Download S430/Kaowool Insulation
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Heater Insulation Kit Sta-Rite Pool/Spa Group 293 Wright Street, Delavan, WI 53115 North America: 800-752-0183, FAX 800-582-2217 International: 262-728-5551, FAX: 262-728-4461, TELEX: ITT 4970245 www.sta-ritepool.com Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA © 2003, Sta-Rite Industries, Inc. Printed in U.S.A. S430 (Rev. 2/14/03) Servicing Procedure (See Figure 1): Heavy parts; can cause personal injury. When lifting, use all proper precautions for the weights involved. 1/2" Insulation Blanket Combination Gas Control Valve OFF 1" Insulation OF F NO Turn Clockwise and press down to turn off gas. NT VE Manual/Gas Valve OFF S ES PR B TA OT PIL Power Flameholder Insulation Cap Condensate Evaporator NO 1" Insulation OFF VEN T SS PRE TAB OT PIL 1/2" Insulation Blanket Remove Water Pressure Switch to help Manifold Drain 3120 1197 Tools/Parts Required Drain Inlet/Outlet Manifold Flat Screwdriver, Phillips Screwdriver 1/4” and 3/8” Socket Sets with Extenders Sockets needed:1/4”, 5/16, 11/32, 7/16, 1/2, 9/16, 7/8 Rubber Mallet Torque Wrench calibrated in Inch-Lbs. High Temperature RTV (600° F. Cont.; 700° F. Intermittent) Flame Holder/Adapter Plate Gaskets (2 - Part No. 42001-0065) 14” & 12” Pipe Wrenchs (1 Each) or 2 Channel-Lock Pliers Optional: Lifting Gear capable of handling 150 Lbs. Inlet 2704 1196 Outlet Open Drain Cock(s) and Plugs OPEN Close Isolation Valves Figure 1: Isolate and Drain Heater; Disconnect Power Safety Precautions: 1. Turn off the filter pump and all electrical power to the heater. Close the external Manual Gas Valve. 2. If the heater is below the water level of the pool, close the isolation valves to avoid draining the pool. 3. Remove the drain plug under the manifold and drain the heater. 4. While the heater is draining, remove the upper left and upper right jacket halves. 5. Remove the switch covers on both sides of the manifold and unplug the wires from the Automatic Gas Shutoff, the High Limit Thermostat, and the Thermistor (See Figure 2, Key No. 1). If necessary, disconnect the Water Pressure Switch and remove it. 6. Disconnect exhaust vent from indoor units. 7. Disconnect the gas pipe at the external union between the heater and the external manual gas valve. 8. Disconnect the incoming electrical wires at the junction box and cut the wire tie holding the Wiring Harness to the Lower Enclosure (See Figure 2, Key No. 2). 9. Disconnect the inlet and outlet unions and move the heater enough to allow removal of the manifold adapter and the inlet/outlet manifold as a unit (See Figure 2, Key No. 3). Risk of electrical shock, fire or explosion. Disconnect all power to the heater and close the external manual gas valve at start of this procedure. Check for gas leaks with a soapy water solution after reassembly. Risk of carbon monoxide poisoning from indoor units if exhaust vent joints are not sealed. Check all vent joints for leakage after reassembly. Heavy parts; can cause personal injury. When lifting, use all proper precautions for the weights involved. Uncured RTV sealants can cause eye irritation. Follow manufacturer’s instructions when using RTV sealants. Location The Insulation is located inside the Combustion Chamber. Function The insulation increases the thermal efficiency of the heater and prevents overheating of parts outside the combustion chamber. 2 10. Unscrew the bolts that attach the manifold adapter to the tube sheet and remove the manifold adapter and the inlet/outlet manifold as a unit. 11. Carefully disconnect all three metering tubes from the Combustion Air Blower Assembly (1 to the Combination Gas Control Valve, 2 to the Air Flow Switch). 