Raypak 130A Manual

IN TALLATION & OPERATING
IN TRUCTION
CATALOG NO. 6100.59F ffective: 04-12-10 Replaces: 06-24-08 P/N 241255 Rev. 7
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
FOR YOUR AFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU MELL GA :
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.
Model 130A
Atmospheric
Above-Ground
Pool & pa
Heater

2
Rev. 7 reflects the following:
Changes to: Text formatting on pages 5 and 8, captions on Fig. 12 and Fig. 13 on page 13, winterizing instructions on
page 21, IPL diagram on page 32, IPL information on pages 33 and 34.

WARNING 4
Pay Attention to These Terms 4
WATER CHEMI TRY 5
Automatic Chlorinators &
Chemical Feeders 5
AFETY 6
Water Temperature Safety 6
INTRODUCTION 6
Ratings & Certifications 6
Model Identification 7
Specifications 7
Unpacking 7
IN TALLATION 8
Installation Codes 8
Clearances 8
Base Installation 8
Outdoor Installation 8
Indoor Installation 10
Combustion & Ventilation Air 10
Gas Connections 11
Water Connections 13
lectrical Connections 15
Control Adjustments—Millivolt 16
Wiring Diagrams 17
Post Start-Up Inspection 20
Cold Weather Operation 20
MAINTENANCE 21
ERVICE 21
Water Pressure Switch 21
Flame Roll-Out Safety Switch 22
High Limits 22
Pilot Safety—Millivolt Models 22
Burner Tray Removal 22
Gas Valve Removal 24
Main Burner & Orifice Removal 24
Igniter Removal & Cleaning ( lectronic) 24
Ignition Control Fault Codes 24
Pilot Removal & Cleaning (Millivolt) 25
Heat xchanger Removal 25
Tube Cleaning Procedure 25
De-sooting Procedure 25
Immersion Well Replacement— Millivolt 26
Replacement Parts 26
TROUBLE HOOTING 27
Mechanical 27
lectrical 28
General—Heater Will Not Fire 30
lectronic Control Logic
Flowchart 30
ILLU TRATED PART LI T 31
CONTENT
3

DANGER: Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
WARNING: Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
CAUTION: Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
NOTE: Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DANGER: Failure to install the drafthood on indoor
installation and properly vent the heater to the
outdoors as outlined in the venting section of this
manual can result in unsafe operation of the heater.
To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the venting
section of this manual for more information regarding
vent system inspections.
WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
Do not handle, use, or store gasoline or other
flammable or combustible materials in the vicinity of
a heater.
WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the user's information manual provided with
this heater. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING - CALIFORNIA PROPO ITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
CAUTION: Verify proper operation after servicing.
WARNING - Pay Attention to These Terms
4
WARNING: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.
When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High fficiency Particulate Air
(H PA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.

5
WATER CHEMI TRY
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water chemistry according to Table A. If the mineral
content and dissolved solids in the water become too
high, scale forms inside the heat exchanger tubes,
reducing heater efficiency and damaging the heater. If
the pH drops below 7.2, this will cause corrosion of the
heat exchanger and severely damage the heater. Heat
exchanger damage resulting from chemical imbal-
ance is not covered by the warranty.
For your health and the protection of your pool equip-
ment, it is essential that your water be chemically
balanced. The following levels must be used as a
guide for balanced water.
• Occasional chemical shock dosing of the pool or
spa water should not damage the heater providing
the water is balanced.
• Automatic chemical dosing devices and salt chlo-
rinators are usually more efficient in heated water,
unless controlled, they can lead to excessive chlo-
rine level which can damage your heater.
• Further advice should be obtained from your pool
or spa builder, accredited pool shop, or chemical
supplier for the correct levels for your water.
Automatic Chlorinators &
Chemical Feeders
All chemicals must be introduced and completely dilut-
ed into the pool or spa water before being circulated
through the heater. Do not place sanitizing chemi-
cals in the skimmer. High chemical concentrations
will result when the pump is not running (e.g.
overnight).
Chlorinators must feed downstream of the heater and
have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off. See
Fig. 1.
NOTE: Corrosive water voids all warranties.
CAUTION: Free chlorine must not exceed 5 ppm
which can damage the heater and void the warranty. NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will
cause rapid corrosion to the heat exchanger.
Such damage is not covered under the warranty.
Recommended Level(s) Fiberglass Pools Fiberglass Spas Other Pool and Spa
Types
Water Temperature 68-88°F (20-31°C) 89-104°F (31-40°C) 68-104°F (20-40°C)
pH 7.3-7.4 7.3-7.4 7.6-7.8
Total Alkalinity (ppm) 120-150 120-150 80-120
Calcium Hardness (ppm) 200-300 150-200 200-400
Salt (ppm) 6000 Maximum 6000 Maximum 6000 Maximum
Free Chlorine (ppm)* 2-3 2-3 2-3
Total Dissolved Solids
(ppm) 3000 Maximum 3000 Maximum 3000 Maximum
*Free Chlorine MUST NOT EXCEED 5 ppm!
Table A: Water Chemistry

