Raypak Versa 105B Brass User manual

CATALOG NO. 6100.61E
Effective: 02-01-05
Replaces: 03-01-03
Part No. 240790
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models
105B Brass
VERSA
ABOVE GROUND POOL
and
SPA HEATER
WARNING: If the information in these instructions are not followed exactly, a fire
or explosion may result causing property damage, personal injury or death.
—WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
—Installation and service must be performed by a qualified installer, service
agency or the gas supplier.
—Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
This manual should be maintained in legible condition and kept adjacent to the
heater or kept in a safe place for future reference.

Contents 4 PART ONE - Owner's Operating Instructions
4 SECTION 1 / START-UP PROCEDURES
4 Before Start-Up
5 Lighting Instructions & Shut-Off Procedures
(manually lighted pilot MV)
6 Operating Instructions & Shut-Off Procedures
(automatically lighted pilot IID)
7 After Start-Up
7 SECTION 2 / CAUTION
7 SECTION 3 / MAINTENANCE & CARE PROCEDURES
8 Pool & Spa Water Chemistry
8 Winterizing the Pool and Spa Heater
9 PART TWO - Installation / Service Instructions
9 SECTION 1 / RECEIVING EQUIPMENT
9 SECTION 2/GENERAL SPECIFICATIONS
9 SECTION 3 / INSTALLATION INSTRUCTIONS
9 Code Requirements
9 Base Installation
10 Clearances
11 Combustion Air
12 Venting Connections
14 Gas Supply Connections
15 Plumbing for Water Connections
17 Electrical Wiring
21 SECTION 4 / SERVICING INSTRUCTIONS
21 General Location of Controls
21 Control Adjustments / Replacements
21 Pressure Switch
22 High Limit
22 Pilot Safety
23 Burner Drawer Removal
23 Gas Valve Removal
23 Main Burner & Orifice Removal
23 Pilot Removal & Cleaning
23 Heat Exchanger Removal
24 Tube Cleaning Procedure
24 Tube Replacement Procedure
24 Desooting Procedure
24 Combustion Chamber Removal
25 Immersion Well Removal
25 Unitherm Governor Removal
26 SECTION 5 / TROUBLESHOOTING GUIDE
26 Mechanical
27 Electrical MV Units
28 Electrical IID Units
29 SECTION 6 / REPLACEMENT PARTS
3

PART ONE - OWNER'S OPERATING INSTRUCTIONS
BEFORE START-UP
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com-
bustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
4
WATER
First thing, insure that system is filled with water and
have pump operating. Water must be flowing through the
heater during operation.
Fig. #9258
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.
SECTION 1- START-UP PROCEDURES

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 clock-
wise 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 drawer. For burner drawer location,
see location of control section, page 18.
HONEYWELL
GAS VALVE
MILLIVOLT
ROBERTSHAW
GAS VALVE
MILLIVOLT
A. This appliance has a pilot that must be lighted by
hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTING smell all around the appli-
ance 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 neigh-
bor's phone. Follow the gas supplier's instruc-
tions.
LIGHTING INSTRUCTIONS
Gas control knobs shown in "Off" position
ROBERTSHAW PILOT HONEYWELL PILOT
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
( MILLIVOLT SYSTEM)
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.
8. Turn knob on gas control counter-clockwise
to "Pilot".
9. Push in control knob all the way and hold in.
Immediately place flame to pilot to light.
Continue to hold control knob in for about 1
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.
*If the pilot does not stay lit after several tries,
turn the gas control knob to "Off" and 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.
Fig. #8084.0 Fig. #8083.0
Fig. #8081.0 Fig. # 8199
TO TURN OFF GAS TO APPLIANCE
*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
underwater. Immediately call a qualified service
technician to inspect the appliance and to re-
place any part of the control system and any gas
control which has been under water.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
5

TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety information above.
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 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 infor-
mation previously stated. 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 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.
Gas control knob shown in "ON" position.
GAS
INLET
OPERATING INSTRUCTIONS
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
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 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 re-
place any part of the control system and any gas
control which has been under water.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
(ELECTRONIC IGNITION SYSTEMS)
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.
4. Turn gas control knob clockwise to "Off".
Make sure knob rest against stop.
5. Replace heater door panel.
1. Set the thermostat at the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
3. Remove heater door panel.
HONEYWELL VR8300 GAS VALVE IID
6

