STA-RITE SR200NA Service Manual
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STA-RITE SR200NA Service Manual

Pool/spa heater
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See the inside of the front cover to determine if a heater is single voltage (115VAC –
built prior to 4/27/04) or dual voltage (120/240 VAC – built 4/27/04 or after.)
Sta-Rite Pool/Spa
Heater Training and
Service Manual
Section 1:
Section 2:
Section 3:
Section 4:
Section 5:
Section 6:
Section 7:
NOTICE:
SR200NA / SRC200NA
SR200LP / SRC200LP
SR333NA / SRC333NA
SR333LP / SRC333LP
SR400NA / SRC400NA
SR400LP / SRC400LP
Design and Function
Installation
Operation
Component Description
Repair Parts List
Glossary
Troubleshooting
Models
SR400HD
S5066 (Rev. 8/20/04)

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Summary of Contents for STA-RITE SR200NA

  • Page 1 Sta-Rite Pool/Spa Heater Training and Service Manual Models SR200NA / SRC200NA SR200LP / SRC200LP SR333NA / SRC333NA SR333LP / SRC333LP SR400NA / SRC400NA SR400LP / SRC400LP SR400HD Section 1: Design and Function Section 2: Installation Section 3: Operation Section 4:...
  • Page 2 IMPORTANT To determine if a heater is single voltage (115VAC – manufactured before 4/27/04) or dual voltage (120/240VAC – manufactured on or after 4/27/04), shut off power to the heater, remove the heater covers and open the control box. 12-Pin Plug D D D D u u u u a a a a l l l l V V V V o o o o l l l l t t t t a a a a g g g g e e e e C C C C o o o o n n n n t t t t r r r r o o o o l l l l B B B B o o o o x x x x .
  • Page 3 1 1 1 1 - - - - 8 8 8 8 0 0 0 0 0 0 0 0 - - - - 7 7 7 7 5 5 5 5 2 2 2 2 - - - - 0 0 0 0 1 1 1 1 8 8 8 8 3 3 3 3 For further information or assistance, call Sta-Rite customer service at...
  • Page 4 SECTION ONE – Heater Design and Function Heater Main Systems The Heater Has NOTE: All heaters built prior Three Main Systems: to 4/27/04 are single voltage • The E E E E l l l l e e e e c c c c t t t t r r r r i i i i c c c c a a a a l l l l S S S S y y y y s s s s t t t t e e e e m m m m (115VAC).

  • Page 5: Operating Control

    SECTION ONE – Heater Design and Function Operating Control Digital Temperature Display LOW SPEED BOOSTER PUMP HIGH SPEED Temperature Up/Down System Operation FILTER Indicator Lights PUMP Dual Temperature Controls Figure 1-3: Control Board / Membrane Pad The heater is operated through an externally mounted INDICATOR Operating Control Center.
  • Page 6 SECTION ONE – Heater Design and Function Electrical Flow Through the Heater PI LO 9 10 Figure 1-4: Electrical Flow 1. The T T T T h h h h e e e e r r r r m m m m i i i i s s s s t t t t o o o o r r r r senses the inlet water temperature. 10.
  • Page 7 SECTION ONE – Heater Design and Function Gas and Air Flow Through the Heater Exhaust Figure 1-5: Air and Gas Flow 1. The Blower draws ambient air into the Burner S S S S a a a a f f f f e e e e t t t t y y y y P P P P r r r r e e e e c c c c a a a a u u u u t t t t i i i i o o o o n n n n s s s s : : : : System by negative pressure through the A A A A i i i i r r r r O O O O r r r r i i i i f f f f i i i i c c c c e e e e .
  • Page 8 SECTION ONE – Heater Design and Function Water Flow Through the Heater Inlet (Cold Water) Primary Heating Coils Outlet Secondary (Warm/ Heating Mixed Coils Water) Figure 1-6: Water Flow S S S S a a a a f f f f e e e e t t t t y y y y P P P P r r r r e e e e c c c c a a a a u u u u t t t t i i i i o o o o n n n n s s s s : : : : 1.
  • Page 9 SECTION ONE – Heater Design and Function Section Review In this section you learned the basic components and operation of the Sta-Rite Pool/Spa Heater. Use this Section Preview to review the main points covered in Section One. Name the three main systems of the heater.

