Certikin MB055PEH User guide

WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable vapours and liquids in the vicinity
of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbour's phone. Follow the gas
supplier's instructions.
- Installation and service must be performed by a Corgi registered installer, service
agency or the gas supplier.
Operating, Installation and
Servicing Instructions for
Pool & Spa Heaters
M3556
MB055PEH
MB055
MB105
MB155
MB185
MB265
MB405
0087
MB055 MB105 MB155 MB185 - MB265 - MB405
Natural Gas L.P.G.
MODEL: MB055PEH MB055 MB105 MB155 MB185 MB265 MB405

1
01-10-98
2 PART ONE - OWNER'S OPERATING INSTRUCTIONS
2 SECTION 1 / START-UP PROCEDURES
2 Before Start-Up
3 Operating Instruction & Shut-Off Procedures
4 After Start-Up
4 SECTION 2 / CAUTION
4 SECTION 3 / MAINTENANCE & CARE PROCEDURE
5 Pool & Spa Water Chemistry
5 Cold Weather Operation
5 Winterizing the Pool & Spa Heater
6PART TWO - INSTALLATION/SERVICE INSTRUCTIONS
6 SECTION 1 / RECEIVING EQUIPMENT
6 SECTION 2 / GENERAL SPECIFICATIONS
8 SECTION 3 / INSTALLATION INSTRUCTIONS
11 Outdoor Heaters
11 Indoor Heaters
14 Combustion Air
15 Gas Supply Connections
16 Plumbing For Water Connections
16 Left Side Water Connection Conversion
20 Electrical Wiring
23 SECTION 4 / SERVICING INSTRUCTIONS
23 General Location of Controls
25 Temperature Controls
25 Pressure Switch
26 High Limit
27 Pilot Safety
27 Burner Drawer Removal
27 Gas Valve Removal
27 Main Burner & Orifice Removal
27 Pilot Removal & Cleaning
28 Heat Exchanger Removal
28 Control Immersion Well Replacement
28 Tube Cleaning
29 Desooting Procedure
29 Combustion Chamber Removal
29 Unitherm Governor Replacement
30 SECTION 5 / TROUBLE SHOOTING GUIDE
30 Mechanical
32 Electrical IID Units 055, 105 & 155.
34 Electrical IID Units 185, 265 & 405.
36 SECTION 6 / REPLACEMENT PARTS
36 Replacement Parts List - 055
38 Replacement Parts List - 105
40 Replacement Parts List - 155
42 Replacement Parts List - 185, 265 & 405
Contents

PART ONE - OWNER'S OPERATING INSTRUCTIONS
2
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS
EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING
PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
01-10-98
SECTION 1 / START-UP PROCEDURES
BEFORE START-UP
BURNERS
Clean air louvres of dust, lint and debris. Keep
heater area clear and free from combustibles, flam-
mable liquids and chemicals. Do not obstruct the
flow of combustion and ventilating air.
WATER
Water must be flowing through the heater during
operation. Ensure that system is filled with water and
the pump is operating.
055 105
155 185 - 265 - 405
8111.tif 405view.tif
105view.tif

CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate
in confined areas, extra care should be exercised when lighting propane heaters.
3
08-08-01
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
A. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.
B. BEFORE OPERATING Smell all around the
appliance area for gas. Be sure to smell
next to the floor because some gas is
heavier than air and will settle on the floor.
* WHAT TO DO IF YOU SMELL GAS
* Do not try to light any appliance.
Do not touch any electric switch;
Do not use any phone in your building.
* Immediately call your gas supplier from a
neighbour's phone. Follow the gas suppli
er's instructions.
* If you cannot reach your gas supplier, call
the fire service.
1. STOP! Read the safety information above on
this label.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot.
Do not try to light the pilot by hand.
5. Remove heater door panel.
6. Turn " OFF " gas supply to appliance.
1. Set the thermostat to the lowest setting.
2. Turn off all the electric power to the appli
ance if service is to be performed.
3. Remove heater door panel.
C. Use only your hand to push in or move the gas
control lever. Never use tools. If the lever will
not push in or move by hand, don't try to repair
it, call a qualified service engineer. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service engineer to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
7. Wait five ( 5 ) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas STOP! Follow " B " in the
safety information above on this label. If you
don't smell gas, go to the next step.
8. Turn " ON " gas supply to appliance.
9. Replace heater door panel.
10. Turn on all electric power to the appliance.
11. Set the thermostat to the desired setting.
12. If the appliance will not operate, follow the
instructions " To Turn Off Gas To Appliance "
and call your service engineer or gas supplier.
4. Turn off gas supply to appliance.
5. Replace heater door panel.
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
CARE OF YOUR HEATER
This heater casing is Polyester powder on top of zinc coated steel to assist in resisting corrosion. It is recommended that
periodically the casing is cleaned and sprayed with WD40 or similar liquid especially when installed outdoors. Exposed
threads on manifolds will benefit from a light coating of grease. Outdoor tops are finished with a special black high
temperature coating and as this is part of the flueing system, subject to high temperatures and the elements, can discolour
and corrode over a period of time.