12. Remove the bolt from the Gas Piping Clamp. 13. Unplug all wires to the Control Box. Unscrew three nuts and remove the Control Box, the Heat Shield, and the Membrane Pad and Cover as a unit (See Figure 2, Key No. 4). 14. Unscrew the four nuts holding the Blower Adapter Plate to the top of the Combustion Chamber and remove the Combustion Air Blower, the Igniter, the Combination Gas Valve and associated piping and the Blower Adapter Plate as a unit (See Figure 2, Key No. 5). Remove the Flameholder and Flameholder Cone (if used). NOTICE: BE CAREFUL not to break or crack the igniter – it is fragile! 15. Unscrew the nuts holding the Combustion Chamber top to the Combustion Chamber body. 16. Unscrew 4 hold-down nuts from the hangers supporting the Combustion Chamber. 17. Wrap a shop rag around each hanger, one at a time (be careful; it’s sharp) and hammer down on the Lower Enclosure while lifting the hanger by the shop rag. This will lift the hanger up off of the hold-down bolt. 18. Lift the Combustion Chamber out of the Lower Enclosure. 20. With a mallet and screwdriver, go around the Combustion Chamber cover tapping up until the RTV separates and releases the Combustion Chamber cover. Be careful not to damage the Combustion Chamber. 21. Remove the Combustion Chamber cover. California’s Proposition 65 lists Refractory Ceramic Fibers heated to 1800° F or higher as a possible human carcinogen. See the warning box on Page 6 for further information. Call 1-800-752-0183 for a Material Data Safety Sheet (MSDS). 22. Remove the top insulation, the Heat Exchanger Coil, the Condensate Evaporator, the Bottom Insulation, and the metal spacer from the Combustion Chamber. Do not remove the RTV that seals the manifold mounting plate to the combustion chamber. 23. Clean up the Combustion Chamber, the Combustion Chamber cover, and the Spacer. Be sure to completely remove all RTV from the Combustion Chamber and Combustion Chamber top. 24. Reinstall the clean spacer in the Combustion Chamber. Install one 1/2” white Insulation Blanket on top of the spacer and one piece of 1” “M” insulation on top of the Blanket. Make sure that the insulation is centered in the Combustion Chamber. NOTICE: Model SR/SRC200 heaters built before 1/1/98 require two 1/2” Insulation Blankets. Flameholder Heavy parts; can cause personal injury. When lifting, use all proper precautions for the weights involved. 19. Cut the RTV all the way around the top of the Combustion Chamber with a screwdriver. 1/2" Top Blanket 5 Flameholder Insulation Cap (Tape to bottom of Flameholder) 1" Top Insulation 4 Condensate Evaporator 2 1" Bottom "M" Insulation 1/2" Bottom Blanket Spacer 3 3122 1197 1 Figure 3: Correct order for installation of insulation. Figure 2: Removal of major sub-assemblies 3 25. Install the new Condensate Evaporator on top of the insulation. 26. Clean the tubesheet and O-Ring sealing surfaces (see Figure 4). 27. Reinstall the Heat Exchanger Coil on the Insulation. Pull the Heat Exchanger Coil and the Bottom Insulation forward together to align with the mounting plate (see Figure 5). 28. Install the manifold and manifold bolts. See Figure 6 for long and short bolt positions. 1. Clean the tube sheet and O-ring sealing surface with a nylon brush, then brighten the tube sheet surface with 320 grit emery cloth. NOTE: When cleaning, be careful not to push the tube sheet into the combustion chamber. If you do, thread a couple of bolts into it and pull it back in place. Models SR200/SRC200 Short Bolt Placement 2. Brush off all dust and debris with a brush and wipe it down with a cloth. 3. Apply silicone grease (supplied) to O-Rings. 