remove any leaves or paper from around the heater.
4. Do not store chlorine, other pool chemicals, or other corrosives in the vicinity of the heater.
5. If the heater is operating on propane gas, the tank must not fall below 30% full or damage to the heater may occur. Manufacturer
will not be responsible for heaters that soot up due to improper gas level in the tank resulting in inadequate gas volume.
6. If another appliance is added to the gas line at a later date, consult the local gas company to be sure the gas line will have the
capacity to supply both units at full input rating at the same time.
7. Do not use the heater if any part has been under water. Contact a qualified service technician to inspect the entire heater and
replace any part of the control system or gas valve that was under water. If heater has been totally submerged in water it must
be removed and the entire heater must be replaced.
8. An inspection program is a good preventative maintenance measure. Keep this manual in a safe place for future reference for
yourself as well as for a service technician to consult when inspecting or servicing the heater. Any additional inspection
procedures are to be performed by a qualified service technician.

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WATER CHEMISTRY:
WARNING: WATER CHEMISTRY Failure to maintain proper water chemistry may cause premature heat
exchanger damage or failure
The heat exchanger in your pool heater is made from the highest quality of copper and nickel (Cupronickel) materials. This premium
material and the exacting processes used to manufacture the heat exchanger is state of the art in pool heater design and
manufacture. However, it remains vital that the heat exchanger be protected from damaging or corrosive chemicals, insufficient
water flow or improperly balanced water chemistry. Heat exchanger damage or failure resulting from improper flow, improperly
balanced pool water or the improper addition of sanitizer into the water is NOT covered under the terms of the warranty. The
following factors are critical to heat exchanger protection. Follow the guidelines in Table15 to help prevent pre-mature damage to or
failure of your heater and heat exchanger.
1. WATER FLOW THROUGH HEATER: Water must be flowing through the heater at the minimum rated flow rate during
operation. Check that the pump is operating and the system is filled with water and purged of all air prior to starting the heater.
The minimum flow rates are listed in the specifications section. Some installations may require an adjustment to the water
pressure switch for proper low-flow protection. Test your system and if necessary, adjust the water pressure switch as described
in WATER TESTING SECTION OF MANUAL.
2. WATER CHEMISTRY: The chemistry balance and mineral content of swimming pool and spa water changes rapidly due to the
addition of sanitizing chemicals, user loads, exposed rain, runoff, and the amount of sun - to name a few. Improper chemistry
(see Table15) balance and mineral content can cause scaling and deposits to form on pool walls, in the filtration system, in the
heat exchanger tubes, and additionally can promote corrosive action to all metals in the water path. Changing spa water
regularly and maintaining the correct chemical balance in your pool/spa will keep the pool/spa safe and sanitary and will help
heat exchanger longevity. Use a 4-way pool/spa water test kit to check your water frequently (at least weekly). Use the following
guidelines to help maintain proper water chemistry:

Table15: Water Chemistry

Recommended
Chemical Effect of Low Levels Effect of High Levels
Level

Chlorine 1 - 3 ppm swimmer irritation, bleaching of

hazy water, algae growth,
clothes/hair, corrosive to heat
bacteria causing infections
Bromine 2 - 4 ppm exchanger
cloudy water, scaling of heat
corrosive to heat exchanger,
pH 7.4 - 7.6 exchanger, reduced sanitizer
swimmer irritation
effectiveness
corrosive to heat exchanger,
Total Alkalinity 80 - 120 ppm scaling of heat exchanger
large fluctuations in pH
Calcium
200 - 400 ppm corrosive to heat exchanger scaling of heat exchanger
Hardness
Salt 2700 - 5000 ppm poor salt chlorinator performance corrosive to heat exchanger

3. SKIMMER CHLORINATION: Placing chlorine or bromine Tablets directly into the skimmer may result in high chemical
concentrations flowing through the heater. DO NOT place chlorine or bromine Tablets in the skimmer.
4. CHLORINATOR INSTALLATION: Chlorinators must be installed downstream of the heater, and a check valve must be installed
between the heater and chlorinator to prevent high chemical concentrations from back flowing into the heater. Make sure your
piping arrangement meets the chlorinator installation requirements shown on page 26.
5. BYPASS VALVE: Bypass heater until water chemistry is properly balanced, so that corrosive and potentially damaging water
will not flow through the heater and therefore the heat exchanger. Close the bypass valve once the water is properly balanced.
WARNING: BYPASS. Failure to close the bypass valve when attempting to operate the heater will result in extensive
damage to the heat exchanger
Ensure water flow through the heater is restored before operating the heater. A bypass feature is also advantageous for service
needs and for the ability to remove the heater from the water path when not heating.

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WINTERIZATION:
In moderate climates, the heater can continue to operate during short-term cold spells. Do not use the heater to maintain the water
temperature just above freezing or for freeze protection. Care must be taken to avoid freeze-up in the heater. When it is used during
freezing weather, the pump must run continuously. The heater is not warranted against freeze-ups. In regions where freezing
temperatures are encountered, all water must be drained from the heater when it is out of service to prevent damage to the heater
and piping. Draining the heat exchanger is recommended as part of the season’s shutdown procedures.

NOTICE: A heater damaged by freezing is not covered under the manufacturer warranty.
DRAINING THE HEAT EXCHANGER: This procedure applies to installations where the heater is located higher than the pool water
level. If it is necessary to drain a pool heater located below the pool water level, you must either partially drain the pool, or isolate
the pool heater from the pool using valves, then follow these steps.

1. Set the heater to STANDBY mode using the keypad.

2. Turn the electricity to the heater OFF at the circuit breaker panel.
3. Turn the heater gas valve OFF using the knob or switch on the valve (see Figure26).
4. Turn the heater’s gas supply OFF at the main shut-off valve outside the heater cabinet.
5. Be sure the circulating pump is OFF.
6. On models with plastic headers, remove the plastic drain plug (see Figure28). On models with bronze headers (ASME models),
open the brass drain valve located on the header (see Figure21).
7. Allow all water to drain from the heater.
8. On models with plastic headers, re-install the plastic drain plug. On models with bronze headers (ASME models), close the
brass drain valve located on the header.

SPRING START-UP: This procedure should be performed annually to ready your heater for the upcoming season. In addition to
the steps outlined below, it is recommended that a PERIODIC INSPECTION also be performed.
1. Inspect and clean the heater, being sure the heater is free of leaves and debris prior to startup.
2. Be sure inlet and outlet piping are properly attached to the heater and the drain valve is closed.
3. Turn the filtration system pump “ON” and allow the system to run long enough to purge all the air from the lines.
4. Turn the gas supply to the heater “ON”.
5. Set the temperature control using the keypad to “POOL” or “SPA” and adjust the set point to the desired temperature setting.
6. If operating difficulties are encountered, contact a qualified service company for assistance.
Figure28: Heat Exchanger Header

COMPONENT SERVICE
WARNING: Only qualified service technicians, with appropriate test equipment, should be allowed to service the heater.
All of the components that comprise the system have an effect on heater operation. Before proceeding with heater related
troubleshooting tips, be certain that the pump is operating correctly, the filters and strainers are not blocked, the valves in
the piping are properly positioned, and the time clocks are properly set.
WARNING: EXPLOSION HAZARD Do not attempt to repair broken or faulty components of this heater. Do not
modify the heater or its components in any manner. To do so may result in a malfunction that could result in death,
personal injury, or property damage. Check with the pool owner to see if any part of the heater has been under
water. Replace any electrically operated component that has been under water.