AFTER START-UP
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be
hot.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.
VISUAL INSPECTION
With the heater on, remove the door and make a
visual check of the pilot and burner.
The flame should be blue with a well-defined pattern.
MAIN BURNER FLAME
PILOT BURNER FLAME
A yellow or "floating" flame indicates restricted air
openings or incorrect injector size. Should this
occur, shut the heater off and contact your installer or
gas supplier.
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to
shut off the burners in the event that water supply to
the heater is interrupted. It is very important to verify
that the switch electrically opens and shuts off the
gas valve when water flow to the heater is inter-
rupted. Otherwise, rapid and severe damage is likely
to occur to the heater. (The water pressure switch
should be checked and adjusted for proper operation
by a qualified service person at the time of installation
checked thereafter.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
SECTION 2/CAUTION
Elevated water temperature can be hazardous, and
the U. S. Consumer Product Safety Commission
recommends the following guidelines:
1. Spa or hot tub water temperatures should
never exceed 40°C (104°F). A temperature
of 38°C (100°F) is considered safe for a
healthy adult. Special caution is suggested
for young children.
2. Drinking of alcoholic beverages before or
during spa or hot tub use can cause
drowsiness which could lead to
unconsciousness and subsequently result
in drowning.
3. Pregnant Women Beware! Soaking in water
over 39°C (102°F) can cause fetal damage
during the first three months of pregnancy
resulting in the birth of a brain-damaged or
deformed child. Pregnant women should
stick to the 38°C (100°F) maximum rule.
4. Before entering the spa or hot tub, users
should check the water temperature with an
accurate thermometer; spa or hot tub ther-
mostats may err in regulating water
temperatures by as much as 2°C (4°F).
5. Persons with a medical history of heart di-
sease, circulatory problems, diabetes, or
blood pressure problems should obtain a
physician's advice before using pools or hot
tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihista-
mines, or anticoagulant, should not use
spas or hot tubs.
SECTION 3/MAINTENANCE AND
CARE PROCEDURES
To be followed one month after start-up and then
semi-annually. A full service by a competent person
(i.e. CORGI registered) should be conducted at least
once a year.
1. Inspect top of heater and drafthood for soot,
(a sticky black substance around finned
tubes and "V" baffles), and open flue gas
passage ways. If soot is present, contact
installer or service agent.
2. Inspect and operate all controls, gas valve
and pressure relief valve.
4
03-06-99
4" MAX
100MM
flame.tif
europilot2.tif

3. Make visual check of the burner and pilot
flame. Flame pattern on the main burner
and pilot is indicated in the previous illustra-
tion. Yellow flame means restriction of the
air openings. Lifting or blowing flame indi-
cates high gas pressure. Low flame means
low gas pressure. Should this occur, shut
the heater off and contact your gas supplier
or qualified service agency.
4. On indoor heaters, clean room intake open-
ings to assure adequate flow of combustion
and ventilation air.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
5. Keep area around heater clear and free
from combustible materials, gasoline and
other flammable and corrosive vapours and
liquids.
POOL & SPA WATER CHEMISTRY
IMPORTANT!These Heaters are not suitable for use
on Salt Chlorinated pools. If this is intended please
contact the Manufacturer.
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain
your water pH between 7.4 and 7.8 and total alkalinity
between 100 and 150 p.p.m. If the mineral content
and dissolved solids in the water become too high,
scale forms inside the heat exchanger tubes, reduc-
ing heater efficiency and also damaging the heater.
If the pH drops below 7.2, the heater will be severely
damaged. This will result in corrosion of the heat
exchanger. Heat exchanger damage resulting
from chemical imbalance is not covered by the
warranty.
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
All chemicals must be introduced and completely
diluted into the pool or spa water before being circu-
lated through the heater. Do not place chlorine
tablets or bromine sticks in the skimmer. High
chemical concentrations will result when the pump is
not running (i.e. overnight).
Chlorinators must feed downstream of the heater
and have an anti-siphoning device to prevent chemi-
cal back-up into the heater when the pump is shut off.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will cause
very rapid corrosion to the heat exchanger in the
heaters. Such damage is not covered under the
warranty.
5
08-08-01
COLD WEATHER OPERATION
MODERATE CLIMATE: Heater operation can
continue during short term cold spells. When
temperatures are below freezing, flow (continuous
pump operation) must be maintained.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze
protection. When heater is used during freezing
weather, care must be taken to avoid freeze ups.
Continuous pump operation is a must. Additional
protection may be required. The heater is not
warranted against freeze ups.
COLD CLIMATE: Prolonged operation with water
temperatures below 10°C (50°F) is not
recommended. When starting the heater with pool
temperatures below 10°C (50°F) operate the
heater continuously until higher temperatures are
reached. Operating the heater for prolonged
periods with pool water below 10°C (50°F) can
seriously damage the heater, and is not covered by
the warranty.
For cold climate areas, please follow the winteriz-
ing procedures listed.
WINTERIZING THE POOL & SPA HEATER
When heaters installed outdoors in freezing cli-
mate areas are to be shut down for the winter,
observe the following step-by-step procedure:
1. Turn off gas valve, manual gas valve, and
electrical supply to the heater.
2. Open drain cock located on the inlet/outlet
header, (under water pipes). Remove
drain
plug from return header. Remove the heat
exchanger inspection panels on the side
opposite water piping to gain access to
the plug on the return header.
Return Header
185, 265 & 405 Models
3. Disconnect compression fittings from the
pressure switch and return header that
connects to the 1/4" copper tube and allow
the tube to drain.
Drain
Plug
plug.tif

