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Raypak Versa 105B Brass Installation And Operating Instructions Manual

Above ground pool and spa heater
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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.
— Do not store or use gasoline or other flammable vapors 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 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 kept in a safe place for future reference.
CATALOG NO. 6100.61E
Effective:
02-01-05
Replaces: 03-01-03
Part No. 240790

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Summary of Contents for Raypak Versa 105B Brass

  • Page 1 INSTALLATION AND OPERATING INSTRUCTIONS Models 105B Brass VERSA ABOVE GROUND POOL 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. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 3: Table Of Contents

    Contents PART ONE - Owner's Operating Instructions SECTION 1 / START-UP PROCEDURES Before Start-Up Lighting Instructions & Shut-Off Procedures (manually lighted pilot MV) Operating Instructions & Shut-Off Procedures (automatically lighted pilot IID) After Start-Up SECTION 2 / CAUTION SECTION 3 / MAINTENANCE & CARE PROCEDURES Pool &...

  • Page 4: Part One - Owner's Operating Instructions

    PART ONE - OWNER'S OPERATING INSTRUCTIONS FOR YOUR SAFETY - READ BEFORE OPERATING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, SECTION 1- START-UP PROCEDURES BEFORE START-UP BURNERS Clean main burners and air louvers of dust, lint and debris.

  • Page 5: (Manually Lighted Pilot Mv)

    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. LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES A. This appliance has a pilot that must be lighted by hand.

  • Page 6: (Automatically Lighted Pilot Iid)

    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. OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES (ELECTRONIC IGNITION SYSTEMS) A. This appliance is equipped with an ignition device which automatically lights the pilot.

  • Page 7: After Start-Up

    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.

  • Page 8: Pool & Spa Water Chemistry

    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.

  • Page 9: Part Two - Installation / Service Instructions

    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.

  • Page 10: Clearances

    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;...

  • Page 11: Combustion Air

    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...

  • Page 12: Venting Connections

    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.

  • Page 13: Vent Piping

    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...

  • Page 14: Gas Supply Connections

    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. Gas Inlet Union Manual Shut Off Valve...

  • Page 15: Plumbing For Water Connections

    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.
  • Page 16 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°...

  • Page 17: Electrical Wiring

    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.
  • Page 18 WIRING DIAGRAM MILLIVOLT UNITS Fig. #2353 If required by local code, install at this location. WIRING DIAGRAM KEY PINK CONNECTOR BLUE CONNECTOR Fig. # 8096...
  • Page 19 WIRING DIAGRAM I.I.D. UNITS IGNITION DEVICE - HONEYWELL Fig. # 9250...
  • Page 20 WIRING DIAGRAM IID UNITS IGNITION DEVICE - ROBERTSHAW Fig. # 9251...

  • Page 21: Section 4 / Servicing Instructions

    SECTION 4 / SERVICING INSTRUCTIONS GENERAL LOCATION OF CONTROLS HIGH LIMITS BYPASS VALVE THERMAL FUSE TRANSFORMER IGNITION CONTROL (IID) BURNERS & PILOT CONTROLS/ADJUSTMENTS/ REPLACEMENTS TEMPERATURE CONTROLS The water temperature is controlled by the heater thermostat on the upper front panel of the heater. The control center contains an On/Off toggle switch and a thermostat.

  • Page 22: High Limit

    PRESSURE SWITCH ADJUSTMENT: 1. With pump and heater on, turn adjustment knob (clockwise) until a click is heard from the gas valve. 2. Turn adjustment knob (counter clockwise) 1/4 turn. 3. Turn pump off and on several times. Heater should shut off immediately. If it does not, repeat steps above until proper adjustment is made.

  • Page 23: Burner Drawer Removal

    BURNER DRAWER REMOVAL 1. Shut off main electrical power switch to heater. 2. Shut off gas upstream of heater. 3. Remove front door. 4. Disconnect gas line from gas valve. 5. Remove (2) screws that mount burner tray to unit. 6.

  • Page 24: Tube Cleaning Procedure

    TUBE REPLACEMENT PROCEDURE On Raypak units, tube replacement may be ef- fected without rolling, as a temporary means of repair, providing there are two or more tubes rolled in to act as stays on the left and right sides.
  • Page 25 CONTROL IMMERSION WELL REPLACEMENT 1. Shut water off to heater and drain heat exchanger. 2. Remove jacket top panel. 3. Remove old control well with bushing and sleeve, with 7/8" wrench or socket. 4. Slip "o" ring gasket over control well and install in header.

  • Page 26: Section 5 / Troubleshooting Guide

    SECTION 5 / TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel 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 licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
  • Page 27 Heater running after pump shuts off... Refractory damage... Sooted heater... RAYPAK POOL OR SPA HEATER ELECTRICAL CHECK WITH MV GAS VALVE CAUTION: For qualified service personnel only. Filter must be on with adequate water flow through heater. Gas valve must be "ON" position. Thermostat set higher than pool water temperature.
  • Page 28 ELECTRICAL (ELECTRONIC IGNITION IID) Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL) SPARK ACROSS IGNITER/SENSOR GAP TURN GAS SUPPLY ON PILOT BURNER LIGHTS? SPARK STOPS WHEN PILOT IS LIT? MAIN BURNER LIGHTS? SYSTEM RUNS UNTIL...

  • Page 29: Section 6 / Replacement Parts

    Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company Freight Prepaid. If determined defective by the Company and within war- ranty, the part will be returned in kind or equal substitution, freight collect.

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