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SERVICE OF HEATER: The following service procedures: HEAT EXCHANGER INSPECTION AND CLEANING and BURNER
INSPECTION AND CLEANING are recommended to be performed as part of annual heater maintenance to ensure proper heater
operation and long life.
HEAT EXCHANGER INSPECTION AND CLEANING: Remove the louvered exhaust cover panel (see Figure1: Sub-Assemblies)
and inspect the external surfaces of the heat exchanger for debris or soot accumulation. If heat exchanger needs cleaning perform
the following procedure:

WARNING: BURN HAZARD: Let heater cool before performing any disassembly or servicing of the heater.
Wear proper PPE when servicing heater.

1. Turn pump, main gas valve and heater power “OFF”. Perform only DRY cleaning with heat exchanger in heater. WET cleaning
requires that the heat exchanger be removed from heater.
2. For DRY cleaning remove debris by hand, soft-tipped brush or shop VAC.
3. For WET cleaning remove heat exchanger by following the “Reversible Water Connections” procedure found in the WATER
PIPING section of this manual. Use a soft-tipped brush (such as a paint brush), to apply a degreaser to the entire heat
exchanger surface (top and bottom). Allow the heat exchanger to sit for a period of time to allow the degreaser to loosen the
debris. Wash the heat exchanger using a garden hose at a medium to low pressure setting. Ensure both the top and bottom
surfaces are cleaned.
4. Check combustion chamber refractory is still in a single-piece casting with no cracks or holes. This evaluation can be performed
with heat exchanger in place with additional lighting or with heat exchanger removed from unit. If combustion chamber
refractory is damaged, the entire chamber must be replaced.
5. Re-assemble the heater by reversing the disassembly steps. Turn pump, main gas valve and heater power “ON”. Test fire
heater.

NOTICE: Although the heat exchanger should be cleaned of soot and reinstalled, the fact that soot occurred should be
investigated. It may indicate other problems such as: Insufficient air supply; Inadequate venting; High or low gas pressure;
Blockage of burner tubes or orifices; Blockage of blower inlet; Low voltage supply causing blower to “spin” slower; Improper
heater location / installation; Incorrect gas supply pipe size; Excessive water flow through heat exchanger; Or an LP tank below
30% full level.

BURNER INSPECTION AND CLEANING: With the heater Figure29: Burner Flame Characteristics
“ON”, remove the front access panel and make a visual
inspection of the main burners through the sight glass (see Flame Height 1 to 2in
Figure23: Location of Components.) The main burner flames
should be about 1” to 2” in height and should not “lift” off the
burner ports (see Figure29: Burner Flame Characteristics). A
normal flame is blue, without yellow tips. Yellow tips or a
totally yellow or “lazy” flame may be an indication of an
incorrect fuel / air mixture. Check the heater for restrictions
to the air supply, heat exchanger, vent system, burner body
and/or gas orifices.
BURNER REMOVAL AND REPLACEMENT: Refer to Figure1, Figure12, and Figure23 as needed.
1. Turn pump, gas supply, and heater power “OFF”. Turn gas valve knob “OFF”.
2. Remove the front access panel.
3. Disconnect the union joint in the gas supply piping outside the heater cabinet.
4. Disconnect the wiring terminals from the gas valve and blower
5. Remove the gas manifold assembly. It is attached to the air box using (4) screws.
6. Remove the screws from the igniter access panel and pull it out of the way. Do not disconnect the wires.
7. Remove the air box cover. Do not remove the blower from the air box cover.
8. Remove the (2) screws securing each burner to the combustion chamber front.
9. Pull the burners straight out of the heater.
10. Reverse the above procedure to re-install the burners.
11. Turn the gas supply “ON”. Use a soapy water solution to check for leaks. Bubbles forming indicate a leak.

WARNING: EXPLOSION HAZARD The use of an open flame to check for gas leaks could cause an explosion
resulting in severe injury and/or death

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12. Turn pump, gas valve knob and heater power “ON”. Test fire heater by following the GAS PRESSURE TEST PROCEDURE.
GAS VALVE REPLACEMENT: Refer to Figure1: Sub-Assemblies, Figure23: Location of Components and Figure26: Gas Valves as
needed.
1. Turn pump, gas supply, and heater power “OFF”.
2. Disconnect the union joint in the gas supply piping outside the heater cabinet.
3. Remove the front access panel.
4. Disconnect the wiring terminals from the gas valve.
5. Remove the gas manifold assembly. It is attached to the air box using (4) screws.
6. Unscrew the gas valve from the gas manifold pipe.
7. Reassemble the gas manifold assembly using the new gas valve. Only use liquid pipe thread sealant on the male threads of the
gas manifold pipe. Do not place pipe dope on the first two threads of any joint.
8. Reverse the above procedure to re-install the gas manifold. Turn pump, main gas, gas valve and heater power “ON”. Test fire
heater by following the GAS PRESSURE TEST PROCEDURE. Check for leaks using soap and water
IGNITER REPLACEMENT: Refer to Figure1: Sub-Assemblies and Figure23: Location of Components as needed.
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel.
3. Disconnect the igniter wires from the ignition control board.
4. Remove the screws from the igniter access panel. Working from the underside of the panel, press the bushing out of the hole in
the sheet metal panel.
5. Slide the igniter wires through the slot on the panel and pull the panel free.
6. Remove the (2) screws that secure the igniter.
7. Pull the igniter straight back until it is free of the combustion chamber refractory and out of the air box.
8. Replace the igniter and reverse the above procedure to reassemble unit.
FLAME SENSOR REPLACEMENT: Refer to Figure1: Sub-Assemblies and Figure23: Location of Components as needed.
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel (4 screws).
3. Disconnect the flame sensor wire from the ignition control board.
4. Remove the screws that secure the flame sensor to remove the sensor.
5. Replace the flame sensor and reverse the above procedure to reassemble unit.
BURNER ORIFICE REPLACEMENT: Refer to Figure1: Sub-Assemblies and Figure23: Location of Components as needed.
1. Turn pump, gas supply, and heater power “OFF”.
2. Disconnect the union joint in the gas supply piping outside the heater cabinet.
3. Remove the front access panel.
4. Disconnect the wires from the terminals on the gas valve.
5. Remove the gas manifold assembly. It is attached to the air box using (4) screws.
6. Remove the orifices using a 7/16” wrench.
7. After cleaning or replacing orifices re-install into the gas manifold pipe being careful not to cross-thread or over tighten as a leak
may result.