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 valve 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.
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 104°F (40°C). A temperature of 100°F
(38°C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subse-
quently result in drowning.
3. Pregnant women beware! Soaking in water over
102° F (39°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 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
four degrees Fahrenheit (2.2°C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pres-
sure 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 anticoagulants, 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.
1. Inspect top of heater and draft hood for soot, (a
sticky black substance around finned tubes,
baffle and open flue gas passageways).
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
2. Clean main burners and pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve.
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice 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 interrupted. Otherwise,
rapid and severe damage will likely 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 and periodically
checked thereafter. Refer to pressure switch servicing
instruction in Section 4 of this manual.)
WARNING: Operation of the heater without water circu-
lation will cause rapid and severe damage to the
heater.
PILOT BURNER FLAME
Fig. # 8144.1
4" MAX
MAIN BURNER FLAME
Fig. # 8958
7

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 protec-
tion. When heaters are 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 50°F is not recommended. When
starting the heater with pool temperatures below 50°F,
operate the heater continuously until higher tempera-
tures are reached. Operating the heater for prolonged
periods with pool water below 50° can seriously dam-
age the heater, and is not covered by the warranty.
For cold climate areas please follow the winterizing
procedures listed below.
WINTERIZING THE 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)
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is
indicated in the previous illustration. Yellow
flame means restriction of the air openings.
Lifting or blowing flame indicates 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.
5. On indoor heaters, clean room intake openings
to assure adequate flow of combustion and
ventilation air.
CAUTION: Combustion air must not be contaminated
corrosive chemical fumes which can damage the
heater.
6. Keep area around heater clear and free from
combustible materials and other flammable and
corrosive vapors and liquids.
BASIC TIPS IF HEATER WILL NOT FIRE:
1. If you have no electrical power; it may be your
"circuit breakers" have tripped. Try re-setting
them.
2. if you have electrical power but the heater will
not fire
check the following:
3. The time clock must be moved to the "ON"
position.
4. Your pump strainer basket may be full. If so
remove debris.
5. your filter may be dirty. If so, backwash or
clean filter.
(To tell if your filter is dirty, the gauge pressure
will be higher than usual).
6. The pump amy have lost it's prime. It may be
running dry, check the pressure gauge on the
filter. If there is no pressure; then you are not
moving water (or your gauge is broken). Try to
get the pump to run at it's normal flow rate.
POOL & SPA WATER CHEMISTRY
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water chemistry according to the chart on page 2. If the
mineral content and dissolved solids in the water be-
come too high, scale forms inside the heat exchanger
tubes, reducing heater efficiency and also damaging the
heater. If the pH drops below 7.2, the heater will be
severly damaged. This will result in corrosion of the heat
exchanger. Heat exchanger damage resulting from
chemical imbalance is not covered by the warranty.
8
Fig. # 9272
DRAIN VALVE
IN/OUT
HEADER

PART 2 - INSTALLATION / SERVICE INSTRUCTIONS
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 Bill of
Lading when signing for equipment. Remove the heater
from the carton and if it is damaged, report the damage
to the carrier immediately.
On occasion, we ship some items loose. Be sure that
you receive the number of packages indicated on the Bill
of Lading.
When ordering parts, you must specify model and
serial number of heater. When ordering under warranty
conditions, you must also specify date of installation.
The manufacturer recommends 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 factory or your local
representative.
SECTION 2
GENERALSPECIFICATION
These heaters are design certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard / CSA Satndard for gas-fired Pool
Heaters.
The heater is interchangeable 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. Millivolt heaters contain a self-generating
electrical system operating between .25 and .75 volts.
AMBIENTTEMPERATURERATINGOFHEATERCOM-
PONENTS
Millivolt Heater with Honeywell Gas Valve
+32°F to+175°F
Millivolt Heater with Robertshaw Gas Valve
0°F to +175°F
Electronic Ignition Heaters*
-32°F to +175°F
*Requires 120V or 240V power supply
Rated inputs suitable for up to 2000 feet elevation. For
elevations above 2000 feet, reduce input 4% for each
1000 feet above sea level, as high elevation reduces
combustion performance.
SECTION 3
INSTALLATION INSTRUCTIONS
IMPORTANT NOTICE
These instructions are intended for the use of quali-
fied personnel only, specifically trained and experienced
in the installation of this type of heating equipment and
related system components. Installation and service
personnel may be required by some states to be li-
censed. If your state is such, be sure your contractor
bears the appropriate license. Persons not qualified
shall not attempt to fix this equipment nor attempt
repairs according to these instructions.
WARNING: Improper installation, adjustment, altera-
tion, service or maintenance may damage the equip-
ment, create a hazard resulting in asphyxiation, explo-
sion or fire, and will void the warranty.
CODE REQUIREMENTS
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 recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
Installation must be in accordance with local codes,
or, in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70.
BASE INSTALLATION
Heater must be mounted on a level surface. It can
be installed on combustible flooring. Heaters must not
be installed on carpeting.
WARNING: Do not install within 3 feet of a Heat Pump
or an outdoor condensing unit. Strong air intake from
these equipment can disturb the combustion process
and cause damage or personal injury.
9
CALIFORNIA PROPOSITION 65
WARNING:
This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.