  • Page 10: Heater Installation

    G G G G a a a a s s s s C C C C o o o o n n n n n n n n e e e e c c c c t t t t i i i i o o o o n n n n s s s s General Requirements for Heater Models SR200NA, SRC200NA, SR333NA, SRC333NA, SR400NA, SR400HD, and SRC400NA, Installation leave the factory equipped to use natural gas.

  • Page 11: Typical Installation

    N N N N O O O O T T T T E E E E that the heater is downstream from the filter. The Sta-Rite heater is available in three input ratings: Also, the Chemical Feeder (Sanitizer) should be...

  • Page 12: Installation Procedures

    SECTION TWO – Heater Installation Installation Procedures 4' Min. 4' Min. 4' Min. 1' Min. Forced Air 3' Minimum clearance if Inlet horizontal distance to exhaust opening is less than 10 feet. Figure 2-2: Clearance From Building Openings - U.S. Heater Placement and Clearances 3' (1M) or more...
  • Page 13 SECTION TWO – Heater Installation Heater Placement, Clearances, and Venting Orient the heater for convenient access to the water Outdoor Installation connections and to the gas and electrical connections (below the vent terminal). If the heater is located under a roof or deck overhang, The exhaust discharges vertically from the vent.
  • Page 14 SECTION TWO – Heater Installation Heater Placement, Clearances, and Venting I I I I n n n n s s s s t t t t a a a a l l l l l l l l a a a a t t t t i i i i o o o o n n n n i i i i n n n n a a a a G G G G a a a a r r r r a a a a g g g g e e e e o o o o r r r r U U U U t t t t i i i i l l l l i i i i t t t t y y y y R R R R o o o o o o o o m m m m Indoor (U.S.) and Outdoor Shelter (Canada) Installation Risk of fire and explosion if installed at...

  • Page 15: Combustion And Ventilation Air Supply

    SECTION TWO – Heater Installation Heater Venting V V V V e e e e n n n n t t t t i i i i n n n n g g g g I I I I n n n n d d d d o o o o o o o o r r r r a a a a n n n n d d d d O O O O u u u u t t t t d d d d o o o o o o o o r r r r S S S S h h h h e e e e l l l l t t t t e e e e r r r r The minimum net free area in square inches shall be I I I I n n n n s s s s t t t t a a a a l l l l l l l l a a a a t t t t i i i i o o o o n n n n s s s s –...
  • Page 16 To connect a negative pressure metal gas vent to the heater, order the appropriate Metal Flue Collar from thechart below: Clean the Interior Surface Metal Flue Collar Kit Sta-Rite Part No. Vent Body 4" x 8" Metal 4x6” 77707-0076 Flue Collar 4x8”...
  • Page 17 SECTION TWO – Heater Installation Heater Venting – Negative Pressure 2. Install the metal Flue Collar in the Vent Body of 4. Install vent pipe so that it can expand and contract the heater (located under the outside vent cover). freely as the temperature changes.
  • Page 18 SECTION TWO – Heater Installation Heater Venting – Negative Pressure Table 2-F: Vent Termination Height Listed vs. Roof Pitch - U.S. Termination Min. 2 Ft. Minimum Height Min. 10 Ft. (3.3 M) (.7 M) Roof Pitch Above Roof* Storm Collar Flat to 6/12 1 Ft.
  • Page 19 M M M M e e e e t t t t a a a a l l l l l l l l i i i i c c c c : : : : Clean the Interior Surface 1. Order an Appliance Adapter Kit: Vent Body Sta-Rite Part No. 77707-0086 for Saf-T Vent Clean and RTV ® This Surface Saf-T Vent ®...
  • Page 20 SECTION TWO – Heater Installation Heater Venting – Positive Pressure wipe the cleaned surfaces dry with a clean cloth or sate drains at low points where condensate might paper towel. Repeat for the exterior of the heater collect. Plumb condensate drains to a drain end of the Appliance Adapter.
  • Page 21 SECTION TWO – Heater Installation Heater Venting – Positive Pressure • at least 4 feet below or horizontally from, or 1 foot above, any doors or windows or gravity air inlet to Metal Special Support a building. Gas Vent weight requires •...

  • Page 22: Pressure Testing

    Sta-Rite conversion kit. 4. Do not use any orifices other than Sta-Rite Pressure Testing replacement orifices. Before operating the heater, test all gas connections for 5.