6
Skimmer
Pool
Check Valve
Check Valve
Pump
Filter
Heater
Auto-Chlorinator
Return to Pool
Fig. 1: Pool/Chlorinator Setup
AFETY
This appliance is to be installed and operated by
trained personnel in accordance with this Installation
and Operation Manual. Be sure to read and under-
stand the entire Installation and Operation Manual
before attempting to install or operate this appliance.
Failure to follow the warnings listed at the beginning of
this manual could result in a fire or explosion, causing
property damage, bodily injury, or death.
Should you have any problems understanding the
warnings and instructions in this manual, STOP, and
get help from a qualified installer, service technician,
or the gas supplier.
Water Temperature afety
levated water temperature can be hazardous. The
U.S. Consumer Product Safety Commission has these
guidelines:
1. Spa water temperatures should never exceed
104°F (40°C). A temperature of 100°F (38°C) is
considered safe for a healthy adult. Special cau-
tion is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use may cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.
3. Pregnant Women Beware! Soaking in water over
102°F (39°C) may 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 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 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.
6. Persons taking medications which induce drowsi-
ness, such as tranquilizers, antihistamines,
anticoagulants, or recreational drugs should not
use spas or hot tubs.
INTRODUCTION
Ratings & Certifications
This pool & spa heater is design-certified and tested
under the latest requirements of ANSI Z21.56 / CSA
4.7 Standard for Gas-Fired Pool Heaters. The heater
can be used either indoors or outdoors. If necessary,
the top of the heater can be changed after installation
to accommodate indoors or outdoors.

7
WARNING: Use of any parts not manufactured
and/or approved by the manufacturer will void the
warranty.
Ambient Temperature Rating of
Components
• Millivolt heater +32°F to +175°F
• lectronic heater only -40°F to +175°F
Model Identification
The model identification number and heater serial
number are found on the heater rating plate.
The model identification number will be similar to
PR130A- N-X, where:
• " P" designates an lectronic heater using Propane
gas
• " N" designates an lectronic heater using Natural
gas
• "MP" designates a Millivolt heater using Propane gas
• "MN" designates a Millivolt heater using Natural gas
• "P" prefix designates plastic (Polymer) headers
• "X" suffix designates Cupro-Nickel tubing
• "C" suffix designates Copper tubing
Heater
Rating
Plate
Fig. 2: Location of Heater Rating Plate
pecifications
Unpacking
On receipt of the heater it is suggested that visual
checks are made for external damage to the shipping
carton. If the carton is damaged, make a note to that
effect on the Bill of Lading when signing for the ship-
ment. Remove the heater from the shipping
packaging. Report any damage to the carrier immedi-
ately.
On occasion, items are shipped loose. Be sure that the
correct number of packages are received, as indicated
on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Authorization to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, specify the model and serial
number of the heater. When ordering under warranty
conditions, specify the date of installation. Records of
the installation must be provided, when requested, to
substantiate a claim.
Debits for defective replacement parts will not be
accepted and will only be replaced in kind per the
manufacturer's standard warranties.
Model
No.
Input
(BTUH)
Gas
Conn.
(NPT)
Water
Conn.
Shipping
Weight, Std.
Heater
w/Stackless
Top
130A 130,000 1/2 in.
1-1/2
in. or 2
in.
NPT
140 lbs.
Table B: 130A Specifications