NOTICE: Do not enlarge orifice holes.

NOTICE: All replacement wiring must be replaced with manufacturer supplied replacement parts.
IGNITION CONTROL SYSTEM: The control system in this heater consists of 4 components (ignition control board, display board,
fuse board and membrane keypad). The locations of these components are shown in Figure23: Location of Components. The
ignition control board functions as the heater’s thermostat control, safety control system, and gas ignition and combustion
monitoring system.
To remove/replace the ignition control board or the fuse board:
1. Turn pump, gas supply, and heater power OFF.
2. Remove the front access panel.
3. Disconnect all wires from the printed circuit board.
4. Detach the board from the sheet metal panel by compressing the plastic standoffs.
5. Replace the board and reverse the above procedure to reassemble unit.

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BLOWER VACUUM SWITCH: The blower vacuum switch is a safety device that prevents the ignition sequence from continuing
unless the blower is developing sufficient airflow for combustion. Figure23: Location of Components shows the location of the
blower vacuum switch in the heater cabinet. When the blower achieves sufficient airflow, the negative pressure created in the
blower housing closes the contacts on the blower vacuum switch, indicating to the ignition control board that it is safe to continue
the ignition sequence. A silicone tube connects the blower vacuum switch with the blower as shown in Figure23: Location of
Components.
To remove the blower vacuum switch:
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel.
3. Remove the wires from the vacuum switch.
4. Pull the tubing from the hose barb on the switch.
5. Remove the (2) screws that secure the pressure switch to the control panel.
6. Replace the pressure switch and reverse the above procedure to reassemble unit.
HIGH LIMIT SWITCHES: The heater is equipped with two automatic high limits, located on the water header. These high limits are
automatically resetting safety devices wired in series with the thermostat and gas valve. See Figure28: Heat Exchanger Header. If
the water temperature exceeds the limit set point, the gas valve will be closed, shutting off gas supply to the burners. Erratic high
limit operation is an indication of water flow issues. Reduced flow may be caused by a clogged filter or strainer, excessive flow
through the external bypass (if one is used), or lime scale accumulation in the heat exchanger.
To replace a high limit switch:
1. Turn pump, gas supply, and heater power “OFF”.
2. Drain the heat exchanger of all water.
3. Unplug the high limit wires from the wiring harness.
4. Unscrew the high limit switch from the header.
5. Replace the high limit switch. Use new sealant on the high limit switch threads before reinstalling.
6. Reverse the above procedure to reassemble unit.
VENT PRESSURE SWITCH: The vent pressure switch is a safety device that disables the unit when the flue opening is blocked,
which prevents sufficient combustion gas flow through the unit. Figure23: Location of Components shows the location of the vent
pressure switch in the heater cabinet. When the flue is blocked, pressure is created and opens the contacts on the vent pressure
switch, directing the ignition control board to deactivate the unit. A silicone tube connects the vent pressure switch to the blower as
shown in Figure23: Location of Components.
To remove the vent pressure switch:
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel.
3. Remove the wires from the pressure switch.
4. Pull the tubing from the hose barb on the switch.
5. Remove the (2) screws that secure the pressure switch to the heater.
6. Replace the pressure switch and reverse the above procedure to reassemble unit.
EXHAUST GAS TEMPERATURE LIMIT: The exhaust gas temperature limit monitors the flue gas temperature above the heat
exchanger and opens when the temperature rises high enough to indicate that the heat exchanger is no longer transferring heat to
the pool water effectively. If the temperature limit opens, effort must be made to assess and rectify the condition that activated the
temperature limit and potentially damaged the heat exchanger. The condition is generally low water flow and/or scaling of the heat
exchanger cupronickel tubes from poor water chemistry. Replace the limit as well as the heat exchanger, if needed, before
operating the unit again.
To replace the exhaust gas temperature limit:
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the upper end cap on the header side of the unit (see Figure1: Sub-Assemblies).
3. Unplug the two wires from the exhaust gas temperature limit located in the flue collector panel above the middle of the header.
4. Unscrew the (2) screws securing the limit to the panel and remove the limit and gasket.
5. Place the new limit and gasket in place and reverse the above procedure to reassemble unit.

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THERMISTOR: The thermistor monitors the return water temperature to thermostatically control pool and spa water to the selected
temperature and to shut the heater off as the return water reaches 104 F. See Figure28: Heat Exchanger Header.
To replace the thermistor:
1. Turn pump, gas supply, and heater power “OFF”.
2. Drain the heat exchanger of all water.
3. Remove the front access panel.
4. Unplug the thermistor connector from the ignition control board.
5. From outside the heater, pull the thermistor leads out of the control box and through the hole in the heater chassis.
6. Unscrew the thermistor from the inlet side of the header.
7. Replace the thermistor. Use new sealant on the thermistor threads before re-installing.
8. Reverse procedure above to reassemble unit.

WATER PRESSURE SWITCH: The water pressure switch (see Figure28: Heat Exchanger Header) is preset at the factory for most
typical, deck level installations. When the heater is located above or below the level of the pool or spa, the pressure switch may
require adjustment to compensate for the change in static head pressure. If adjustment is needed, the procedure is detailed in
WATER PRESSURE SWITCH TEST / ADJUSTMENT PROCEDURE.

NOTICE: Do not operate the pool heater without the function of a properly adjusted pressure switch or flow switch.
To replace the pressure switch:
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the (4) screws securing the upper end panel and remove the panel.
3. Remove the (2) screws securing metal trim panel to the upper trim panel.
4. Remove the wires from the pressure switch.
5. Unscrew switch from header.
6. Replace the pressure switch. Use new sealant on the pressure switch threads before re-installing.
7. Reverse procedure above to reassemble unit.

TRANSFORMER: The transformer converts the field supply voltage (either 240 VAC or 120 VAC) to a 120 VAC output for blower
and igniter power, and a 24 VAC output for powering the ignition control board, control circuits, and gas valve. See Figure23:
Location of Components for its location.
To replace the transformer:
1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel.
3. Unplug transformer from the fuse board
4. Remove the (2) screws that secure the transformer to the control box.
5. Replace the transformer.
6. Reverse procedure above to reassemble unit.

BYPASS SERVICE CARTRIDGE: The following procedure details how to remove and replace the internal pressure bypass valve in
the header. This procedure applies only to plastic (non-ASME) headers. On bronze (ASME) headers, the bypass service cartridge is
not field-replaceable. Please contact technical support for more information.