  • Page 23: Power Supply Requirements

    SECTION TWO – Heater Installation Heater Electrical Connections on the outside of the jacket under the junction box Power Supply Requirements for this purpose. 3. Electrical power circuits to the pool heater must fol- Heaters built before 4/27/04 require a line voltage sup- low local codes and National Electrical Code or ply of 115-120 VAC, single-phase, 60 Hz.
  • Page 24 SECTION TWO – Heater Installation Heater Electrical Connections F F F F i i i i r r r r e e e e m m m m a a a a n n n n ’ ’ ’ ’ s s s s S S S S w w w w i i i i t t t t c c c c h h h h / / / / R R R R e e e e m m m m o o o o t t t t e e e e 4.
  • Page 25 SECTION TWO – Heater Installation Heater Water Connections P P P P r r r r e e e e s s s s s s s s u u u u r r r r e e e e R R R R e e e e l l l l i i i i e e e e f f f f V V V V a a a a l l l l v v v v e e e e C.
  • Page 26 SECTION TWO – Heater Installation Heater Water Connections P P P P r r r r e e e e s s s s s s s s u u u u r r r r e e e e S S S S w w w w i i i i t t t t c c c c h h h h S S S S e e e e t t t t t t t t i i i i n n n n g g g g s s s s : : : : W W W W a a a a t t t t e e e e r r r r P P P P i i i i p p p p i i i i n n n n g g g g S S S S p p p p e e e e c c c c i i i i f f f f i i i i c c c c a a a a t t t t i i i i o o o o n n n n s s s s The water Pressure Switch turns off the burner if the The heater is designed to be connected directly to...
  • Page 27 12%; at 5,000 feet eleva- Inlet from tion, derate the heater 20%. If local authorities allow it, Filter the Sta-Rite heater only requires to be derated 1.7% per 1,000 feet above sea level. Figure 2-18: Manual Bypass Valve 2-18...
  • Page 28 SECTION TWO – Heater Installation Winterizing W W W W i i i i n n n n t t t t e e e e r r r r i i i i z z z z i i i i n n n n g g g g the pool, install a drain cock in the outlet pipe to (See Figure 2-19) drain the manifold.
  • Page 29 SECTION TWO – Heater Installation Post Installation Checklist / Section Review Respond to the following statements: Post Installation Checklist Adraft hood is required for indoor heater installation. ___1. Is the heater correctly grounded and bonded? Yes _____ No _____ ___2. Is the heater rated for the correct fuel (natural or LP gas) for the installation? Before operating the heater, the heater and its gas con- ___3.
  • Page 30 SECTION TWO – Heater Installation Section Review The pressure switch must be adjusted when a heater is Which of the following outdoor heater installation mounted more than ______ below deck level. guidelines is incorrect? ____ 2 feet (.67 M) ____ Allow a 6-inch (15 cm)clearance above the heater.

  • Page 31: Important Safety Precautions

    SECTION THREE – Heater Operation Important Safety Precautions Cold Weather Operation Important Safety Precautions Follow the instructions below before operating or ser- The heater may be operated in the wintertime, provid- vicing the heater. ed air temperatures remain above freezing and the water temperature is not permitted to drop below 65°F.

  • Page 32: Turning Off Gas To The Heater

    SECTION THREE – Heater Operation Operating Instructions 8. Turn the Gas Control Knob counterclockwise to the Indexing Point ON position. On newer models, throw the ON-OFF toggle to ON. Gas control is shown OFF. 9. Replace and bolt together both halves of the Jacket Turn Counter-clockwise and release to turn gas on.

  • Page 33: Preliminary Checklist

    SECTION FOUR – Routine Maintenance and Professional Servicing Routine Maintenance and Professional Servicing c. Raise the temperature on the Operating Control Preliminary Checklist Panel to turn on the Burner. d. Wait 1 minute. The Burner should not come on. If Complete the following checklist before servicing the the Burner or Blower does come on at this point, heater.
  • Page 34 SECTION FOUR – Routine Maintenance and Professional Servicing Servicing the Heater Control Board - Operating Control Operating Control Heater Display Cover P/N 42001-0008S Membrane Pad (Included with Kit No. 77707-0004) Control Board Enclosure Kit P/N 77707-0004 Control Board P/N 42001-0096S Index Plate Wiring Harness Not Shown...
  • Page 35 SECTION FOUR – Routine Maintenance and Professional Servicing Transformer Transformer P IL P/N 42001-0057S 2685 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n The Transformer is located on the back of the Control Box.
  • Page 36 SECTION FOUR – Routine Maintenance and Professional Servicing Thermistor Thermistor P IL P/N 42001-0053S 2653 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 3.