8
IN TALLATION
Installation Codes
Installations must be in accordance with local, state,
provincial, and national codes, laws, regulations and
ordinances. In the absence of local codes, installations
must be in accordance with the latest editions of the:
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
• National lectrical Code, ANSI/NFPA 70
• For Canada only: CAN/CGA B149 installation Code
(B149) and CSA C22.1 C. .C. Part 1 and Part 2
Clearances
The required minimum clearances from combustible
surfaces are shown in Table C below.
When installed according to the listed minimum clear-
ances from combustible construction, the pool heater
can be serviced without removing permanent con-
struction around the heater.
However for ease of servicing, we recommend a
clearance of at least 24" in the front, and at least
18" on the rear. This will enable the heater to be serv-
iced in its installed location, that is, without movement
or removal of the heater.
Heater Side Outdoor
Installations
Indoor
Installations
Top* Unobstructed 42 in.
Front 6 in. Alcove
Vent N/A 6 in.
Back 12 in. 12 in.
Right Side 6 in. 6 in.
Left Side 6 in. 6 in.
*Clearance from top of vent terminal.
Table C: Required Minimum Clearances from
Combustible Surfaces.
12"
Minimum
12"
Minimum
4"
Minimum
HEATER
SheetMetal
24 Gauge
Hollow concrete cinder block,
align holes and leave ends open.
Fig. 3: Alternate Method for Providing a Non-
Combustible Base
Clearances less than these may require removal of the
heater to service either the heat exchanger or the
burner tray. In either case, the heater must be installed
in a manner that will enable the heater to be serviced
without removing any structure around the heater.
Base Installation
Heater must be mounted on a level base, such as
cementable slab, cement blocks or another non-com-
bustible surface. An alternate method for providing a
base for combustible floors is illustrated. Heaters may
not be installed on carpeting.
Outdoor Installation
NOTE: This heater is design-certified for outdoor
installation when equipped with the approved top(s)
for outdoor use.
WARNING: The heater should not be located in an
area where water sprinklers, or other devices, may
cause water to spray through the cabinet louvers
and into the heater. this could cause internal rusting
or damage electrical components, and void the
warranty.
WARNING: Do not install within 3 feet of a heat
pump or an outdoor condensing unit. strong air
intake from this type of equipment can disturb the
combustion process and cause damage or personal
injury
NOTE: The heater should not be located in an area
where possible water leakage will 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
adequate drainage, be installed under the heater.
The pan must not restrict combustion air flow.

9
Fig. 4: 130A Dimensions
Heater with Outdoor tackless Top
Heaters must not be installed under an overhang of
less than 3 ft from the top of the heater. Three sides
must be open in the area under the overhang. Roof
water drainage must be diverted away from heaters
installed under overhangs with the use of gutters.
• For U.S. installations, the point from where the flue
products exit the heater must be a minimum of 4 ft
below, 4 ft horizontally from, or 1 ft above any door,
window or gravity inlet into any building. The top sur-
face of the heater shall be at least 3 ft above any
forced air inlet, or intake ducts located within 10 ft
horizontally. See Fig. 7
• For installations in Canada, pool heaters shall not be
installed with the top of the vent assembly within 10
ft below, or to either side, of any opening into the
building. Refer to the latest revisions of CAN/CGA-
B149
Outdoor High-Wind Top
High Wind Conditions
(Outdoor Units Only)
In areas where high winds are frequent, it may be nec-
essary to locate the heater a minimum of 3' from high
vertical walls, or install a wind-break so the heater is
not in direct wind current.
In areas of daily high winds, it may be necessary to
replace the outdoor stackless top with a stack adapter
in combination with a wind-resistant/weather-proof
outdoor stack. See Fig. 5.
The outdoor stack serves the same function as the low
profile stackless top and should be installed in accor-
dance with the same clearance requirements. Follow
the installation instructions provided with the High
Wind Kit for installation.
NOTE: The outdoor high-wind top is optional
equipment and does not come standard with the
heater. Use the following part numbers: P/N 004301
(Green), P/N 011558 (Gray)
HIGH-WIND
TOP
Fig. 5: Outdoor High-Wind Top