01-10-98
6
PARTTWO - INSTALLATION/SERVICE INSTRUCTION
SECTION 1 / RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the
carton is damaged, a note should be made on the delivery note when signing for equipment. Remove the
heater from the carton and if it is damaged, report the damage to the carrier immediately. Save the carton.
These items are shipped loose inside the carton with the 055 & 105 heater:
1. CPVC Adaptors (2)
2. Plastic Flange (1)
These items are shipped loose inside the carton with the 155, 185, 265 & 405 heater:
1. In/Out Flanges (2)
2. 1-1/2" Flange Gaskets (2)
3. 2" Flange Gaskets (2)
4. Flange Bolts (4)
5. 2" CPVC Adapters (2)
Be sure that you receive the number of packages indicated on the delivery note.
When ordering parts, you must specify model and serial number of heater. When ordering under warranty
conditions, you must also specify date of installation.
It is recommended that this manual be reviewed thoroughly before installing your pool/spa heater. If there
are any questions that this manual does not answer, please contact the supplier.
SECTION 2 / GENERAL SPECIFICATIONS
All heaters are inter-changeable and can be used either indoor or outdoors. The appropriate top designated
for that type of use is required. If desired, the top can be changed at a later date to change from outdoor to
indoor or vice versa.
GENERAL SPECIFICATIONS
WATER CONTENT Litre Model 0.8 Model 1.1 Model 1.8
(gal) 055 (0.18) 105 (0.3) 155 (0.4)
Model 1.9 Model 1.9 Model 2.6
185 (0.4) 265 (0.4) 405 (0.5)
MAXIMUM WATER PRESSURE 8 bar (125 psi)
bar (psi)
MAXIMUM WATER FLOW TEMP 45.0
°C (°F) (110)
ELECTRICAL SUPPLY 230V 50Hz
FUSED AT 3A. POWER 100W
WARNING: This appliance must be installed and serviced by a CORGI registered installer.

7
13-08-03
PERFORMANCE SPECIFICATIONS
GAS CATEGORY, TYPE, AND II2H3P G20 @ 20 mbar (8 in. wg)
SUPPLY PRESSURE. G31 @ 37 mbar (14.8 in. wg)
7
U.K. & Ireland.
PERFORMANCE SPECIFICATIONS - NATURAL GAS
GAS TYPE AND SUPPLY PRESSURE G20 @ 20 mbar (8 in. wg)
MODEL 055 105 155 185 265 405
BURNER mbar 6.3 6.8 7.7 8.1 8.3 8.7
PRESSURE (in. wg) ( 2.5 ) ( 2.7 ) ( 3.1 ) (3.2) (3.3) (3.5)
HEAT GROSS kW 12.9 26.67 38.98 49.53 71.5 108.4
INPUT (Btu/h) (44,000) (91,000) (133,000) (169,000) (244,000) (370,000)
NET kW 11.6 24.0 35.08 44.58 64.4 97.6
(Btu/h) (39,600) (81,900) (119,700) (152,100) (219,600) (333,000)
HEAT kW 10.06 20.8 30.4 38.63 55.8 84.58
OUTPUT (Btu/h) (34,300) (71,000) (103,700) (131,820) (190,300) (288,600)
GAS RATE m3/h 1.22 2.5 3.7 4.6 6.6 10.28
INJECTOR DIA. mm 1.78 1.78 1.85 1.78 1.78 1.78
& (MARKING) gauge (50) (50) (49) (50) (50) (50)
NUMBER OF BURNERS 4 8 10 13 19 29
& INJECTORS
PERFORMANCE SPECIFICATIONS - PROPANE GAS
GAS TYPE AND SUPPLY PRESSURE G31 @ 37 mbar (14.8 in. wg)
MODEL 055 105 155 185 265 405
BURNER mbar 23.8 19.0 21.5 28.5 29.4 29.3 30.0
PRESSURE (in. wg) (9.6) ( 7.6 ) ( 8.6 ) ( 11.4 ) (11.8) (11.7) (12.0)
HEAT GROSS kW 14.1 12.9 26.67 38.98 49.53 71.5 108.4
INPUT (Btu/h) (48,000) (44,000) (91,000) (133,000) (169,000) (244,000) (370,000)
NET kW 13.0 11.9 24.54 35.86 45.57 65.8 99.8
(Btu/h) (44,500) (40,500) (83,720) (122,360) (155,480) (224,480) (340,400)
HEAT kW 11.0 10.06 20.8 30.4 38.63 55.8 84.58
OUTPUT (Btu/h) (37,400) (34,300) (71,000) (103,700) (131,820) (190,300) (288,600)
GAS RATE m3/h 0.50 0.47 0.97 1.43 1.82 2.57 4.04
INJECTOR DIA. mm 1.09 1.09 1.09 1.06 1.06 1.06
& (MARKING) gauge (57) (57) (57) (59) (59) (59)
NUMBER OF BURNERS 4 8 10 13 19 29
& INJECTORS
055
Easiheat