  • Page 37: Ignition Control Module

    Risk of control malfunction, overheat- Hazardous voltage. Both the Control Box only ing, possible fire or explosion. Use Sta-Rite and the Ignition Control Module contain line voltage. parts when replacing the Ignition Control Module. Disconnect the heater from the main power source...

  • Page 38: Water Pressure Switch

    SECTION FOUR – Routine Maintenance and Professional Servicing Water Pressure Switch Water Pressure Switch P IL P/N 42001-0060S 2656 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 6.

  • Page 39: High Limit Switch

    SECTION FOUR – Routine Maintenance and Professional Servicing High Limit Switch High Limit Switch P IL P/N 42001-0063S 2654 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 3.
  • Page 40 SECTION FOUR – Routine Maintenance and Professional Servicing Automatic Gas Shutoff (AGS) Switch Automatic Gas Shutoff (AGS) Switch Yellow dot indicates that switch opens at 140° F PI LO 42002-0025S 2655 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 3.

  • Page 41: Air Flow Switch (Afs)

    SECTION FOUR – Routine Maintenance and Professional Servicing Air Flow Switch (AFS) Air Flow Switch P IL P/N 42001-0061S 2657 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n The Air Flow Switch (AFS) is fastened to the Control Box.
  • Page 42 SECTION FOUR – Routine Maintenance and Professional Servicing Stack Flue Sensor / Stack Flue Switch Stack Flue Stack Flue Sensor (SFS) Switch (ES2) P/N 42002-0024S P/N 42001-0062S (Obsolete) 3701 0600 See Page 4-41 for Retrofit Probe Information L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 2.
  • Page 43 3. Release the button and then press it momentarily. The may correct itself. If not, call 3-digit display will now show either “SF0” or “SF1”. Sta-Rite Pool Customer Service. 250-290° F Low – Check thermal regulator; 4. Use the arrow buttons on the membrane pad to set (121-143°...

  • Page 44: Combustion Air Blower

    SECTION FOUR – Routine Maintenance and Professional Servicing Combustion Air Blower Combustion Blower P IL P/N 42001-0206S 2658 1096 P P P P r r r r e e e e s s s s s s s s u u u u r r r r e e e e D D D D i i i i f f f f f f f f e e e e r r r r e e e e n n n n t t t t i i i i a a a a l l l l The Burner System includes the Combustion Air M M M M o o o o d d d d e e e e l l l l M M M M i i i i n n n n i i i i m m m m u u u u m m m m ( ( ( ( i i i i n n n n W W W W .
  • Page 45 Steps 1 through 7 above. See the following NOTE. Sta-Rite part. Do not modify it or try to use a different N N N N O O O O T T T T E E E E : : : : When replacing or reassembling the orifice/grille.
  • Page 46 SECTION FOUR – Routine Maintenance and Professional Servicing Combination Gas Control Valve Combination Gas Valve P IL P I L P/N 42001-0051S 2659 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n Replacing the Combination Gas Control Valve: 1.
  • Page 47 SECTION FOUR – Routine Maintenance and Professional Servicing Combination Gas Control Valve NOTE: The gas piping and unions have been omitted for clarity; make this test with all gas piping connected (as for normal service). To Air Flow Switch To Air Flow Switch To High Side of Differential...
  • Page 48 SECTION FOUR – Routine Maintenance and Professional Servicing Combination Gas Control Valve (Continued from the preceding page) NOTE: The gas piping and unions have been omitted for clarity; make this test with all gas piping connected (as for normal service). To Air Flow Switch To Air Flow...