1. Turn pump, main gas valve, and heater power off.

2. Drain heat exchanger according to instructions in Section III of this manual.
3. Remove 6 screws and remove the upper plastic heater side panel, to allow access to the header.
4. Remove the cartridge retaining nut from end of header (see Figure28).
5. Slide out the bypass cartridge from the end of the header (see Figure28).
6. Check the function of the bypass valve to ensure the valve flaps rotate smoothly on the shaft, and the spring fully closes the
valve.
7. Apply silicone O-ring grease (Jack’s 327 Multilube p/n SP032712, or equivalent) on O-ring seals on the bypass cartridge before
inserting into the header.
8. Insert bypass cartridge into header with the arrow on the end of the cartridge pointing up.
9. Re-install cartridge retaining nut. Nut should be tightened hand-tight only. DO NOT OVER-TIGHTEN.
10. Re-install the upper plastic heater side panel.
11. Reverse procedure above to reassemble unit.

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COMBUSTION BLOWER: The blower provides the air that mixes with the gas in the burners for the combustion process. The
blower operates during the pre-purge time (approximately 30 seconds) at the beginning of each ignition cycle, during the entire time
the gas valve is open and the burners are firing, and for 30 seconds after the gas valve closes. See Figure23: Location of
Components and Figure30: Blower.

To replace the blower: Figure30: Combustion Blower

1. Turn pump, gas supply, and heater power “OFF”.
2. Remove the front access panel. Air Inlet
Vent
3. Disconnect the blower wire harness from the Plate
ignition control board. Pressure
4. Disconnect the tubing from the hose barb on the Tap
blower housing.
5. Remove the blower from the air box cover (4
screws). Combustion Blower
6. Remove the blower air inlet plate from the blower Blower Gasket
(4 screws).
7. Be sure the blower outlet gasket is in place before
proceeding. Reverse the above procedure to Blower Air Box
reassemble the blower. Vacuum Cover
Tap

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TROUBLESHOOTING:
Error and Display Codes: See Table16: Display Code Index.

Troubleshooting the unit: See Table17: Troubleshooting Lookup Chart.

AUTOMATIC RESET TIME: The heater will automatically reset when an error condition is corrected and resume operation. The
heater can be manually reset using the keypad by cycling the MODE button through “STANDBY” and back to the original operating
mode (“POOL” or “SPA”).

WARNING: These instructions are intended for the use of qualified personnel trained and experienced in the installation
and servicing of this type of heating equipment and its related system components. Some states may require installation
and service personnel to be licensed. Persons not qualified should not attempt to repair this equipment according to these
instructions. These instructions and procedures are not for the use of “do-it-yourself” consumers.

WARNING: BURN HAZARD The operation of the heater with the pump shut off could cause heater
overheating and fire. Never operate heater with the pump shut off.

NOTICE: As a preliminary check, make sure that all wire connections are clean and tight and that all wiring conforms to the
wiring diagram.

FUSE SPECIFICATIONS: The fuse designations are printed on the power board and the ignition control board. See Figure23:
Location of Components for board locations. Fuses are available as common hardware items or may be purchased from
manufacturer in a service parts kit. The fuse specifications are:

 F1 fuse (low voltage): 3A blade style fast-acting automotive fuse, type 257
 FC1 & FC2 (transformer primary) and FC4 (transformer secondary):3A slo-blo fuse, 5 x 20 mm
INTERNAL WIRING: If the heater display is blank after the electrical has been installed, refer to Troubleshooting Lookup Chart to
determine the cause. Note, the ribbon cable between the display board and the ignition control board is keyed to ensure correct
connection.

SUPPLY WIRING: If the heater is connected to the line side of the circuit it will be powered at all times. In this situation, when the
pump shuts down the heater will display a fault code of “LO”. If there is a call for heat and the pump then restarts there will be a 2-
minute delay for the heater to fire. After the pump has been running for at least 2 minutes there is no delay for heater operation.
Wiring the heater to the load side of the timer or controller will not result in a 2-minute delay if the pump primes quickly enough to
activate the heater’s water pressure switch. If the pump is slow to prime the heater may display an “LO” fault code and will take 2
minutes to automatically restart. If the pump has primed, this wait can be avoided by manually clearing the error code via the
keypad by changing the mode through the “STANDBY” setting and returning to the initial setting (“SPA” or “POOL”).When a heater
is wired to the line side of the power circuit (continuous power) the blower will not operate when the pump is cycled via a time clock
or other switch method.

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Table16: Display Code Index

NOTE: Continuation of control sequence is immediate after error is corrected. Automatic
reset may take up to 2min for control self-diagnostics to complete. Lockout recover may
take up to 60 min.
Code Description Information
Air switch circuit Blower vacuum switch closed when expected open. If the blower vacuum
AC closed error switch is closed before blower has started, the ignition control board will not
start the blower until circuit is opened.
Air switch circuit Blower vacuum switch open when expected closed. If the blower vacuum
open error switch does not close after the blower starts for ignition or opens unexpectedly
AO during operation / post purge the ignition control board will shut off gas and air
flow and attempt a new ignition. If the blower vacuum switch does not close
after the blower starts for ignition the ignition control board will suspend the
ignition trial and go into lockout. The blower will continue to run.
Ignition control If the ignition control board does not satisfy self-diagnostic or input data values
bd board data error are corrupted on power up or initial trial for ignition, the ignition control board
will lockout until error condition is corrected..
bd Gas valve sensed If gas valve is powered when it should be off the heater will shut down and go
as “ON” error into lockout. Blower will operate until error condition is corrected.
Gas valve sensed If gas valve is unpowered but flame is sensed the blower will run for 5 s then
bd as “OFF” error start a new ignition sequence. If error occurs 10 times during a call for heat the
ignition control board will go into lockout.
Bypass operation This is normal display when heater is being controlled by a remote thermostat.
mode No service is required. If heater is not being controlled by remote thermostat,
bo change setting by using the MODE key to put the heater into STANDBY. Press
and hold the DOWN key and then press and hold the MODE key. Hold down
both keys for 3 seconds until the indication ‘‘bO’’ is removed from the display.

Communication If communication between the ignition control board and the display board is
CE error not established within 3 s of power-up or is lost for 30s during operation unit
will shut down and error will be displayed. The error code will be cleared upon
a valid data exchange between boards.
EE EEPROM error An error was detected in the ignition control board.
High flame sensor If flame is sensed with the gas valve off the ignition control board will go into
HF signal error lockout. The blower will run until error condition is corrected. When corrected,
the ignition control board will run blower for 5 s then automatically restart after
2 minutes.