10
Indoor Installation
The heater is design-certified for indoor installation
when equipped with the approved drafthood.
Locate heater as close as is practical to a chimney or
gas vent. Heater must always be vented to the out-
side. See Vent Piping section for details. Minimum
allowable space is shown on the nameplate. Follow
the installation instructions provided with the Indoor
Drafthood Kit for installation.
Indoor Drafthood
Combustion & Ventilation Air
(Indoor Units Only)
The heater must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are one opening that is 12 inches from the
ceiling for ventilation, and one opening that is 12 inch-
es from the floor for combustion air as outlined in the
latest edition of the National Fuel Gas Code, ANSI
Z223.1(Canada-CAN/CGA-B149) and any local codes
that may have jurisdiction.
NOTE: For Canada, indoor installation is restricted
to an enclosure that is not occupied and does not
directly communicate with an occupied area. Refer
to the latest edition of CAN/CGA-B149 for specific
requirements.
Indoor
Drafthood
Fig. 6: Indoor Drafthood
NOTE: The indoor drafthood is optional equipment
and does not come standard with the heater. Use the
following part number: P/N 003723.
All Air From Inside the Building
ach opening shall have a minimum net free area of
130 sq. in.
All Air From Outdoors
When air is supplied directly from outside of building,
each opening shall have a minimum net free area of
33 sq. in.
Vent Piping
Vent piping the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least 10 ft (drafthood relief opening to vent terminal),
the vent pipe size may be reduced as specified in the
National Fuel Gas Code, ANSI Z223.1 (Canada -
CAN/CGA-B149). As much as possible, avoid long
horizontal runs of vent pipe and too many elbows.
If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 in. per ft rise and should
be supported at not more than five foot intervals.
Plumbers tape, criss-crossed, will serve to space
both horizontal and vertical piping. Gas vents support-
ed only by the flashing and extending above the roof
more than five feet should be securely guyed or
braced to withstand snow and wind loads. We recom-
mend use of insulated vent pipe spacers through the
roof and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which com-
plies with local codes or, in the absence of such codes,
the latest edition of the National Fuel Gas Code, ANSI
Z223.1 (Canada - CAN/CGA-B149).
The discharge opening must be a minimum of 2 ft ver-
tically from the roof surface and at least 2 ft higher than
any part of the building within 10 ft. Vent stack shall be
at least 5 ft in vertical height above the drafthood out-
let. The vent cap location shall have a minimum
clearance of 4 ft horizontally from, and in no case
below, unless a 4 ft horizontal distance is maintained,
from electric meters, gas meters, regulators and relief
equipment.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. Do
not store chlorine, bromine, baquasil or acid in the
same room as the heater.

11
4ft
Minimum
4ft
Minimum
1ft
Minimum
4ft
Minimum
3ft
Minimum
10 ft
Minimum
Forced AirInlet
Fig. 7: Outdoor Installation Clearances
Fig. 8: Vent Piping Requirements
The weight of the vent stack or chimney must not rest
on heater drafthood. Support must be provided in
compliance with applicable codes. The heater top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Type "B" double-wall or equivalent vent pipe is recom-
mended. However single-wall metal vent pipe may be
used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1 (Canada - CAN/CGA-
B149).
Gas Connections
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve locat-
ed outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
CAUTION: Do not use 5, 10 or 20 gallon propane
tanks, like those used with consumer bar-b-ques, to
supply gas to this heater.
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 1/2 psig (3.5 kPa). 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.