  • Page 49: Gas Orifice

    S S S S a a a a f f f f e e e e t t t t y y y y P P P P r r r r e e e e c c c c a a a a u u u u t t t t i i i i o o o o n n n n s s s s : : : : are installing a heater labeled for natural gas, but the supply is Propane (or vice versa), use a Sta-Rite con- version kit to convert the heater to the available fuel Risk of fire or explosion.
  • Page 50 If the air/gas ratio is not correct, or if you are getting 7. Install the O-Ring on the adjustment orifice. Verify any of the indications of poor combustion, call Sta-Rite the correct size of the orifices included in your kit Customer Service at 1-800-752-0183 for information (see instructions included with kit).

  • Page 51: Hot Surface Igniter

    SECTION FOUR – Routine Maintenance and Professional Servicing Hot Surface Igniter Igniter P/N 77707-0054 includes Igniter and Gasket Igniter Bracket P/N 42001-0030S Igniter P/N 42001-0054 Igniter Gasket P/N 42001-0066S (Not shown) 2664 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 6.
  • Page 52 SECTION FOUR – Routine Maintenance and Professional Servicing Flameholder/Burner Flameholder Kit SR200 Series: P/N 77707-0202 SR333 Series: P/N 77707-0203 SR400 Series: P/N 77707-0204 Flameholder Flameholder Flameholder Insert 2667 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 3.
  • Page 53 SECTION FOUR – Routine Maintenance and Professional Servicing Inlet/Outlet Manifold (Heaters built after 3/15/01) Inlet/Outlet Manifold Assembly P IL P/N 77707-0206 2662 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n T T T T h h h h e e e e T T T T h h h h e e e e r r r r m m m m a a a a l l l l R R R R e e e e g g g g u u u u l l l l a a a a t t t t o o o o r r r r S S S S p p p p r r r r i i i i n n n n g g g g i i i i s s s s b b b b e e e e h h h h i i i i n n n n d d d d The inlet and outlet piping is connected to the t t t t h h h h e e e e p p p p l l l l u u u u g g g g a a a a n n n n d d d d w w w w i i i i l l l l l l l l c c c c a a a a u u u u s s s s e e e e t t t t h h h h e e e e p p p p l l l l u u u u g g g g t t t t o o o o f f f f l l l l y y y y i i i i f f f f n n n n o o o o t t t t r r r r e e e e s s s s t t t t r r r r a a a a i i i i n n n n e e e e d d d d .
  • Page 54 SECTION FOUR – Routine Maintenance and Professional Servicing Inlet/Outlet Manifold (Heaters built after 3/15/01) 4. Clean the tube-sheet and O-Ring sealing surfaces as shown in Figure 4-2. Clean the tube sheet and O-ring sealing surface with a nylon brush, then brighten the tube sheet surface with 320 grit emery cloth.
  • Page 55 SECTION FOUR – Routine Maintenance and Professional Servicing Inlet/Outlet Manifold (Heaters built after 3/15/01) Models SR200/SRC200 Short Bolt Placement Thermistor 2-3/4" 2-3/4" 2-1/2" 2-1/2" 2-3/4" 2-3/4" Models SR400/SRC400 Short Bolt Placement 4071 0901WC Figure 4-5 Safety switch locations on the one-piece manifold.
  • Page 56 SECTION FOUR – Routine Maintenance and Professional Servicing Inlet/Outlet Manifold (Heaters built before 3/15/01) Inlet/Outlet Manifold Assembly P IL P/N 42001-0207 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 4.
  • Page 57 SECTION FOUR – Routine Maintenance and Professional Servicing Thermal Regulator (All Heaters) Thermal Regulator Kit PI LO Rotate regulator until moving parts clear the flat side P/N 77707-0010 of the hole (Plug only) 2660 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n T T T T h h h h e e e e T T T T h h h h e e e e r r r r m m m m a a a a l l l l R R R R e e e e g g g g u u u u l l l l a a a a t t t t o o o o r r r r S S S S p p p p r r r r i i i i n n n n g g g g i i i i s s s s b b b b e e e e h h h h i i i i n n n n d d d d The Thermal Regulator is located behind the threaded t t t t h h h h e e e e p p p p l l l l u u u u g g g g a a a a n n n n d d d d w w w w i i i i l l l l l l l l c c c c a a a a u u u u s s s s e e e e t t t t h h h h e e e e p p p p l l l l u u u u g g g g t t t t o o o o f f f f l l l l y y y y i i i i f f f f n n n n o o o o t t t t...
  • Page 58 SECTION FOUR – Routine Maintenance and Professional Servicing Internal Bypass Valve (Heaters built before 3/15/01) Internal Bypass Valve Kit P/N 77707-0001 Spring Retainer P/N 42001-0015 PI LO Spring P/N 37607-0010 Separator Plate P/N 42001-0011 Bypass Valve Poppet P/N 42001-0014 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 5.
  • Page 59 SECTION FOUR – Routine Maintenance and Professional Servicing Manifold Adapter (Obsolete) Manifold Adapter Kit PI LO P/N 42001-0117S (200K) P/N 42001-0118S (333K) P/N 42001-0119S (400K) L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n 4.