SECTION 3 / INSTALLATION
INSTRUCTIONS
IMPORTANT NOTICE
These instructions are intended for the use of quali-
fied personnel only, specifically trained and experi-
enced in the installation of this type of heating equip-
ment and related system components. Installation
and service personnel must be CORGI registered.
Persons not qualified must not attempt to fix this
equipment nor attempt repairs according to these
instructions.
WARNING:
Improper installation, adjustment, alteration, service
or maintenance may damage the equipment, create
a hazard resulting in asphyxiation, explosion or fire,
and will void the warranty.
STATUTORY REQUIREMENTS
Gas Safety (Installation and Use)
Regulations, 1994
It is the law that all gas appliances are installed by
competent persons in accordance with the above
regulations. Failure to install appliances correctly
could lead to prosecution. It is in your own interest,
and that of safety, to ensure that the law is complied
with.
General Requirements
The appliance must be installed by a competent
person ie. CORGI registered in accordance with the
relevant requirements of the Gas Safety Regulations,
current I.E.E. Regulations, Model Water Byelaws,
Local Water Authority Byelaws and any relevant
requirements of the local gas supplier, local authority
and the relevant British Standard Codes of practice
and Building Regulations. Manufacturers notes must
not be taken in any way as overriding statutory
obligations. Typical documents include:
Models 055, 105 & 155
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 60 KW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60KW).
BS. 5449 Forced circulation hot water systems.
BS. 6798 Installation of gas fired hot water boilers of
rated input not exceeding 60 KW.
BS. 6891: Installation of low pressure pipework.
Health & Safety Document No. 635.
The Electricity at Work regulations, 1989.
CP341; Water Supply.
British Gas Publications:
IM2; Purging Procedures of Non-domestic Gas Installations
IM5, Soundness Testing Procedures for Industrial and
Commercial Gas Installations.
8
01-10-98
Sheet Metal
24 Gauge
0.7mm
12" Min.
300mm
12" Min.
300mm
4" Min.
100mm
Hollow concrete cinder block, align holes and
leave ends open. Alternative method for
providing a non-combustible base.
Models 185, 265 & 405
BS. 6891; Installation of low pressure pipework.
BS. 6644; Installation of Gas Fired Hot Water
Boilers 60kW to 2MW.
CP 341; Water Supply.
British Gas Publications:
IM2; Purging Procedures on Non-domestic
Gas Installations.
IM5; Soundness Testing Procedures for
Industrial and Commercial Gas Installations.
IM11; Flues for Commercial and Industrial
Gas Fired Boilers and Air Heaters.
Model Water Byelaws.
This appliance must be installed externally in open air
(without a flue) or indoors (with a suitable flue system)
in a room separated from living rooms and provided
with appropriate ventilation direct to the outside.
The appliance must be used only in accordance with
these instructions. Incorrect use is dangerous and
invalidates all warranties and Certification.
Conversion Instructions.
The heater is supplied in two versions,one for use
with Natural Gas, G20 at 20 mbar inlet pressure, the
other for Propane, G31 at 37 mbar. If it is necessary
to convert the heater for use on the other gas the
appropriate conversion kit must be purchased and
fitted using the instructions provided.
NOTE: The heater should not be located in an area
where possible water leakage will result in damage
to the area adjacent to the appliance or to the
structure. When such locations cannot be
avoided, it is recommended that a suitable drain pan,
adequately drained, be installed under the appliance.
The pan must not restrict combustion air flow.
BASE INSTALLATION
Heater must be mounted on a level base, such as
cement slab, cement blocks or other non-combus-
tible surface. An alternative method for providing a
base for combustible floors is illustrated below.
Heaters must not be installed on carpeting.
base.tif