2-3/4" 2-3/4" * * 4067 0901 2-1/2" 2-1/2" Figure 4: Clean the Tube Sheet and O-Ring sealing surfaces thoroughly as described above. * A. Center Insulation in lower enclosure. Add Evaporator Plate. Evaporator Plate Insulation B. Center Heating Coil on Insulation. * C 2-3/4" 2-3/4" Heating Coil Models SR400/SRC400 Short Bolt Placement 2-3/4" Do not disturb RTV in these areas * * 2-1/2" C. Slide Coil, Insulation, and Evaporator Plate into Manifold Mounting Plate. 2-3/4" Tube Sheet Lower Enclosure D. No Gaps between insulation and Tube Sheet 2-1/2" *Hand-tighten all long bolts; then tighten indicated bolts enough to allow short bolts to engage. Here and Here • Install O-rings on tube ends; install manifold. • SR/SRC200 and SR/SRC400: Tighten all long bolts HAND TIGHT; then tighten the bolts next to the short bolts a little more with a wrench. • Insert and start the two short bolts until they engage three or four threads, then tighten all bolts according to the normal torque pattern shown on Page 5. • SR/SRC333: These models use long bolts only. Tighten all bolts HAND TIGHT; then tighten according to the normal torque pattern shown on Page 5. 4076 1001 Figure 5: Align bottom insulation and Heat Exchanger Coil as shown. Figure 6: Install bolts as shown. 4 29. Tighten the bolts to the torque spec as shown in Figure 7. 33. Reinstall the Combustion Chamber top and fasten with nuts on studs from Combustion Chamber body. 34. Reinstall the Combustion Chamber in the Lower Enclosure and fasten with hold-down nuts. 35. Reinstall the Flameholder and Flameholder Cone (if used), and then the Combustion Air Blower, the Igniter, the Combination Gas Valve and associated piping and the Blower Adapter Plate as a unit; use new gaskets. Be sure to reinstall the Insulation Cap on the bottom of the Flameholder. Tighten Adapter Plate nuts to 70-80 in.-lbs. torque. See Figure 9. Torque Pattern - All Models 9 8 5 4 1 2 3 6 7 10 75-115 in.-lbs./8.4-12.9 N-m Reinstall Control Box and Heat shield Assembly 1. Make sure that all bolts are engaged and hand tight. 2. Torque the bolts in sequence as shown. Some noise (popping, etc.) is normal as you tighten. 3. Go around the manifold and retighten the bolts as needed to 75-115 in-lbs. (8.4-12.9 N-m) (you may have to do this several times). Flameholder/Adapter Plate Gasket Flameholder/Combustion Chamber Gasket Figure 7: Torque Specs. 30. Turn on the water and check for leaks between the Manifold Adapter and the Tube Sheet. 31. Install one piece of 1” top Insulation on top of the Heat Exchanger and one 1/2” Insulation Blanket over the top Insulation. Make sure that the insulation is centered on the coil so that an equal number of heater coil fins shows around the insulation. 32. Apply fresh High Temperature RTV (600°F Continuous, 700° F. Intermittent rating) all the way around the inside top of the Combustion Chamber and the outside of the Combustion Chamber cover (see Figure 8). 3123 1197 1 dapter 2 r/Combustion asket Apply RTV here and here. 3123 1197 3 At reassembly, connect tubing as shown: 1. From Air Inlet Port to Combination Gas Valve; 2. From Air Inlet Port to Air Flow Switch; 3. From bottom of Blower to Air Flow Switch. Figure 9: Make sure new gaskets are in place when reassembling combustion chamber. Apply RTV bead all the way around both Combustion Chamber and Cover. 3140 0198 Figure 8: RTV Application For Reassembly 5 36. Reinstall Control Box and Heat Shield assembly; fasten with three nuts. 37. Reconnect the water pressure switch (if necessary). 38. Reconnect the metering tubes from the Air Flow Switch and the Combination Gas Control Valve to the Combustion Air Blower Assembly (see Figure 9). 