  • Page 60: Heat Exchanger

    SECTION FOUR – Routine Maintenance and Professional Servicing Heat Exchanger Tube Sheet Coil Assembly Kit SR/SRC200 Series: P/N 77707-0232 SR/SRC400 Series: P/N 77707-0234 SR/SRC333 Series: P/N 77707-0233 SR400HD Series: P/N 77707-0244 Heat Exchanger 2666 1096 L L L L o o o o c c c c a a a a t t t t i i i i o o o o n n n n For a complete inspection of the Heat Exchanger, remove it from the unit.
  • Page 61 SECTION FOUR – Routine Maintenance and Professional Servicing Heat Exchanger (Continued from the preceding page) N N N N O O O O T T T T E E E E : : : : When replacing the Heat Exchanger: 5.

  • Page 62: Control Board

    SECTION FOUR – Routine Maintenance and Professional Servicing Control Board Plug 6-pin connector in here CR21 F F F F u u u u n n n n c c c c t t t t i i i i o o o o n n n n tiates a 20-second heating cycle of the hot surface igniter (HSI).
  • Page 63 SECTION FOUR – Routine Maintenance and Professional Servicing Schematic Ladder Wiring Diagram Heaters built after 4/27/04 Heaters built before 4/27/04 (Dual Voltage) (Single Voltage) LADDER DIAGRAM LADDER DIAGRAM 120/240 120 VAC NEUTRAL IGNITER IGNITER BLOWER BLOWER 120 VAC 120/240 CLASS II CLASS II TRANSFORMER TRANSFORMER...
  • Page 64 SECTION FOUR – Routine Maintenance and Professional Servicing Single Voltage Pool Heater Wiring Connection Diagram (115VAC) CONNECTION DIAGRAM AGS Switch Air Flow Switch Y/BL Stack Flue Sensor Extra Switch 1 Gas Valve Hi-Limit Switch Pressure Switch OPERATING CONTROL MEMBRANE PAD CONNECTION JMP3 VERSION 1 PAD...
  • Page 65 SECTION FOUR – Routine Maintenance and Professional Servicing Dual Voltage Pool Heater Wiring Connection Diagram (120-240-VAC) CONNECTION DIAGRAM If cable from AGS Switch Air Flow Switch Membrane Pad is a 6-Conductor Stack Flue Sensor Extra Switch 1 Cable, connect it Gas Valve Y/BL Hi-Limit Switch...
  • Page 66 SECTION FOUR – Routine Maintenance and Professional Servicing R R R R E E E E A A A A D D D D M M M M E E E E F F F F I I I I R R R R S S S S T T T T ! ! ! ! Single Voltage Wiring Harness Connection Instructions Main Bundle includes all...
  • Page 67 SECTION FOUR – Routine Maintenance and Professional Servicing Single Voltage Wiring Harness Connection Instructions Step 1 FENWAL DIAGNOSTIC INDICATOR MODE CONTROL FAULT CAUTION: HI VOLTAGE - DISCONNECT WIRING BEFORE SERVICING L1 L2 S2 IGM – 4 Grey (IGN) Black (L1) White (L2) Grey (IGN) Terminal Board –...
  • Page 68 SECTION FOUR – Routine Maintenance and Professional Servicing Single Voltage Wiring Harness Connection Instructions IGM–1 To Control Airflow Yellow (24VAC) Switch–2 Board Blue (AF) Step 2 FENWAL DIAGNOSTIC INDICATOR MODE CONTROL FAULT IGM–1 CAUTION: HI VOLTAGE - DISCONNECT WIRING BEFORE SERVICING Yellow w/Red Stripe (VAL) Transformer–2 L1 L2 S2...
  • Page 69 SECTION FOUR – Routine Maintenance and Professional Servicing Single Voltage Wiring Harness Connection Instructions J1 – 5 J7 – 4 J5 – 2 From Membrane Control Board Step 3 Fenwal–1 Black (F1) FENWAL Fenwal–1 DIAGNOSTIC INDICATOR Black (F2) MODE CONTROL FAULT CAUTION: HI VOLTAGE - DISCONNECT WIRING BEFORE SERVICING L1 L2 S2 Transformer–2...
  • Page 70 SECTION FOUR – Routine Maintenance and Professional Servicing Vent Body Retrofit For Enclosed Installations S S S S a a a a f f f f e e e e t t t t y y y y P P P P r r r r e e e e c c c c a a a a u u u u t t t t i i i i o o o o n n n n s s s s : : : : Risk of fire, explosion, and electrical Second Cut: Appliance...