9
01-10-98
CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see the
chart below.
CLEARANCE FROM COMBUSTIBLE
MATERIAL (mm)
Plant Room Installation
Model Top Back Right Left Front
055 900 50 150 150 Clear
105 900 50 150 150 Clear
155 1050 300 150 300 Clear
185-405 750 150 300 150 Clear
Outdoor Installation
Model Top Back Right Left Front
055 Clear 50 150 150 Clear
105 Clear 50 150 150 Clear
155 Clear 300 150 150 Clear
185-405 Clear 150 150 150 Clear
4'
Min
4'
Min
Forced Air
Inlet
4' Min
10'
Min.
1' Min
1.0m 3' Min
3.0m
1.25m
1.25m
1.25m
0.3m
For servicing, provide at least 600mm (24") in front of
the heater for burner tray removal, and at least
450mm (18") on water connection side of the heater
to inspect and delime the heat exchanger.
Heaters must not be installed under an overhang of
less than 1.0m (3 feet) from the top of the heater.
Three (3) sides must be open in the area under the
overhang. Roof water drainage must be diverted
away from the heaters installed under overhangs
with the use of gutters:
The point from where the flue products exit the heater
must be a minimum of 1.25m (4 feet ) below, four (4)
feet horizontally from or 0.3m (1 foot) above any
door, window or gravity inlet to a building. The top
surface of the heater shall be at least 1.0m (3 feet)
above any forced air inlet, or intake ducts located
within 3.0m (10 feet) horizontally.
HIGH WIND CONDITIONS
(OUTDOOR HEATERS ONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 1.0 m
from high vertical walls, or install a wind break so the
heater is not in direct wind current.
clear.tif

10 08-08-01
Heater with
Outdoor
Stackless Top
Press tab
to locate
Pagoda Top
(Shipped
Loose with
Heater)
105 & 155 Models
FLUE TERMINAL (Outdoor) Stackless Top Illustra-
tion
Top Vent
Opening
Heater Vent Opening
Jacket Top
185, 265 & 405 Models
FLUE TERMINAL (Outdoor) Stackless Top Illustra-
tion
1. Insert tabs into keyhole (4 places).
2. Snap tabs into keyholes so as not to pull out.
tab2.tif
tab1.tif
055expl1.tif
OUTDOOR HEATERS
These heaters are certified by British Gas plc for
outdoor installation, when equipped with the
approved tops designated for outdoor use.
WARNING:The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet louvres and into
the heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.
It is recommended that the casing is cleaned and
sprayed with WD40 or similar liquid, and exposed
threads on the manifolds are lightly coated in grease,
after assembly.
FLUE CONNECTIONS AND DIMENSIONS
055 Models
FLUE TERMINAL (Outdoor) Stackless Top Illustra-
tion
1: Remove the (8) screws which fasten jacket top
to heater.
2: Line up top vent opening over heater vent
opening
3: Lower outdoor top onto unit lining up slots in
outdoor top with screw holes in jacket top.
4: Reinstall (8) screws to secure jacket top and
outdoor top to unit.

11
01-10-98
185, 265 & 405 Models
FLUE TERMINAL (Indoor) Draught Diverter
Illustration
1. Remove the louvred jacket top by removing
four (4) No.10 flat head screws.
2. If originally installed, remove "Pagoda" top
from the louvered jacket top.
3. Place the inner stack adapter panel over the
flue collector inside the heater. Make sure
the flanged side of the flue opening is up.
4. Turn the stack (diverter) upside down and set it
down bottom side up.
5. Turn the jacket top panel (removed in step 1)
down and place it through the stack.
6. Attach the three (3) mounting brackets to the
stack using the screws provided and the holes
that are pre-drilled in the stack. Make sure the
brackets are positioned with the flange near
the top side of the stack (see illustration
below).
Caution must be taken not to over tighten and
strip the screw threads.
7. Turn the assembled stack and jacket top, right
side up. The jacket top will be trapped
between the brackets and the top of the stack.
Place the stack over the inner adapter panel
flanged hole and lower the louvered jacket top
panel back into its original position. Reinstall the
four (4) No.10 flat head screws removed in
step 1 above.
S8960
Draught
Diverter
Jacket
Top
Mounting
Screws (8)
Screw Hole
Location
3.25"
82.5mm
Draught
Diverter
No.10 Screw (3)
Flue Collector
(Part of Heater)
Inner Stack
Adapter Panel
Jacket Top Panel
(Part of Heater)
Mounting Bracket (3)
INDOOR HEATER
The design is also certified by British Gas plc for
indoor installation when fitted with the appropriate
draught diverter and a suitable flue system to outside.
Note that the heater must be in a room separated
from living rooms and provided with appropriate
ventilation direct to the outside.
055 Models
FLUE TERMINAL (Indoor) Draught Diverter
Illustration
Locate and assemble as shown. Secure with screws
supplied in envelope inside carton.
105 & 155 Models
FLUE TERMINAL (Indoor) Draught Diverter
Illustration
Locate and assemble as shown. Secure with screws
supplied in envelope inside carton.
Draught
Diverter
055expl2.tif
405term.tif
term.tif
Mounting
Screws