USE ONLY GENUINE REPLACEMENT PARTS 41

 51300004201B

Table16: Display Code Index

NOTE: Continuation of control sequence is immediate after error is corrected. Automatic
reset may take up to 2min for control self-diagnostics to complete. Lockout recover may
take up to 60 min.
High temperature A) Inlet water temperature sensor is reporting a temperature in excess of
sensing error 104°F. Normal operation resumes 2 minutes after inlet water temperature
sensor reports temperatures of 104°F or less. This error functions for both
normal and remote thermostat modes. or
HS B) Inlet water temperature sensor is reporting a temperature change at a rate
faster than 6°F in 60 seconds or less while the heater is firing, indicating a
potentially damaging low water flow condition. Normal operation resumes
when temperatures stabilize. If this condition is detected 3 times in a one hour
period, the heater will lockout.

Ignition failure If the maximum number of ignition retries is exceeded, the heater will shut
IF error down and go into lockout. Automatic reset is 60 minutes.

Igniter open error If the ignition control board is not in lockout and senses that the igniter circuit is
IO open when the blower is running the ignition control board will turn off the
blower and go into lockout. Automatic restart 2 min after error is corrected.
Limit string open If the limit string opens the heater shuts down and goes into lockout. Automatic
LO error restart is 2 minutes after the error condition is corrected and the limit string
closes.
Electrical power This code will display if supply power polarity is reversed, low voltage is
PF supply wiring error detected, or if the ground path is not sufficient. Reset is immediate after error is
corrected.

Sb Keypad stuck If one of the keypad buttons is closed (or pressed) for more than 30 s the unit
button error will shut down. The error code will be cleared when the condition is corrected.

Temperature. If an excessive temperature difference between the redundant thermistors (5

sensor failure °F or more) or a sensor “out of bounds” condition with either thermistor (less
SF
error than 10°F or greater than180°F) will result in unit shut down and the error code
displayed. Automatic restart is 2 minutes after the error is corrected.

42 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
No code 1. Check for Low & Disconnect plug from P5 connector from Fuse Board. Measure for 24VAC
displayed High voltage output between pins of receptacle on Fuse Board. Reconnect plug. Disconnect
from fuse board plug from P6 of Fuse Board. Measure for 120VAC between pin 3 and 5 of
Heater will receptacle on Fuse Board. Reconnect plug. If OK, proceed to section titled
not power up ‘‘Low voltage circuit fault’’. Otherwise, proceed to step 2.
2. Ensure power Measure for field supply voltage across terminals of TB1 terminal block on
supply to heater is Fuse Board. If OK, proceed to step 3
turned on.
3. Check for faulty Inspect Fuse Board wiring. Ensure all plugs are securely fastened to Fuse
fuse board wiring. Board. If OK, proceed to step 4.
4. Verify that FC1 Remove FC1 and FC2 fuses from fuse holder. Measure continuity across
and FC2 fuses on fuse. If fuses are open, proceed to section titled ‘‘Open FC1 and/or FC2
fuse board are Fuses’’. If fuses are OK, reinstall them and proceed to step 5.
working
5. Verify that Check that proper Voltage Selector Plug 120 or 240 VAC is installed in
voltage selector Fuse Board. If OK, proceed to step 6
plug is installed
6. Check for Disconnect plug from P4 connector from Fuse Board. Measure for24VAC
defective between pins 1 & 2 of plug of Transformer and 120VAC between pins 4 &
transformer. 6. If 24VAC or 120VAC is not present, replace Transformer. Otherwise,
proceed to step 7.
7. Fuse Board is Replace Fuse Board.
defective
No code 1. Check for Low Disconnect plug from P5 connector from Fuse Board. Measure for24VAC
displayed Voltage Output from across pins. Reconnect plug. If OK, proceed to step 2.Otherwise, proceed
Fuse Board to step 5.
Low voltage
circuit fault. 2. Check for faulty Inspect ignition control board wiring. Ensure all plugs are securely
ignition control fastened. If OK, proceed to step 3.
board wiring.
3. Verify low voltage Verify 24VAC across R and C terminals on ignition control board. If not
input to ignition OK, replace harness. If OK, procced to step 4.
control board

4. Verify that F1 Remove F1 fuse from fuse holder. Measure continuity across fuse. If OK,
Fuse on ignition replace ignition control board. If fuse is open, proceed to section titled
control Board is not ‘‘Open FC3 or FC1 Fuses’’.
open.
5. Verify that FC3 Remove FC3 fuse from fuse holder. Measure continuity across fuse. If fuse
on Fuse Board is is open, proceed to section titled ‘‘Open FC3 or FC1 Fuses’’. If OK, reinstall
not open fuse and proceed to step 6.

6. Check for Disconnect plug from P4 connector from Fuse Board. Measure for24VAC
defective between pins 1 & 2 of plug from transformer. If 24VAC is not present,
Transformer. replace Transformer. Otherwise, proceed to step 7.
7. Fuse Board is Replace Fuse Board
defective

USE ONLY GENUINE REPLACEMENT PARTS 43

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
No code 1. Verify that Check that proper Voltage Selector Plug is installed. If OK, proceed to step
displayed 120VAC Voltage 2.If 120VAC plug is installed and field supply voltage is 240VAC, FC1 and
Selector Plug is not FC2 fuses may be blown. Install the correct Voltage Selector Plug and new
Open FC1 installed with a FC1 and FC2 fuses.
and/or FC2 240VAC field power
Fuses. supply.

2. Check for faulty Inspect Transformer wiring. Ensure insulation on wiring is not worn. If OK,
Transformer wiring. proceed to step 3.

3. Defective Replace Transformer.

Transformer
No code 1. Check for faulty Inspect Gas Valve wiring. Ensure insulation on wiring is not worn. If OK,
displayed Gas Valve wiring. proceed to step 2.

Open FC3 2. Verify that Gas Measure for resistance across Gas Valve terminals and between each
and/or F1 Valve is not terminal and ground. If short exists, replace Gas Valve. If OK, proceed to
Fuses defective. step 3.

3. Check for faulty Inspect ignition control board wiring is to supplied wiring diagram. Ensure
ignition control insulation on wiring is not worn and no bare wire is exposed. If OK proceed
board wiring. to step 4.

4. Ignition control Replace ignition control board.

board is defective.
No code 1. Check for faulty Inspect Igniter wiring. Ensure insulation on wiring is not worn. If OK,
displayed Igniter wiring. proceed to step 2.

Open FC4 2. Check for faulty Inspect Blower wiring. Ensure insulation on wiring is not worn. If OK,
Fuse. Blower wiring. proceed to step 3.
3. Check for Disconnect Igniter plug from ignition control board. Measure resistance
defective Igniter. across Igniter. Resistance should be 10.9-19.7 ohms at 77°F. If out of this
range, replace igniter. If OK, proceed to step 4

4. Check for Disconnect Blower plug from ignition control board. Measure resistance
defective Blower. across Blower windings. Winding resistance across lead should be in the
following range: Red-to-White: 4 to 5 ohms. If measured values vary
substantially from these values, blower is defective. Replace. Otherwise
proceed to step 5.
5. Ignition control Replace ignition control board.
board is defective.
AC 1. Check for Disconnect Blower plug from ignition control board. With heater off,
displayed defective blower on measure continuity across pins 1 and 2 of receptacle on ignition control
relay or ignition board. If closed, ignition control board relay is defective. Replace ignition
Air switch control board. control board. If OK, proceed to step 2.
circuit closed 2. Vacuum switch is Replace blower vacuum switch.
error defective.