12
(field supplied)
(field supplied)
(field supplied)
Fig. 9: Gas Line Sediment Trap
NOTE: Do not use Teflon tape on gas line pipe
thread. A flexible pipe sealant suitable for LP gases
is recommended.
Gas Pressure Regulator
If adjustment is needed, remove seal and turn adjust-
ment screw clockwise to increase pressure or
counter-clockwise to decrease pressure.
Gas Pressure* Natural Gas Propane Gas
Max. Inlet
(static) 10.5 in. WC 13 in. WC
Min. Inlet
(dynamic) 7 in. WC 11 in. WC
Manifold Gas
(dynamic) 3.5 in. WC 10 in. WC
*Static means without heater operating, dynamic refers to heater
operating.
Table D: Gas Pressure
Gas Pressure Adjustment Locations
Gas Pressure Adjustment
A.
Gas Pressure Adjustment
B.
C.
Gas Pressure Adjustment
Fig. 10A: Honeywell DSI VR 8205 Gas Valve
Fig. 10B: Robertshaw MV Gas Valve
Fig. 10C: Honeywell MV Gas Valve

13
Electronic Ignition Gas Valves
Manual
Shut-Off
Valve Manometer
Gas Pressure Test at
Gas Valve
Fig. 11: Location of Gas Pressure Adjustment
Pipe izing for Gas Connections
Water Connections
The heater requires water flow and positive pressure
to fire and 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 directly to the
discharge side of the filter pump;
2. The outlet side of the filter is then plumbed to the
inlet of the heater; and
3. The outlet of the heater is plumbed to the return
line to the pool or spa. The pump, filter and heater
are thus plumbed in series.
Model
No.
Input
( BTU)
1/2 in. 3/4 in. 1 in.
N P N P N P
130A 130 15 35 60 145 200 500
Natural Gas 1000 BTU/FT3 0.60
Specific Gravity @ 0.5 in. WC Pressure Drop
Propane Gas 2500 BTU/FT3 1.53
Specific Gravity @ 0.5 in. WC Pressure Drop
Table E: Maximum Equivalent Pipe Length
Plumbing from the heater back to the pool or spa must
not have any valves or restriction that could prevent
flow when the pump is operating.
Heater must be located so that any water leaks will not
damage the structure of adjacent area. PVC pipe may
be glued directly into optional or field-supplied header
unions.
Flow Rates
Polymer Headers
Before attaching the optional 2-inch unions to the
In/Out header, make sure the O-rings are properly
seated in the grooves. Use AquaLube or equivalent
non-petroleum-based lubricant on the O-ring. Hand
tighten the unions. Glue PVC piping directly to the
unions.
Model No. Min. gpm Max gpm*
130A 20 70
*When flow rates exceed maximum 70 gpm, an external auxiliary
bypass valve is required. See xternal Auxiliary Bypass Valve sec-
tion for details.
Table F: Water Flow Rates
In/Out Header
O-Ring
Tail Piece
Nut
2“ Pipe
Drain Plug
In/Out Header
Hose Connector
Hose
Fig. 12: In/Out Header for 2" Installation
Fig. 13: Optional In/Out Header for 1-1/2"
or 1-1/4" Hose Connection

14
High-temperature CPVC header flanges and header
flange nuts are available as an option. If there is any
possibility of back-siphoning when the pump stops, it
is recommended that a check valve (or valves) also be
installed in the system.
Internal Automatic Bypass Valve
A built-in automatic bypass valve is provided in the
In/Out header. The internal bypass valve automatical-
ly responds to changes in water pressure in the piping
system. The proper amount of water flow is maintained
through the heater under varying pressures dictated
by the conditions of the pump and filter.
External Auxiliary Bypass Valve
An auxiliary bypass valve must be used when flow
rates exceed 70 gpm. Usually a high-performance
pump size larger than one horsepower will exceed this
flow rate. This valve is required to complement the
function of the automatic bypass valve, particularly
when starting the heater in winter or early spring when
the spa or pool temperature is below 50°F. It also
serves to eliminate needless pressure drop through
the heater and accompanying reduction in the flow
rate to the spa jets, etc.
Bypass Disc
Spring
Bypass Body
Fig. 14: Internal Automatic Bypass Valve
From Heater
ToHeater
To Pool/Spa
Bypass Valve
From
Pool/Spa
Full Port
Ball Valve
or Globe
Valve
Fig. 15: Auxiliary Bypass Valve
NOTE: Do not use a gate valve as an auxiliary
bypass valve.
Auxiliary Bypass Valve Adjustment
To set bypass: With clean filter, adjustment is made by
feeling the inlet and outlet pipes at the heater. Outlet
pipes should be slightly warmer than inlet and comfort-
able to the touch. If pipe is hot, close bypass; if cold,
open bypass.
Pressure Relief Valve Installation
To conform to local building codes, it may be neces-
sary to install a pressure relief valve. A 3/4" pressure
relief valve, having a capacity equal to the BTUH out-
put of the heater to be installed, is recommended for
this heater. The maximum pressure relief valve setting
is 125 psi. This relief valve needs to be installed on the
outlet pipe from the header as noted in Fig. 16 below.
Pipe onto Discharge Side of Piping
Fig. 16: Pressure Relief Valve Installed