CLEARANCES
ALL HEATERS
For clearances from combustible surfaces, see
chart below.
Clearances from Combustible construction.
Indoor Installation:
Top* (Drafthood) - 30"; Vent - 6";
Back - 5"; Right Side - 6";
Left Side - 6"; Floor - 0.
Outdoor Installation:
Top* (Stackless Top) -
unobstructed; Back - 5"; Sides - 6".
* Clearance from Top of Vent Terminal
For servicing, provide at least 24" in front of the
heater for burner tray removal, and at least 18" on the left
side of the heater to inspect and delime the heat
exchanger.
10
OUTDOORHEATERS
These heaters are design certified for outdoor
installation, when equipped with the approved top des-
ignated 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 louvers and into the
heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.
Heaters must not be installed under an overhang of less than three (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 four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the heater
shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally.
Heater with outdoor top Fig # 9259
4 foot
Minimum
4 foot
Minimum
1 foot
Minimum
4 foot
Minimum
3 foot
Minimum
10 foot
Minimum
Forced Air Inlet

HIGH WIND CONDITIONS
(OUTDOOR UNITS ONLY)
In areas where high winds are frequent, it may be
necessary 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 illustration below.
The outdoor stack serves the same function as the
low profile stackless top and should be installed in
accordance with the same clearance requirements.
11
INDOORHEATERS
The design is certified for indoor installation when
equipped with the approved draft hood. Locate heater as
close as practical to a chimney or gas vent. Heater must
always be vented to the outside. See Vent Piping Section
for venting details. Minimum allowable space is shown on
the nameplate.
COMBUSTION AIR (INDOOR UNITS ONLY)
Air For combustion And Ventilation
(Indoor Units Only)
The heater must have both combustion and venti-
lation air. Minimum requirements for net free air supply
openings, one 12 inches from ceiling for ventilation and
one 12 inches from the floor for combustion air as outlined
in the latest edition of the National Fuel Gas Code, Z223.1
and any local codes that may have jurisdiction.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater.
a. All Air From Inside The Building:
Each opening shall have a minimum of 105 net free
square inches.
b. All Air From Outdoors:
When air is supplied directly from outside of
building, each opening shall have a minimum of 27
net free square inches.
STACK ADAPTER
OUTDOORSTACK
Fig # 9253
INDOORTOP
Fig # 9254

VENTING CONNECTIONS
VENT TERMINAL (Outdoor) STACKLESS TOP
STEP 1: Remove the (4) screws which fasten
jacket top to heater.
STEP 2: Lower outdoor top onto unit lining up
slots in outdoor top with screw holes in
jacket top.
STEP 3: Reinstall (4) screws to secure jacket top
and outdoor top to unit.
VENT TERMINAL (Outdoor) OUTDOOR STACK
STEP 1 Line up (8) holes in jacket top with (8) holes
in adapter assembly.
STEP 2 Lower entire outdoor stack assembly on to
jacket top.
STEP 3 Secure with fasteners provided.
12
VENT TERMINAL (Indoor)
Locate and assemble as shown. Secure with
screws supplied in envelope inside carton.
OUTDOORTOP
JACKET TOP
MOUNTING
SCREWS (4)
Fig # 9255
OUTDOOR
STACK
W/ADAPTER
Fig # 9256
MOUNTING
SCREWS (8)
JACKET
TOP
MOUNTING
SCREWS (8)
JACKET
TOP
DRAFTHOOD
Fig # 9257