44 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
AO 1. Check for faulty Check tubing and replace if necessary. If OK, proceed to step 2.
displayed vacuum switch
tubing
Air switch
2. Check for faulty Inspect vacuum switch wiring. Ensure wire harness terminals are securely
circuit open
vacuum switch fastened to spade terminals on vacuum switch. If OK, proceed to step 3.
error
wiring or
connection.
3. Check for faulty Inspect blower wiring. Ensure plug on blower is securely fastened to
blower wiring or ignition control board. If OK, proceed to step 4.
connection
4. Check for Disconnect Blower plug from ignition control board. Measure resistance
defective vacuum across Blower windings. Winding resistance across lead should be in the
switch following range; Red-to-White: 4 to 5 ohms. If measured values vary
substantially from these values, Blower is defective. Replace. If OK,
proceed to step 5.

5. Check for Disconnect Blower plug from ignition control board. Place heater in Pool or
defective blower Spa Mode. Lower set point temperature to generate call for heat. During
relay. pre-purge period, measure for 120VAC across pins 1 and 2.If 120VAC is
not present, ignition control board relay is defective. Replace ignition
control board. If OK, proceed to step 6

6. Vacuum switch is Replace blower vacuum switch.

defective
bd 1. Verify that FC4 Remove FC from fuse holder. Measure continuity across fuse. If OK,
displayed Fuse on Fuse reinstall fuse and proceed to step 2. If Fuse is open, proceed to section
Board is not open. titled ‘‘Open FC4 Fuse’’.
Ignition 2. Verify high Disconnect plug from P6 connector of Fuse Board. Measure for120VAC
control board voltage output from across pins 3 and 5 of P6 receptacle on Fuse Board. If OK, reconnect plug
data error Fuse Board. and proceed to step 3. If not OK, go to step 4.
3. Check for Disconnect plug from E10 connector of ignition control board. Measure for
defective Harness. 120VAC across pins 1 and 3 of Plug on Harness. If OK, replace ignition
control board. If not OK, replace Harness.

4. Check for Disconnect plug from P4 connector of Fuse Board. Measure for120VAC
defective between pins 4 and 6 of plug from Transformer. If OK, proceed to step 5.
Transformer. If not OK, replace Transformer.

5. Fuse Board is Replace Fuse Board.

defective
bo 1. Check to see if This is normal display when heater is being controlled by a remote
displayed Ignition control thermostat. No service is required. If heater is not being controlled by
board is in Bypass remote thermostat, change setting by using the MODE key to put the
Bypass Operation heater into STANDBY. Press and hold the DOWN key and then press and
Operation hold the MODE key. Hold down both keys for 3 seconds until the indication
‘‘bO’’ is removed from the display.

USE ONLY GENUINE REPLACEMENT PARTS 45

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
CE 1. Disconnect and Reset communication between Display Interface and Ignition control board
displayed then re- connect
power to heater.
Control to 2. Check for faulty Inspect Display Interface Wiring. Ensure Display Interface Plug is securely
display wiring or attached to ignition control board. If OK, proceed to step 3.
communica- connection.
tion error
3. Display Interface Replace Display Interface and/or ignition control board
and/or Ignition control
board are defective.
EE 1. EEPROM error Replace ignition control board.
displayed Defective ignition
control board
HF 1. ignition control Using the sight glass, check to see if the flame is present in the unit. If not,
displayed board is defective replace ignition control board. If flame is present, use a voltmeter to
determine if 24 VAC is present at the gas valve connections. If so, replace
High flame ignition control board. If not, move to step2.
sensor signal
error 2. Gas Valve is Replace Gas Valve
defective
HS 1. Check remote Verify set point setting of remote thermostat is at or below 104°F. If set
displayed thermostat setting point of remote thermostat is OK, or if heater is not configured for remote
thermostat, proceed to step 2.
High temp. 2. Verify that the Verify that water flow to heater is above minimum required (see
sensing Error water flow is SPECIFICATION in Getting Started Section). Note that intermittent periods
adequate of low water flow will cause this error. If OK, proceed to step 3.
3. Check inlet water Compare the heater's temperature reading to the pool water temperature
temperature sensor with an accurate thermometer. If significantly different, replace inlet water
temperature sensor.
IF 1. Ensure gas Ensure that main gas shutoff installed adjacent to heater is open. Ensure
displayed supply shut off that knob on gas valve inside unit is in ‘‘on’’ position. If OK, proceed to step
valves are open. 2.
Ignition 2. Check for low Ensure inlet gas supply pressure is between the minimum and maximum
failure error gas supply press. values indicated on rating plate. If OK, proceed to step 3.
3. Check for faulty Inspect flame sense wiring. Ensure wire harness terminals are securely
flame sense fastened to flame sense and to ignition control board. If OK, proceed to
connection. step 4.
4. Check for faulty Inspect gas valve wiring. Ensure wire harness terminals are securely
gas valve fastened to spade terminals on gas valve. If OK, proceed to step 5.
connection
5. Check for gas 1. Measure voltage across gas valve during trial for ignition. If 24VAC is
valve failure or gas present and gas valve does not open, gas valve is defective. Replace gas
valve relay failure. valve.
2. If 24VAC is not present, gas valve relay on ignition control board is
defective. Replace ignition control board.
6. Check for Inspect gas orifices for blockages which could prevent gas flow. Remove
blockage and inspect burners for blockages.
IO 1. Check for faulty Inspect Igniter wiring. Ensure Igniter Plug is securely attached to ignition
displayed connection. control board. If OK, proceed to step 2.
2. Igniter is Replace Igniter.
Igniter open defective
error

46 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
LO 1. Verify that the This is a normal display when the pump is off. Turn pump on. LO code
displayed pump is running. should clear. If LO does not clear, proceed to step 2.
2. Verify that water Verify that water flow rate to heater is above minimum required (see
Water
flow is adequate SPECIFICATION in Getting Started Section). If OK, proceed to step 3
Pressure
Switch Fault
3. Check for faulty Inspect water pressure switch wiring. Ensure wire harness terminals are
wiring or securely fastened to spade terminals on water pressure switch. If OK,
connection. procced to step 4.

6. Check for correct Adjust water pressure switch setting as presented in Manual (only if heater
water pressure is above or below water level). If LO does not clear, proceed to step 7.
switch setting.