  • Page 71 SECTION FOUR – Routine Maintenance and Professional Servicing Vent Body Retrofit For Enclosed Installations (Continued from the preceding page) 7. Heat around the inside of the Combustion chamber 11. Check the fit between the Elbow and the Flue Collar with a propane torch to soften the Combustion Chamber Flue Collar.
  • Page 72 SECTION FOUR – Routine Maintenance and Professional Servicing Vent Body Retrofit For Enclosed Installations (Continued from the preceding page) 14. Remove the Metal Elbow and degrease the gluing apply additional RTV around the outside of the surfaces of the Combustion Chamber Flue Collar joint and pack it in to make a good seal.
  • Page 73 SECTION FOUR – Routine Maintenance and Professional Servicing Heater Exhaust Temperature Probe Installation ( ( ( ( 4 4 4 4 2 2 2 2 0 0 0 0 0 0 0 0 1 1 1 1 - - - - 0 0 0 0 4 4 4 4 0 0 0 0 5 5 5 5 K K K K i i i i t t t t ) ) ) ) T T T T o o o o v v v v e e e e r r r r i i i i f f f f y y y y w w w w h h h h e e e e t t t t h h h h e e e e r r r r C C C C o o o o n n n n t t t t r r r r o o o o l l l l B B B B o o o o a a a a r r r r d d d d i i i i s s s s N N N N e e e e w w w w o o o o r r r r O O O O l l l l d d d d 1.
  • Page 74 SECTION FOUR – Routine Maintenance and Professional Servicing Service Routine maintenance (such as, testing the water pres- The Combustion Air Blower includes the: sure relief valve and the water pressure switch) shall be A. Air Orifice performed: B. Air/Gas Mixing Tube A.
  • Page 75 SECTION FOUR – Routine Maintenance and Professional Servicing Service S S S S e e e e r r r r v v v v i i i i c c c c i i i i n n n n g g g g t t t t h h h h e e e e W W W W a a a a t t t t e e e e r r r r S S S S y y y y s s s s t t t t e e e e m m m m Respond to the following statements “Yes”...

  • Page 76: Repair Parts

    SECTION FIVE – Repair Parts List Repair Parts For complete For complete Electrical System Electrical System parts breakdown parts breakdown (Key Nos. 1 through 4), (Key Nos. 1 through 4), See Page 5-5 See Page 34 PI LO For complete For complete Burner System parts breakdown...
  • Page 77 SECTION FIVE – Repair Parts List Repair Parts – Burner System For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No. 42001-0085S. PI LO 2692 1196...
  • Page 78 SECTION FIVE – Repair Parts List Repair Parts – Burner System Model SR400NA SR200NA SR333NA SR400LP SR200LP SR333LP SRC400NA SRC200NA SRC333NA SRC400LP Part Description Qty. SRC200LP SRC333LP SR400HD Combination Gas Control Valve Kit 42001-0051S 42001-0051S 42001-0051S 3/4” Union 38404-4097S 38404-4097S 38404-4097S •...
  • Page 79 SECTION FIVE – Repair Parts List Repair Parts – Water System 2691 1196 Model SR400NA SR200NA SR333NA SR400LP SR200LP SR333LP SRC400NA SRC200NA SRC333NA SRC400LP Part Description Qty. SRC200LP SRC333LP SR400HD Tube Sheet Coil Assembly Kit – NA and LP Series...
  • Page 80 SECTION FIVE – Repair Parts List Repair Parts – Electrical System Model SR400NA SR200NA SR333NA SR400LP SR200LP SR333LP SRC400NA SRC200NA SRC333NA SRC400LP Part Description Qty. SRC200LP SRC333LP SR400HD • Display Cover Retainer Cap Kit (Incl. Key No. 1)* 77707-0009 77707-0009...
  • Page 81 Pressure Relief Valve - A valve mounted on the manifold adapter does not use a draft hood. that will automatically open at a preset pressure. For the Sta-Rite Excess Air - Air supplied for combustion beyond that which is heater the rating is 50 psi (345 kPa). This must be an ASME valve required for perfect combustion.

