Swimming Pool Heater User Manual

To replace thermal control valve and/or bypass
valve parts:
1. Turn pump, main gas valve and heater power off.
2. Remove drain plug and drain water out of heat
exchanger.
3. Remove screws from right access panels and
remove.
4. Remove wires from high limit switches on header.
5. Unplug thermistor wire lead from control board.
6. Remove pressure switch tube from header.
7. Loosen union nuts and detach pool plumbing
from header.
8. Remove (12) nuts from the header.
9. Remove the header and header o-ring from the
heat exchanger.
To replace bypass valve parts:
10. The adapter/shaft assembly and spring are
removed by unscrewing the adapter as shown in
Figure 55.
11. Remove the plastic bypass insert and valve disk
from header.
12. Replace parts with new plastic bypass insert,
adapter, shaft, spring, and plastic valve disk.
13. Inspect and ensure valve disk slides freely on the
shaft. See Figure 55.
14. Re-install by reversing above procedure.
To replace thermal control valve:
10. Remove plastic bypass insert from header.
11. Remove the thermal control valve from header.
12. Test the thermal control valve by placing it into a
hot water bath (above 108°F) and watching for
movement that compresses the spring and opens
the annular area in the center of the valve. If this
action does not take place, replace the valve with
a new one that has been tested as above. See
Figure 56.
13. Inspect and ensure valve disk slides freely on the
shaft. See Figure 55.
14. Re-install by reversing above procedure.
Transformer:
The transformer converts the field supply voltage
(120 VAC / 240 VAC) to a 120 VAC output for power-
ing the blower and ignitor circuits, and to a 24 VAC
output for powering the control module, control cir-
cuits, and gas valve.
T
o replace the transformer:
1. Turn pump, gas supply and heater power off.
2. Remove two screws and open front control panel.
3.
Unplug transformer connectors from fuse board.
4. Remove the screws securing transformer to the
mounting bracket and remove transformer.
5. Replace the transformer and reverse the above
procedures.
Combustion blower:
T
he combustion blower provides the air that mixes
w
ith the gas from the main burners for the combus-
tion process. On initial start-up, the blower operates
for 20 seconds to purge gas out of the heater. Then,
the main gas valve opens for a period of 4 seconds
and the heater lights. The blower operates the entire
time the gas valve is open and for 30 seconds after
the valve closes.
To replace the combustion blower:
1. Turn pump, main gas valve and heater power off.
2. Remove (hot) vent screws and remove panel.
3. Remove main top.
4. Disconnect wires and hoses attached to the blower.
5. Remove air deflector.
6. Remove screws attaching blower to flue collector.
7. Remove vent from blower.
8. Replace blower.
9. Reverse the above procedures for installation.
35
By-pass valve:
T
he header houses an automatic by-pass valve.
T
he valve provides proper water flow through the
heat exchanger as the filter system water pressure
varies. The valve assembly consists of a plunger, a
spring, and a shaft. The plunger glides along the
shaft as system water pressure compresses the
spring. Very high acid or chlorine concentrations
may damage the valve parts or very hard water may
leave deposits on the shaft causing the valve to
stick. If the valve sticks open, very little water will
pass through the heat exchanger causing overheat-
ing and possibly opening the high limit contacts. If
the valve sticks closed, too much water will flow
throughout the heat exchanger causing condensa-
tion to occur. Either situation may result in insuffi-
cient heating of the pool or spa.
Thermal control valve:
T
he header also houses a thermal control valve.
T
his valve helps to control condensation forming on
the heat exchanger by not allowing water to flow
through the heat exchanger until the water reaches a
temperature of 105°F. Very hard water may leave
deposits on the valve plunger causing the valve to
stick. If the valve sticks open, cold water can flow
through the heat exchanger causing condensation to
occur. If the valve sticks closed, very little water will
flow through the bypass hole which will open the high
limit contacts.
34
By-pass Valve
Figure 55
Thermal Control Valve
Figure 56