12
10-12-01
SPECIFICATIONS & DIMENSIONS 055 - 105 - 155
MODEL FLUE DIA WATER CONNECTIONS SHIPPING WEIGHT
kg (lbs)
mm (in.) APPLIANCE DIVERTER
055 100 (4) 1-1/2" NPT 31.8 (70) 2.3 (5)
105 127 (5) 1- 1/2" NPT 48 (105) 3.5 (8)
155 152 (6) 2" NPT 62 (135) 3.5 (8)
825mm
(32 - 1/2")
Gas Connection
60mm
(2 - 3/8")
525mm
(20 - 3/4")
455mm
(18")
620mm
(24 - 1/2")
130mm
(5 -1/8")
325mm
(12 - 7/8")
475mm
(18 - 3/4")
65mm
(2 - 1/2")
85mm
(3 - 3/8")
190mm
(7 - 1/2")
Gas
Connection
65mm
(2 - 1/2")
325mm
(12 - 3/4")
510mm
(20")
690mm
(27 - 1/4")
1070mm
(42")
610mm
(24")
DIMENSIONS - 105 Model Only
DIMENSIONS - 055 Model Only
dim055.tif
dim105.tif
835mm
(32 - 7/8")

13
10-12-01
A
*Electrical Connection On Left Side is 486mm (19-1/8")
(38")
Gas Connection (13-1/4")
(C)
Indoor
Draft
(40")
(7-1/2")
(3-3/8")
86mm
191mm
1015mm
675mm (26-1/2")
(*21-1/4")
*540mm
(26 ½")
673mm
965mm
336mm
Dim405.tif
(C)
INDOOR DRAUGHT
HOOD
185 1590MM (62 5/8")
265 1597mm (62 7/8")
405 1570mm (65 3/8")
SPECIFICATIONS & DIMENSIONS 185 - 265 - 405
MODEL WIDTH FLUE DIA WATER SHIPPING WEIGHT
(A) CONNECTIONS kg (lbs)
mm (in.) mm (in.) APPLIANCE DIVERTER
185 464 (18 1/4) 150 (6) 2" NPT 86.8 (191) 5.5 (12)
265 568 (22 3/8) 175 (7) 2" NPT 97 (214) 7 (15)
405 743 (29 1/4) 230 (9) 2" NPT 115 (253) 9 (20)
DIMENSIONS - 155 Model Only
610mm
(24")
1140mm
(44 - 7/8")
770mm
(30 - 3/8")
390mm
(15 - 3/8")
370mm
(14 - 1/2")
680mm
(26 - 3/4")
900mm
(35 - 1/2")
220mm
(8 - 3/4")
85mm
(3 - 3/8")
Gas
Connection

14
18-11-02
VENTILATION REQUIREMENTS
The heater must have both ventilation and
combustion air. Safe and efficient operation of the
heater is vitally dependant upon a good supply of
fresh air to the room in which the appliance is in-
stalled. Minimum requirements for net free air supply
openings direct to outside air at both high and low
level are detailed in the table at the bottom of this
page.
Position grilles to avoid the risk of accidental
blockage or flooding. Further guidance is given in
BS6644.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty.
NOTE: The design is also certified by British Gas
plc for indoor installation when fitted with
appropriate manufacturer's draught diverter and a
suitable flue system to outside. The heater must be
in a room separated from living rooms and
provided with appropriate ventilation direct to
outside. It must not be installed in a cupboard or
compartment which is directly connected to a living
space.
FLUE SYSTEM
WARNING:
Indoor boilers require a draught diverter that must be
connected to a flue pipe and properly flued to the
outside. Failure to follow this procedure can cause
fire or fatal carbon monoxide poisoning.
To ensure safe and satisfactory operation of the
heater, the flue system must be capable of the com-
plete evacuation of flue products at all times. The
effective height of the flue terminal above the draught
diverter must ensure sufficient buoyancy to
overcome the resistance of the bends and horizontal
runs of the flue pipe. The number of bends and length
of horizontal run must be kept to a minimum to reduce
resistance.
The chimney must terminate in a downdraught free
zone.
The flue/chimney design should avoid the formation
of excessive quantities of condensate and for this
reason it is recommended that all chimneys are
suitably insulated and lined.
The draught diverter supplied with the heater must be
used.
Drain points should be fitted at the bottom of all
vertical flue sections. Drain pipes must be a minimum
of 25mm (1 in) internal diameter and manufactured
from acid condensate resistant material (eg stainless
steel) and positioned so that pipe runs and discharge
points are not subject to the effects of frost and that
flue gases cannot leak into the room.
Any terminal fitted must be of a type acceptable to
British Gas plc.
As part of commissioning, the flue must be satisfac-
tory when tested for flue flow and spillage as detailed
in BS5440 Part 1.
Flue.pcx
Model Input Plant Room (cm²) ref. BS5440 for models under 60kW
(kW) Inside Outside
High Low High Low
055
13 117 234 59 117
105 27 243 486 122 243
155 39 351 702 176 351
185 50 450 900 225 450
265 72 --297 600
405 108 --378 756
ref. BS6644 for models over 60kW
Compliance with the recom-
mendations made in BS 6644;
British Gas publication IM11
"Flues for Commercial and
Industrial Gas fired boilers and
air heaters" and the "Third
Edition of the 1956 Clean Air Act
memorandum" should be strictly
observed where applicable.