VENT PIPING
WARNING: Indoor boilers require a draft hood that must
be connected to a vent pipe and properly vented to the
outside. Failure to follow this procedure can cause fire or
fatal carbon monoxide poisoning.
Vent piping the same size or larger than the draft
hood outlet is recommended, however, when the total
vent height is at least ten (10) feet (draft hood relief
opening to vent terminal), the vent pipe size may be
reduced as specified in Chapter 10 of the National Fuel
Gas Code, ANSI Z 223.1. As much as possible avoid long
horizontal runs of vent pipe and too many elbows. If
installation requires horizontal non-vertical runs, the vent
pipe must have a minimum of 1/4 inch per foot rise and
should be supported at not less than five foot intervals.
Plumbers tape, crisscrossed, will serve to space both
horizontal and vertical piping. Gas vents supported 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 recommend use of insulated
vent pipe spacer through the roofs and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies
with the local codes or, in the absence of such codes, to
the latest edition of the National Fuel Gas Code, ANSI Z
223.1.
The discharge opening must be a minimum of two
feet vertically from the roof surface and at least two feet
higher than any part of the building within ten feet. Vent
stack shall be at least five feet in vertical height above the
draft hood outlet. The vent cap location shall have a
minimum clearance of 4 feet horizontally from, and in no
case above or below, unless a 4-foot horizontal distance
is maintained, from electric meters, gas meters regula-
tors and relief equipment.
The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from supported to
maintain proper clearances from combustible construc-
tion.
Type "B" double wall or equivalent vent pipe is
recommended. However single wall metal vent pipe may
be used as specified in the latest edition of the National
Flue Gas Code ANSI Z 223.1.
Fig. # 8119
13

GAS SUPPLY CONNECTIONS
Gas piping must have a sediment trap ahead of
the heater gas controls, and 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 1/2 psig (3.45 KPA). 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 PRES-
SURED GAS VALVES ARE NOT COVERED BY
WARRANTY. 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 teflon tape on gas line pipe thread.
A flexible sealant is recommended.
A minimum of 7" W.C. and a maximum of 14" W.C.
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 12"
W. C. and a maximum of 14" for propane gas.
GAS PRESSURE REGULATOR
The gas pressure regulator is preset and sealed at
4" W.C. for natural gas, and ll" W. C. for propane gas.
Between the gas valve and the burners is a l/8" pipe
plug. The pressure at this point, taken with a manome-
ter, should be about 3.7" W. C. natural gas and l0.5"
W.C. propane gas. If an adjustment is needed, remove
seal and turn adjustment screw clockwise to
increase pressure or counter-clockwise to
decrease pressure.
PIPE SIZING FOR GAS CONNECTIONS
MAXIMUM EQUIVALENT PIPE LENGTH
Natural Gas 1000 BTU/ FT . 60 Specific Gravity
@ 0.5" WC Pressure Drop
Propane Gas 2500 BTU/ FT l.53 Specific Gravity
@ 0.5" WC Pressure Drop
1/2" 3/4"
MODEL N P N P
105B 25 55 95 200
3
3
Manual Shut Off
Valve
Sediment Trap
Fig. # 9434
ROBERTSHAW MV
Gas Pressure Adjustment
Fig. # 9263
HONEYWELL VALVE MV
Gas Pressure Adjustment
HONEYWELL IID
VR 8300 GAS VALVE
Gas Pressure Adjustment
Fig. # 9265
14
Fig. # 9264
Gas Inlet
Heater Jacket
Union

PLUMBING FOR WATER CONNECTIONS
LOCATION
The VERSA 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.
Plumbing from the heater back to the pool must not have
any valves or restriction that could prevent flow when the
pump is operating. To do so will void the warranty.
FLOW RATES
MIN.GPM: 20, MAX.GPM: 115*
*When flow rates exceed 115 GPM an external auxiliary
bypass valve is required. See External Auxiliary Bypass
Valve section for details.
15
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.
PREMIUMBRONZEHEADER
The inlet/outlet single header flanges are designed for four
type of water connections. There are two sets of flange
gaskets supplied with your header; one set installed,
between flanges and in/out header, and the other set
shipped loose in the unit. Use the appropriate gasket
design, for all your heater connections.
GASKET DESIGN #1: (Factory Installed) Accepts
1-1/2" copper tube or 1-1/4" galvanized pipe as a slip
connections.
GASKET DESIGN #2: (Loose in a Bag) 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.
#1 #2
Fig. #8095.1 Fig. # 8097.1
INLET/OUTLETHEADER
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
All chemicals must be introduced and completely
diluted into the pool or spa water before being circulated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
trations 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 chemical back-
up into the heater when the pump is shut off.
Fig # 9272
FLANGE GASKET
HEADER FLANGE
Fig # 9273
CAUTION: NEVER install PVC directly in header
flanges. Use the 2" CPVC adapter (supplied by others).
NOTE: If 2" piping is used in the heater, this piping must
be anchored (copper) or screwed into the flange (metal)
if operating pressures above 30 PSI are encountered.
CAUTION: Never install PVC directly in header flanges.
The initial connection must be made with high
temperature materials such as CPVC or copper.
For IID pilots: PVC may be utilized immediately after the
initial connections.
For Standing pilots: Copper or high temperature CPVC
pipe and two elbows are required between the heater and
the PVC connections (heat sinks not supplied).
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 colored
gray. PVC may be used immediately after the CPVC
adapters.
INLET/OUTLET HEADER
2" CPVC Adapters
(supplied by others)