7. Water pressure Replace water pressure switch.

switch is defective
LO 1. Check for faulty Inspect vent pressure switch wiring. Ensure wire harness terminals are
displayed wiring or securely fastened to spade terminals on vent pressure switch. If OK,
connection. proceed to step 2.
Vent
2. Verify state of Remove wire leads from vent pressure switch and jumper leads. Operate
Pressure
vent pressure heater. Measure continuity across vent pressure switch. If closed, LO code
Switch Fault
contacts. is not caused by vent pressure switch fault. If open, proceed to step 3.
cont…
Remove jumper from wire leads and reconnect wire leads to vent pressure
switch.

3. Check for Ensure that flue is not blocked or restricted. See indoor vent sizing
restricted or blocked requirements in installation manual. Verify heat exchanger is not blocked.
flue. Verify burners are not blocked. If OK, proceed to step 4.

4. Vent pressure Replace vent pressure switch.

switch is defective.

LO 1. Check for faulty Inspect temperature limit switch wiring. Ensure wire harness terminals are
displayed wiring or securely fastened to spade terminals on temperature limit switches. If OK,
connection. proceed to step 2.
Temp. Limit
Switch Fault 2. Verify state of Remove wire leads from limit switch and jumper leads. Operate heater.
cont… temperature limits’ Measure continuity across limit switches. If closed, LO code is not caused
contacts by temperature limit switch fault. If open, proceed to step 3. Remove
jumper from leads and reconnect leads to temperature limits.
3. Verify that water Verify that water flow rate to heater is above the minimum required (see
flow is adequate SPECIFICATION in Getting Started Section). If OK, proceed to step 4.
4. Temperature limit Replace temperature limit switch.
switch is defective.

USE ONLY GENUINE REPLACEMENT PARTS 47

 51300004201B

Table17: Troubleshooting Lookup Chart

Code/ Fault Diagnostic Step Suggested Troubleshooting Action
LO 1. Check for faulty Inspect temperature limit switch wiring. Ensure wire harness terminals are
displayed wiring or connection securely fastened to spade terminals on temperature limit switch located in
the flue collector panel above the center of the header. If OK, proceed to
Exhaust Gas step 2.
Temp. Limit
Fault cont… 2. Verify state of Remove wire leads from limit switch and measure continuity across limit
temperature limit’s switch contacts. If closed, LO code is not caused by exhaust gas
contacts temperature limit switch fault. If open, proceed to step 3.

3. Heat exchanger This is generally due to low water flow, poor water chemistry, or other
has been damaged factors. Correct issues with water flow through the heater and water
chemistry and then replace the heat exchanger and exhaust gas
temperature limit. Continuing to run the heater after this limit has tripped
will cause damage to the entire unit and will not be covered by the
warranty.
PF 1. Polarity reversed Reverse L and N (120vac) or L1 and L2 (240VAC).
displayed 2. Insufficient Check for proper ground to unit and at service disconnect box
ground continuity
3. Low voltage Check that proper Voltage Selector Plug is installed.
detected
4. Ignition control
board damaged
Sb 1. Keypad stuck Replace Display Interface Assembly.
displayed button error, keypad
is defective
SF 1. Check for faulty Inspect sensor wiring. Ensure sensor is plugged into back of ignition control
displayed wiring or board. If OK, proceed to step 2.
connection.
Temp. sensor
2. Sensor is Replace temperature sensor.
failure error
defective

WARNING: Pool heaters are heat producing appliances. To avoid possible over heating of the outer jacket and damage
or injury with such an event: (1) no materials should be stored against the jacket and (2) care should be taken to avoid
unnecessary contact (especially by children) with the jacket.
WARNING: When lighting a gas heater, the lighting instructions must be followed exactly to prevent “flashback” of
excess gas in the heater. Electronic ignition heaters and electric heaters must have the power shut off when making
adjustments for servicing, or coming into contact with the heater.

WARNING: UNDER NO CIRCUMSTANCES SHOULD FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT

THINNERS, BE USED OR STORED IN THE VICINITY OF THE HEATER OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE HEATER.

48 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

PARTS:
Figure31: Service Parts Exploded View

USE ONLY GENUINE REPLACEMENT PARTS 49

 51300004201B

Table18: Service Kits

250 400 500
# Item Description 150 200 300 350
250ASME 400ASME 500ASME
TOP FLUE
FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT FDXLJKT
COVER (PLASTIC
1150 1200 1250 1300 1350 1400 1500
1 HEADER)
ASME (BRONZE FDXLJKT FDXLJKT FDXLJKT
N/A N/A
HEADER) * 1250A 1400A 1500A
FRONT ACCESS
DOOR ASSY FDXLFAD FDXLFAD FDXLFAD FDXLFAD FDXLFAD FDXLFAD FDXLFAD
(PLASTIC 1150 1200 1250 1300 1350 1400 1500
HEADER)
2
ASME FRONT
ACCESS DOOR FDXLFAD FDXLFAD FDXLFAD
N/A N/A
ASSY (BRONZE 1250A 1400A 1500A
HEADER) *
REAR ACCESS
DOOR ASSY FDXLRAD FDXLRAD FDXLRAD FDXLRAD FDXLRAD FDXLRAD FDXLRAD
(PLASTIC 1150 1200 1250 1300 1350 1400 1500
HEADER)
3
ASME REAR
ACCESS DOOR FDXLRAD FDXLRAD FDXLRAD
N/A N/A
ASSY (BRONZE 1250A 1400A 1500A
HEADER) *
TOP FRONT
FDXLTFP FDXLTFP FDXLTFP FDXLTFP FDXLTFP FDXLTFP FDXLTFP
PANEL (PLASTIC
1151 1201 1251 1301 1351 1401 1501
HEADER)
4 ASME TOP
FRONT PANEL FDXLTFP FDXLTFP FDXLTFP
N/A N/A
(BRONZE 1251A 1401A 1501A
HEADER) *
5 BOTH END CAPS FDXLBEC1930
HEADER SIDE
6 FDXLHTP1931
TRIM PANELS
RETURN SIDE
7 FDXLRTP1931
TRIM PANELS
8 BASE LEG FDXLPBL1930
FLUE
COLLECTOR
9 SIDE PANEL W/ FDXLFCS1931
TEMPERATURE
LIMIT
RAIN GUARD FDXLRGK FDXLRGK FDXLRGK FDXLRGK FDXLRGK FDXLRGK FDXLRGK
10
ASSEMBLY 1151 1201 1251 1301 1351 1401 1501
HEAT BARRIER FDXLHBP FDXLHBP FDXLHBP FDXLHBP FDXLHBP FDXLHBP FDXLHBP
11
PANEL 1150 1200 1250 1300 1350 1400 1500
EXHAUST GAS
12 FDXLEGL1930
TEMPERATURE
LIMIT (ONE-USE)
IGNITER ACCESS
13 FDXLIAC1930
COVER
CONVERSION
FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK
KIT, NA TO LP,
2150NP 2200NP 2250NP 2300NP 2350NP 2400NP 1500NP
QUICK-CHANGE
14
CONVERSION
FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK FDXLGCK
KIT, LP TO NA,
2150PN 2200PN 2250PN 2300PN 2350PN 2400PN 2500PN
QUICK -CHANGE