15
18-11-02
GAS SUPPLY CONNECTIONS
Gas piping must have a manual shut-off valve located
outside the heater jacket. All gas piping should be
tested after installation in accordance with local
codes.
CAUTION: The heater and its manual shut off valve
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in
excess of 150mbar (2.2psi). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRESSURED
GAS VALVES ARE NOT COVERED BY WAR-
RANTY. The heater and its gas connections shall be
leak tested before placing the appliance in operation.
Use soapy water for leak test. DO NOT use open
flame.
NOTE: Do not use PTFE tape on the gas line pipe
thread. A Flexible sealant is recommended.
A minimum of 17 mbar (6.8”) WG and a maximum of
25 mbar (10”) W.G.upstream pressure under load,
and no load conditions are provided for natural gas or
a minimum of 25 mbar (10”) W.G.and a maximum of
45 mbar (18”) W.G for propane gas.
GAS PRESSURE REGULATOR
The gas pressure regulator is preset in the factory.
If an adjustment is needed, remove cap and turn
adjustment screw clockwise to
increase pressure or counterclockwise
to decrease pressure.
Turn to page 7 for burner pressure and other
relevant performance specifications.
Burner Pressure
Adjustment
Vr8600.tif
Honeywell Gas Valve
PIPE SIZING FOR GAS CONNECTIONS
MAXIMUM EQUIVALENT PIPE LENGTH METRES
N - NATURAL GAS @ 1.0 mbar PRESSURE DROP
P - L.P.G. @ 2.5 mbar PRESSURE DROP
10mm 15mm 22mm 28mm
MODEL N P N P N P N
055 61215
105 3520
155 10.5 >24 36
185 8 >24 29
265 4.5 18 14.5
405 8.5 7

16
01-10-98
PLUMBING FOR WATER CONNECTIONS
LEFT SIDE WATER CONNECTION CONVERSION
185, 265 & 405 Models Only
Dis-assembly:
1. Remove the jacket top, upper side panels, right
and left side access panel (see figure 1).
2. Remove rain shield front and side panel assembly
as follows: (see figure 2).
a) Remove front screws attaching rain shield
to the vertical surface behind the control
compartment.
b) Remove four (4) screws attaching the rain
shield to the rear vertical support panel.
c) Remove front and side rain shield panels,
leaving the back shield in place.
3. Remove the flue collector housing
(see figure 3).
4. Disconnect wires to high limit and AGS (Auto
matic Gas Shut-off) limit switches in return and
inlet/outlet header castings (see figure 4).
5. Remove pressure switch as follows:
(see figure 4).
a) Disconnect wires to pressure switch.
b) Disconnect tube fitting from header casting.
c) Remove pressure switch with tubing through
the front of the heater.
6. Remove thermostat temperature sensor
(see figure 4).
Rain Shield
Side Panel
Figure 2
Left Side
Access
Panels
Figure 4
Figure 3
Figure 1
fig3.tif
Flue
Collector
Front Screws Rain Shield Front Panel
fig2.tif
Four (4) Rear Screws
(2 per side)
fig4.tif
A.G.S.
High
Limit
Wires
Inner Jacket
Panel
Pressure
Switch
Tube
High
Limit Wires
Upper Side
Panel
Jacket Top
Panel
fig1.tif
Thermostat
Temperature
Sensor
Re-Route
Sensor Bulb
Through Hole

17
01-10-98
CIRCUIT
BOARD
Wire Hole In Rear
Panel Of Control Box
Three (3) Pin
Sensor Plug
Control Panel Door
(Shown In Open Position)
7. a) Disconnect the three (3) pin sensor plug
from the poolstat circuit board (see figure
5).
b) Push the connector plug and wires down
through the control box holes (see figure 5)
and then through the inner jacket panel hole
into the heat exchange area (see figure 4).
Reverse Heat Exchanger:
8. Lift the complete heat exchanger straight up and
out of the unit.Use care not to damage the
combustion chamber blocks.
9. Re-route the pressure switch tube back through
the right side of the inner cabinet panel.
10.Rotate the heat exchanger (inlet/outlet casting
will be on the left) and lower it back into place
above the combustion chamber. Again, be careful
not to damage the combustion chamber blocks.
Assembly:
11. Re-route the three (3) pin plug and sensor wires
from the heat exchange area through the
hole in on the right side of the inner cabinet panel
then up into the control box. Plug the three (3)
pin connector back into the poolstat circuit board
(see figure 5).
12. Connect the pressure switch tube to the same
hole it was removed from in the return header.
13. Re-route the pressure switch wires to the right
side and connect them to the pressure switch.
14. OPTIONAL, re-route the AGS wires to the left
side and overheat thermostat capillary to the
right side. Connect the wires to the sensors in
the header castings.
15. Replace the flue collector. Use caution not to
damage any wiring and make sure no wiring
comes in direct contact with the flue collector.
16. Replace the rain shield and screws (see figure
2).
17. Reverse and replace right and left access panels
18. Replace top side panels and jacket top panel.
board.tif