EXTERNAL AUXILIARY BYPASS VALVE
(Where required)
An auxiliary bypass valve should be used when flow
rates exceed 115 GPM (usually a high performance
pump size larger than 2 HP 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 down below 55°F. It also serves to
eliminate needless pressure drop through the heater and
accompanying reduction in the flow rate to the spa jets,
etcetera.
From Heater To Heater
To Pool From Pool
Auxiliary Bypass Valve (do not use gate 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.
INTERNAL AUTOMATIC BY-PASS VALVE
A built-in automatic by-pass valve is provided in the
in/out header. 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.
Fig. # 8078.0
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 BTU/HR output of the
model to be installed is recommended for this appliance.
A 3/4" NPT connection is provided in the inlet/outlet
header for installation of a pressure relief valve. The valve
shall be installed in a vertical position.
PRESSURE RELIEF
VALVE
PRV
DISCHARGE
CONNECTION
INLET/OUTLETHEADER
Fig. # 8095.0
NOTE: To avoid water damage or scalding due to 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. Valve lever
should be tripped at least once a year to ensure that
waterways are clear.
Fig. # 8150.
NOTE: High chemical concentration 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.
UNITHERM GOVERNOR OPERATION
(PREMIUM BRONZE HEADERS ONLY)
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain constant
heater internal temperature between 105° - 115°F despite
continually changing flow rates from the filter and chang-
ing 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 100°F.
It is also needed to inhibit scale formation in the tubes by
maintaining temperatures well below accelerated scaling
temperatures.
16

ELECTRICAL WIRING
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105 °C wire or its
equivalent, except all black wire must be replaced with
150 °C wire or its equivalent.
MILLIVOLT SYSTEM
The Millivolt System Residential Heater is equipped
with a self-generating electrical system in which the
electric current is provided by means of a pilot generator.
No external electrical connections are required.
When installing a remote switch, do not exceed 10
feet of wiring from the heater. Use 18 gage stranded wire.
ELECTRONIC INTERMITTENT IGNITION DEVICE
SYSTEM (IID)
NOTE: When the electrical hookup to the heater
requires both 24V and 115V or 240V, each input
voltage must be isolated in separate conduit.
The Electronic Intermittent Ignition Device automati-
cally lights the pilot and main burners upon a call for the
heat. The heater is supplied with a dual voltage trans-
former for 120V or 240V input power hookup.
NOTE: IID Propane Units Only
Heater is equipped with an electronic ignition device with
a 100% safety lockout feature. If the heater fails to start
or lockout. Reset the ignition device by interrupting the
power to the heater for 60 seconds.
CAUTION: If service replacement of the electronic igni-
tion device is required. Replace only with a 100% safety
lockout device with 90 second trial for pilot ignition.
17
Fig. # 8929.1
Robertshaw Intermittent
Ignition Device
Honeywell Intermittent
Ignition Device
Fig. # 8085
For 120 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the
white wire to the “L2” or neutral leg of the power supply.
Attach the wire nut to the red wire. There should be no
connection to the red wire for 120V operation.
Fig. #9240
For 240 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the
red wire to the “L2” or second hot leg of the power supply.
Attach the wire nut to the white wire. There should be no
connection to the white wire for 240V operation.
Fig. # 9241
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 Electrical
code, ANSI/NFPA 70.
NOTE: Input power to the heater (120/240V) should be
supplied from the load (Pump) side of time clock or
switch. Connecting heater to continuous power source
will allow "Fail" indications (service and pressure switch)
when pump is not operating.

18
WIRING DIAGRAM MILLIVOLT UNITS
Fig. #2353
WIRING DIAGRAM KEY
Fig. # 8096
PINK CONNECTOR BLUE CONNECTOR
*
* If required by local code, install at this location.

WIRING DIAGRAM I.I.D. UNITS
IGNITION DEVICE - HONEYWELL
Fig. # 9250
19

WIRING DIAGRAM IID UNITS
IGNITION DEVICE - ROBERTSHAW
Fig. # 9251
20