* ASME parts for ASME models only

50 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

Table18: Service Kits

250 400 500
# Item Description 150 200 300 350
250ASME 400ASME 500ASME
BLOWER INLET FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN FDXLBBN
15
BAFFLE 1150 1200 1250 1300 1350 1400 1500
COMBUSTION FDXLBWR
16 FDXLBWR1930
BLOWER 1500
17 IGNITOR FDXLIGN1930
18 FLAME SENSOR IDXLFLS1930
GASKET KIT,
19 FDXLGSK1930
BLOWER/IGN
BLOWER
20 VACUUM FDXLBVS1930
SWITCH
VENT PRESS
SWITCH,
21 OUTDOOR AND FDXLVPS1930
INDOOR,
0-2000
VENT PRESS
SWITCH,
22 FDXLVPS1931
INDOOR,
2,000-10,100
23 TRANSFORMER IDXL2TRF1930
IGNITION
24 CONTROL FDXLICB1930
BOARD
FIELD WIRING
25 FDXLFWP1930
PANEL
BEZEL & KEYPAD
26 FDXLBKP1932
ASSEMBLY
GASKET KIT,
27 FDXLGSK1932
BEZEL
GASKET KIT,
28 FDXLGSK1931
FLUE/RAIN GRD
GASKET KIT, CC
29 FDXLGSK1934
FRONT/AIR BOX
WATER
30 PRESSURE FDXLWPS1931
SWITCH
31 THERMISTOR FDXLTER1931
HEADER
32 FDXLHDW1930
HARDWARE KIT
33 PLUG CHXPLG1930
DRAIN PLUG
34 SPX400FG
WITH GASKET
35 HIGH LIMIT KIT FDXLHLI1930
BYPASS
36 CARTRIDGE FDXLCRN1930
RETAINING NUT
BYPASS
37 FDXLBPK1930
CARTRIDGE KIT
HEADER
38 MOUNTING BASE FDXLHBM930
KIT
* ASME parts for ASME models only

USE ONLY GENUINE REPLACEMENT PARTS 51

 51300004201B

Table18: Service Kits

250 400 500
# Item Description 150 200 300 350
250ASME 400ASME 500ASME
RETURN
MANIFOLD
39 FDXLPRM1930
REPLACEMENT
KIT
INLET/OUTLET
FDXLFHD1930
HEADER ONLY
40
INLET/OUTET
FDXLFHA1930
HEADER ASSY
HEAT
EXCHANGER FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA
41
ASSY (PLASTIC 1150 1200 1250 1300 1350 1400 1500
HEADER)
ASME WATER
FDXLWPS FDXLWPS FDXLWPS
42 PRESSURE N/A N/A
1930 1930 1930
SWITCH*
43 THERMISTOR* FDXLTER1930
ASME
CHXRLV
44 PRESSURE N/A N/A CHXRLV1930
1930
RELIEF VALVE *
ASME DRAIN FDXLDRV
45 N/A N/A FDXLDRV1930A
VALVE, * 1930A
ASME HEAT
EXCHANGER FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA FDXLHXA
46
ASSY (BRONZE 1150 1200 1250A 1300 1350 1400A 1500A
HEADER) *

* ASME parts for ASME models only

52 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

Table18: Service Kits (Items Not Shown in Diagram)

250 400 500
Item Description 150 200 300 350
250ASME 400ASME 500ASME
ASME UNION
FLANGE KIT
FDXLUNK
(INCL. FITTINGS, N/A N/A FDXLUNK1930A
1930A
BOLTS,
GASKETS) *
UNION FLANGE
KIT (INCLUDES
SPX3200UNKIT
FITTINGS, UNION
NUTS, GASKETS)
TIE-DOWN KIT FDXLTDK1930
BURNER FDXLBRN1930 (qty8) / FDXLBRN1931 (qty1)
INSULATION,
RETURN SIDE FDXLGSK1933
TUBE SHEET
HEADER 0-
FDXLFOR1930
RING KIT
VOLTAGE
SELECTOR FDXLVSJ1930
JUMPER
FUSE SERVICE
FDXLFSK1930
KIT
FUSE KIT, 3.0A,
FOR FIELD
FDXLFSKF30
WIRING PANEL
(QTY 10)
FUSE KIT, 3.0A,
FOR IGNITION
FDXLFC30
CONTROL
BOARD (QTY 10)
HIGH ALTITUDE
CONVERSION
FDXLHAK1930
KIT,
2,000-10,100
WIRING
HARNESS KIT, FDXLWHA1930
COMPLETE

* ASME parts for ASME models only

USE ONLY GENUINE REPLACEMENT PARTS 53

 51300004201B

Table18: Service Kits (Items Not Shown in Diagram)

Item 250 400 500
150 200 300 350
Description 250ASME 400ASME 500ASME
INDOOR VENT
ADPTR KIT, UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT UHXNEGVT
NEG-PRESS 11506 12006 12506 13008 13508 14008 15008
CATI 6”dia 6”dia 6”dia 8”dia 8”dia 8”dia 8”dia
(VERTICAL)
INDOOR VENT
4”dia ADPT KIT
UHXPOSZ
POS-PRESS N/A N/A
12504
CATIII
(HORZ/VERT) ‡

HeatFab SS N/A UHXHFA

N/A
4”dia Adapter 004
DuraVent SS N/A UHXDVA N/A
4”dia Adapter 004
INDOOR VENT
6”dia ADPT KIT,
UHXPOSHZ UHXPOSHZ UHXPOSHZ
POS-PRESS N/A
11506 12006 12506
CATIII
(HORZ/VERT)**
INDOOR VENT
6”dia ADPT KIT,
N/A UHXPOSHZ UHXPOSHZ
POS-PRESS
14006 15006
CATIII
(HORZ/VERT) ‡

HeatFab SS N/A UHXHFA

6”dia Adapter 006
DuraVent SS N/A UHXDVA
6”dia Adapter 006
INDOOR VENT
8”dia ADPT KIT,
UHXPOSHZ UHXPOSHZ UHXPOSHZ
POS-PRESS N/A N/A
13008 13508 14008
CATIII
(HORZ/VERT)**

‡Adapter kit requires additional vent adapter selection of appropriate UHXHFA or UHXDVA

** See Table9 for Heatfab part numbers included in adapter kits

54 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

USE ONLY GENUINE REPLACEMENT PARTS 55

 51300004201B

56 USE ONLY GENUINE REPLACEMENT PARTS

 51300004201B

USE ONLY GENUINE REPLACEMENT PARTS 57