15
If required, this needs to be installed in a field-supplied
fitting external to the heater. The valve shall be
installed in a vertical position. Do not over-tighten.
Install pressure relief valve hand tight plus 1/2 turn.
Valve lever should be tripped at least once a year to
ensure that waterways are clear. if relief valve does
not function properly, replace it immediately.
Heat Exchanger Pressure Drop
Table
Electrical Connections
Be sure that electrical service to the heater has prop-
er overload fuse or circuit breaker protection, wire size
and connections which comply with all applicable
codes.
Millivolt Heaters
The Millivolt models are equipped with a self-generat-
ing electrical system in which the electrical current is
provided by a pilot generator. No external electrical
connections are required.
WARNING: To avoid water damage or scalding due
to relief valve operation, drain pipe must be
connected to valve outlet and run to a safe place of
discharge. Drain pipe must be the same size as the
valve discharge connection throughout its entire
length and must pitch downward from the valve. No
shut-off valve shall be installed between the relief
valve and the drain line.
Flow (gpm) Pressure Drop (ft of Head)
20 1.3
30 1.7
40 2.0
50 2.7
60 3.5
70 4.2
Table G: 130A Pressure Drop
When installing a remote switch, do not exceed 10 ft of
wiring from the heater. Use 18-gauge stranded wire.
Electronic Heaters
The Direct Spark Ignition Device automatically lights
the main burners upon a call for heat. The heater is
supplied with a dual voltage transformer for 120/240
VAC input power hookup.
Heater must be electrically grounded and bonded in
accordance with local codes, or, in the absence of
local codes, with the latest edition of the National
lectrical Code, ANSI/NFPA 70. (Canada - Canadian
lectrical Code, CSA C22.1, Part 1 and Part 2.)
NOTE: If it is necessary to replace any of the
original wiring, use 105°C wire or its equivalent,
and/or 150°C wire or its equivalent, like the original
wiring. See Figures 19 and 20 for wire ratings.
NOTE: lectronic heaters come standard with a 120
VAC 3-prong power cord. For 240 VAC applications,
see instructions below. Power source must be a
wired ground, with ground fault circuit interruption
circuitry.
Fig. 17: Electronic Heater Power
NOTE: Input power to the heater (120 VAC) can be
supplied from the load (pump) side of time clock or
directly from the GFCI power source. It is preferred
to make connection to the load/pump side of the time
clock.
WARNING: Risk of electrical shock. More than
one disconnect switch may be required to de-
energize the equipment before servicing.
CAUTION: Label all wires prior to disconnection
when servicing controls. wiring errors can cause
improper and dangerous operation.

16
Installation Instructions—240 Volt
1. Disconnect and remove 120 volt power cord.
2. Install wire nut on white transformer wire.
3. Wire nut 240 volt supply lines to the red and black
wire on the transformer.
4. Wire nut green supply ground line to green trans-
former wire
CAUTION: This appliance has provisions to be
connected to an alternate supply source. To reduce
the risk of electric shock, disconnect all connections
before servicing.
240V HOOK-UP
HEATER
L1
L2
RED RED
BLACK
HOT
HOT
BLACK
GREENGREEN
WHITE
SUPPLY
SIDE
Fig. 18: 240V Hook-Up
Control Adjustments—Millivolt
The pool or spa water temperature is controlled by the
thermostat on the upper front panel of the heater. The
control center contains an On/Off toggle switch and a
thermostat. The switch functions as a means for turn-
ing the heater On or Off.
The thermostat is fitted with a means of limiting the
upper temperature limit below the maximum level. The
knob stop adjustment ring shown in Fig. 19 is
adjustable by loosening the set screw, rotating the
knobstop ring to the desired location, and retightening
the set screw.
HOT
COOL
Knobstop Ring
Knobstop Set Screw
Fig. 19: Water Temperature Thermostat
NOTE: Maximum temperature is 104°F.