  • Page 82: Read Me First

    SECTION SEVEN – Troubleshooting Read Me First!! NOTE: Connecting a single-voltage (115VAC) heater 2. Remove the covers and check for a 12-pin plug in to a 240VAC line, or installing the black 120 volt plug the back of the control box. in the control box of a dual-voltage heater and then A.
  • Page 83 SECTION SEVEN – Troubleshooting Initial Troubleshooting Start here for directions to specific Troubleshooting Chart Go to chart “HEATER WILL Is green “POOL” or “SPA” LED NOT FIRE - A” “on”? (Page 7-3) Go to chart “HEATER WILL Is red “SERVICE SYSTEM” NOT FIRE - B”...
  • Page 84 SECTION SEVEN – Troubleshooting Heater Will Not Fire - A Start Depress “POOL” or “SPA” ON Heater should fire on demand Is green “SPA” or button on Membrane Pad. for heat. “POOL” LED “on” Does “POOL” or “SPA” LED come on? Check that single- Check for line voltage to Restore power to heater.
  • Page 85 SECTION SEVEN – Troubleshooting Heater Will Not Fire - B Start Increase POOL/SPA tempera- Is red “SERVICE Is red “SERVICE SYSTEM” ture setting on Membrane HEATER” LED “on” LED on? Pad above actual water tem- perature. Heater should fire on demand for heat. If not, Verify that pump is on, filter is and no other red LED’s light, not blocked, and the water...
  • Page 86 SECTION SEVEN – Troubleshooting Heater Will Not Fire - C Start Is “SERVICE HEATER” LED Go to “INITIAL “on”? TROUBLESHOOTING” Turn off power to heater for 5 seconds, Continue to observe heater and turn back on. for several minutes. Cycle Make sure tempera- heater on and off several ture setting is above...
  • Page 87 SECTION SEVEN – Troubleshooting Heater Will Not Fire - D IMPORTANT! READ ME FIRST!! IMPORTANT! READ ME FIRST!! meter will read either 0 VAC or 240 VAC. If your ICM is If your heater is correctly connected to 240 Volts AC, The good, your meter will read some voltage between 0 and Ignition Control Module (ICM) will convert the 240VAC to 240 VAC.
  • Page 88 SECTION SEVEN – Troubleshooting Diagnostic LED’s: AGS, AFS, HLS, PS, THERMISTOR Verify that water flow rate is Service pump and filter to AGS or HLS “on” above minimum required for restore proper flow. After ser- heater. vicing, verify proper operation Replace High Limit of Pressure Switch (PS).
  • Page 89 SECTION SEVEN – Troubleshooting Diagnostic LED’s: SFS Replace Heater Membrane SFS “on” Pad Assembly, reset power to Heater and retry. Heater should fire. A) Is the Stack Flue Switch or Sensor correctly connected to Replace Heater Control Board the wiring harness? with new style board, reset B) Is the Membrane Pad Reconnect correctly.

  • Page 90: Burner Troubleshooting

    SECTION SEVEN – Troubleshooting Burner Troubleshooting S S S S Y Y Y Y M M M M P P P P T T T T O O O O M M M M C C C C A A A A U U U U S S S S E E E E R R R R E E E E M M M M E E E E D D D D Y Y Y Y Loud, high-pitched whine Flame is too rich.

  • Page 91: Troubleshooting Questions

    SECTION SEVEN – Troubleshooting Troubleshooting Questions The following condition exists when you arrive at the The following condition exists when you arrive at the customers installation: customers installation: • Green “POOL” or “SPA” LED is on • Green “POOL” or “SPA” LED is on •...

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