39. Reconnect exhaust vent pipe and seal with RTV or epoxy according to vent manufacturer’s instructions. White to White Green (Ground) to Green (Ground) Black to Black Risk of carbon monoxide poisoning. Make sure that entire exhaust vent is sealed after reinstallation. 40. Reconnect all wiring. See Figure 10 for Junction-box connections, and see Page 7 for complete wiring schematic. 41. Before starting the heater, test for gas leaks from piping and around Combustion Chamber cover with a soapy water solution. 42. Check for water leaks at unions and at manifold flange (where it joins the tube sheet). 43. Reinstall jacketing and test heater by running it through one complete cycle. Test for exhaust leaks from exhaust vent pipe while cycling heater. 44. Heater is ready for service. Bonding Wire Wiring Harness to Control Box Wire into bottom of Junction-box in Flexible Conduit View From Above (Interior) Figure 10: Junction Box Wiring Connections For detailed installation, operation, maintenace and safety information about the Sta-Rite pool heater, call customer service at 1-800-752-0183 and request a Sta-Rite Pool/Spa Heater Training and Service manual, publication S5066. Prolonged exposure to the ceramic fiber insulation in the combustion chamber may cause cancer. May also cause temporary eye, skin, or respiratory tract irritation. Avoid breathing fiber particulates and dust. Wear a NIOSH/MSHA approved respirator, loose, long sleeved clothing, eye protection, and gloves when working with or around insulation. Wash work clothes separately. Rinse washing machine after use. For first aid: Eyes: Flush with water. Skin: Wash with soap and water. If swallowed: Do not induce vomiting. Get medical attention if gastrointestinal symptoms develop. If inhaled: Get to fresh, clean air. If any of the irritations above persist, seek medical attention immediately. For additional product information or for a Material Safety Data Sheet (MSDS), call 1-800-752-0183 6 CONNECTION DIAGRAM AGS Switch Air Flow Switch Stack Flue Sensor Extra Switch 1 Gas Valve Y/R Y/BL Y/O Hi-Limit Switch Y/W Y Pressure Switch Y Y Y Y O O BL O BL W O THERMISTOR ES1 OPERATING CONTROL AFS GAS Y Y Y Y MEMBRANE PAD CONNECTION AGS SFS J6 1 HLS FS PS 24VAC R VAL TH IND GND 24VAC Y BR BR PR PR R JMP3 9 W Y/W VERSION 1 PAD 1 External Control Interface Circuit Disabled, Heater Membrane Pad Enabled CONTROL CENTER SPA CONTROL Spa Line Common Line Pool Line External Control Interface JMP3 BK Y BK 1 F1 24 F2 VAC IGNITION CONTROL MODULE DIAGNOSTIC INDICATOR JMP3 Y Y 24VAC 1 FC1 FC2 S1/ 120 L1 L2 External Control Interface Circuit Enabled, "Pool On" and "Spa On" Keys Disabled. "OFF" Key on Membrane Pad Remains Functional. S2 SEC TH IND VAL GND PRIM GY Y/W GY 120VAC Y/O Y/BL W BK Y/R 120VAC IGNITER BLOWER Y/W 120VAC GND MOT BK G TRANS L1 F1 F I R E M A N S TRANS FL S W I T C H L2 BM 1 J6 BK GND Y W W W GND 9 JUNCTION BOX GROUND (GND) W G BK 120VAC (HOT) W If cable from Membrane Pad NEUTRAL (NEU) is a 6-Conductor Cable, connect it to pins 4 - 9 on Operating NOTICE: If, while there is 120VAC connected to the heater, you touch Control Board as shown. either 120VAC terminal with any 24VAC wire that is connected to the control board (including the Fireman's Switch jumper), you will immediately destroy the control board and void the warranty. Replace jumper with leads to Fireman's Switch (field installed) 3661 0200 7 1 2 3 4 5 6 3125 1197 REPAIR PARTS LIST Key No. 1 2 3 4 5 6 Part Description Flameholder Insulation Cap 1/2” Blanket 1” Top Insulation Condensate Evaporator 1” “M” Insulation 1/2” Blanket* Qty. Part No. 1 1 1 1 1 1 42001-0075 42001-0071 42001-0070 42001-0065 42001-0072 42001-0073 * Model SR/SRC200 heaters built before 1/1/98 use 2 of Part No. 42001-0073. 8