17
Wiring Diagrams
HI Limit HI Limit
(In/Out) (In/Out)
Thermostat Manual
Switch
Switch Switch
AGS
Water
Press
Gas Valve
Roll Out
Valve
Pilot
Generator
To Firemans Switch
(fieldinstalled)
Optional
BK BK
R
Y/BK
TH/PP
WR
+
-
PP
TH V/BK
V/BK
O
O
Fig. 20: Wiring Diagram—Millivolt Models
Fig. 21: Wiring Diagram—Electronic Models

18
FOR YOUR SAFETY READ BEFORE OPERATING
A. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell near
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. Force 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 technician to inspect the appliance and
to replace any part of the control system and
any gas control which has been under water.
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the burners.
Do not try to light the burners by hand.
5. Remove heater door panel.
6. Turn gas control knob clockwise to
"Off".
7. Wait 5 minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to
the next step.
8. Turn gas control knob counter-clockwise
to "On".
9. Replace heater door panel.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
1. Set the thermostat at the lowest setting.
2. Turn off all the electrical power to the appli-
ance if service is to be performed.
3. Remove heater door panel.
4. Turn gas control knob clockwise
to "Off."
5. Replace heater door panel.
SHUT-OFF PROCEDURES
HONEYWELL
VR 8205 GAS
VALVE
GAS
INLET
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

19
A. This appliance has a pilot that must be lit by
hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTI G, smell all around the
appliance area for gas. Be sure to smell near
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. ever use tools. If the knob will
not push in or turn by hand, do not try to repair
it. Call a qualified service technician. Force or
attempted repair may result in a fire or explo-
sion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified serv-
ice technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been under water.
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On/Off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn
clockwise to "Off".
NOTE:
Knob cannot be turned from "Pilot" to Off"
unless knob is pushed in slightly. Do not
force.
6. Wait 5 minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the
safety information above. If you don't smell
gas, go to the next step.
7. Locate pilot mounted on the right side panel of
the burner tray.
LIGHTING INSTRUCTIONS
8. Turn gas control knob counter-clockwise
to "Pilot"
9. Place flame to end of pilot tube. Push in
control knob all the way and hold to light pilot.
Continue to hold control knob in for about one
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
If knob does not pop up when released, stop
and immediately call your service technician or
gas supplier.
10. Stand to the side of the heater and turn the
gas control knob counter-clockwise
to "On".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
SHUT-OFF PROCEDURE
Gas Pressure
Adjustment
HO EYWELL
MILLIVOLT
GAS VALVE
I VE SYS/
ROBERTSHAW
MILLIVOLT
GAS VALVE
HO EYWELL PILOT ROBERTSHAW PILOT
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.

20
Post tart-Up Inspection
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
With the heater on, remove the door and make a visu-
al check of the pilot and burner. The flame should be
blue with a well-defined pattern.
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact the installer or gas sup-
plier.
WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
to the appliance.
4“ MAX
Fig. 22: Correct Main Burner Flame Pattern
Head of Pilot
must be above
Burner Deck.
Fig. 23: Millivolt Pilot Burner Flame
Igniter
Minimum Spark Gap is 0.15” - 0.18”
3/8” Nominally from burner surface
Fig. 24: DSI Igniter Location
Cold Weather Operation
Moderate Climate
Heater operation can continue during short-term cold
spells. When temperatures are between 0° and 32°F,
flow (continuous pump operation) must be maintained.
Cold Climate
Prolonged operation with water temperatures below
50°F is not recommended. When starting the heater
with water temperatures below 50°F, operate the
heater continuously until higher temperatures are
reached. Operating the heater for prolonged periods
with pool water below 50°F can seriously damage the
heater, and is not covered by the warranty.
For cold climate areas, please follow the winterizing
procedures listed in the next section.
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.