18
18-11-02
PVC Pipe
2" CPVC Adapters
Inlet/Outlet Header
CONNECTIONS
All Models
LOCATION
The heater requires water flow and pressure to
operate properly. It must therefore be installed
downstream of the discharge side of the filter pump.
A typical installation is plumbed as follows:
1. The inlet side of the filter is plumbed to the
discharge side of the filter pump.
2. The outlet side of the filter is then plumbed to the
inlet of the heater.
3. The outlet of the heater is plumbed to the return line
to the pool or spa. The pump, filter and heater are
plumbed in series.
Plumbing from the heater back to the pool must not
have any valves or restriction that could prevent flow
when the pump is operating.
Use the pressure loss chart below to specify a
suitable pump.
PRESSURE LOSS CHART 055 / 105 / 155 MODEL ONLY
500
400
300
200
100
0
0 100 200 300 400
LITRES / MIN
PRESSURE LOSS CHART 185 / 265 / 405 MODELS ONLY
600
500
400
300
200
100
0 100 200 300 400
LITRES / MIN
Heater must be located so that any water leaks will
not damage the structure of adjacent area. High
temperature 2" plastic pipe (CPVC) may be threaded
directly into the header flanges. This is not the same
as the Schedule 80 PVC pipe which is also coloured
grey. PVC may be used immediately after the CPVC
adapters.
NOTE:If operating pressure above 2 bar (30psi) are
encountered then connection pipes must either be
screwed into the flange or suitably anchored.
CAUTION: NEVER install PVC directly into header
flanges.
FLOW RATES
MINIMUM/min. MAXIMUM/min.
MODEL PIPE SIZE Litres (Gals) Litres (Gals)
055 1-1/4"-1-1/2" 77 (17) 225 (50)
105 1-1/4"-1-1/2" 77 (17) 430 (95)
155 1-1/4"-1-1/2" -2" 77 (17) 430 (95)
185 1-1/4"-1-1/2" -2" 77 (17) 470 (104)
265 1-1/4"-1-1/2" -2" 95 (21) 470 (104)
405 1-1/4"-1-1/2" -2" 150 (33) 470 (104)
*When flow rates exceed maximum an external
auxiliary bypass valve is required. See external
bypass valve section for details.
COMPANION FLANGE CONNECTIONS
DO NOT use petroleum base assembly fluids (such
as Petroleum Jelly or lubricating oil). If assembly lube
is required, use a silicone base such as Amoral etc.
055 Model Only
The inlet/outlet header flange accepts a 1 ½"
copper tube or 1 ¼" galvanized pipe as a slip
connection directly into the manifold. The flange is
also threaded for 1 ½" pipe thread.
M
B
A
R
M
B
A
R
mbsmall.tif

19
10-12-01
155, 185, 265 & 405 Models Only
Inlet/Outlet Header
DANMAINES
Flange Gasket
Header Flange
S80
1 2
155, 185, 265 & 405 Models Only
There are two sets of flange gaskets supplied with
your heater. Use the appropriate gaskets for all your
heater connections. Discard unused set.
GASKET DESIGN 1: Accepts 1-1/2" copper tube or
1-1/4" galvanized pipe as a slip connection.
GASKET DESIGN 2: Accepts 2" copper tube as a slip
connection. The flange is threaded for 2" screw in
pipe connections. Also used with the 2" CPVC
adapters.
UNITHERM GOVERNOR OPERATION
Does not apply to 105 Model
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain con-
stant heater internal temperature between 40.6 to
46.1°C despite continually changing flow rates from
the filter and changing pool temperatures. This
narrow range is needed to prevent damaging
condensation on the burners which will occur if the
heater runs for any length of time below 37.8°C. It is
also needed to inhibit scale formation in the tubes by
maintaining temperatures well below accelerated
scaling temperatures.
INTERNAL AUTOMATIC BY-PASS VALVE
Does not apply to 055 Model
In addition to the Unitherm Governor, a built-in auto-
matic by-pass valve is provided in the in/out header.
While the Unitherm Governor responds to the
changes in water temperature in the heater, the
internal by-pass valve automatically responds to
changes in water pressure in the piping system.
Proper amount of water flow is maintained through
the heater under varying pressures dictated by the
conditions of the pump and filter.
055 Models Only
055hdr.tif
Inout.tif
gasket.tif
ugov.tif
IN OUT
IN
OUT
105 Model Only
The 105 accepts direct connection to 1½" plastic pipe
using the adapters provided.
105 headers.tif
Inlet/Outlet Header
1½" NPT
Inlet/Outlet
Connections