CPE-i&s-05
INSTALLATION AND SERVICE MANUAL
GAS HEATERS FOR COMMERCIAL
POOL APPLICATIONS
500,000 - 2,070,000 Btu/hr MODELS
Starting Serial #F0600187510
WARNING
ƽ
:
If the
information in this manual
is not followed exactly, a
fire or explosion may
result causing property
damage, personal injury or
loss of life.
– This appliance MUST
NOT be installed in any
location where gasoline or
flammable vapors are
likely to be present, unless
the installation is such to
eliminate the probable
ignition of gasoline or
flammable vapors.
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.
WARNING
ƽ
: Improper
installation, adjustment,
alteration,
service
or
maintenance can cause
property damage, personal
• Immediately call your
gas supplier from a
injury,
exposure
to
neighbors
Follow
phone.
gas
hazardous materials or
loss of life. Refer to this
manual. Installation and
service must be performed
by a qualified installer,
service agency or the gas
supplier. This pool heater
contains materials that
have been identified as
carcinogenic, or possibly
carcinogenic, to humans.
WARNING
ƽ
: Do not use
the
this pool heater if any part
has been under water. The
supplier’s instructions.
• If you cannot reach your
gas supplier, call the fire
department.
possible damage to
a
flooded pool heater can be
extensive and present
numerous safety hazards.
Any pool heater that has
been under water must be
replaced.
– Installation and service
must be performed by a
qualified installer, service
agency or the gas supplier.
Save this manual for future reference.
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Installation and Service Manual
GENERAL PRODUCT
SAFETY INFORMATION
The information contained in this manual is intended for use
by qualified professional installers, service technicians or gas
suppliers. Consult your local expert for proper installation or
service procedures.
INFORMATION
Special Instructions
This manual supplies information for the installation,
operation and servicing of this pool heater. Read and
understand this manual completely before installing the pool
heater.
IMPORTANT: Read this owner’s manual carefully
and completely before trying to install, operate,
or service this pool heater. Improper use of this
pool heater can cause serious injury or death
from burns, fire, explosion, electrical shock, and
carbon monoxide poisoning.
Installation and service must be performed by a qualified
service installer, service agency, or the gas supplier.
Unpacking
ƽ DANGER: Carbon Monoxide poisoning
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying the
pool heater which may show signs of being hit or otherwise
being mishandled. Verify total number of pieces shown on the
packing slip with those actually received. In case there is
damage or a shortage, immediately notify the carrier.
may lead to death!
IMPORTANT: Consult and follow local building
and fire regulations and other safety codes that
apply to this installation. Consult your local gas
utility company to authorize and inspect all gas
and flue connections.
Codes
The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These shall be carefully followed in
all cases. Authorities having jurisdiction shall be consulted
before installations are made. In the absence of such
requirements, the installation shall conform to the latest edition
of the National Fuel Gas Code, ANSI Z223.1 and/or
CAN/CGA-B149 Installation Code. All pool heater heat
exchanger construction conforms to the latest edition of the
ASME Boiler and Pressure Vessel Code, Section IV, Part
HLW.
ƽ WARNING: Should overheating occur or
the gas supply fail to shut off, do not turn off or
disconnect the electrical supply to the pump.
Instead, shut off the gas supply at a location
external to the pool heater.
ƽ WARNING: To minimize the possibility of
serious personal injury, fire or damage to your
pool heater, never violate the following safety
rules.
Warranty
Factory warranty (shipped with pool heater) does not apply to
pool heaters installed or operated improperly. Improper
installation or system design causes most operating problems.
1. Excessive water hardness causing a lime build up in the
copper tube is not the fault of the equipment and is not
covered under the appliance manufacturer’s warranty (see
Water Chemistry, page 44).
2. Excessive pitting and erosion on the inside of the copper
tube may be caused by too much water velocity through
the tubes and is not covered by the appliance
manufacturer’s warranty.
1. Pool heaters are heat producing appliances. To avoid
damage or injury, do not store materials against the pool
heater or the vent-air intake system. Use proper care to
avoid unnecessary contact (especially children) with the
pool heater and vent-air intake components.
2. Never cover your pool heater, lean anything against it,
store trash or debris near it, stand on it, or in any way block
the flow of fresh air to your pool heater.
3. UNDER NO CIRCUMSTANCES must flammable
materials such as gasoline or paint thinner be used or
stored in the vicinity of this pool heater, vent-air intake
system or any location from which fumes could reach the
pool heater or vent-air intake system.
3. Corrosion due to water chemistry imbalance is not the fault
of the equipment and is not covered by the appliance
manufacturer’s warranty (see Water Chemistry, page 44).
4. This pool heater is only for use with the type of gas
indicated on the rating plate.
5. If you smell gas shut off gas supply.
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Commercial Pool Heaters
•
•
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
6. This appliance is a high efficiency pool heater which has
been designed to operate scale-free and trouble free for
many years. Particular attention should be directed to the
following items.
•
Correct piping to the pool filter system with
specified pipe materials and size.
Electrical interconnection of the pool heater
controls, bypass pump and filter pump to ensure
continuous circulation.
•
•
•
Proper venting.
Water chemistry.
7. Follow all clearances from combustibles contained in this
manual.
8. Appliance surfaces become hot during operation. Be
careful not to touch hot surfaces. Keep all adults, children,
and animals away from an operating pool heater. Severe
burns can occur.
9. This pool heater must have an adequate supply of fresh air
during operation for proper gas combustion and venting.
10. Make sure all exhaust venting is properly installed and
maintained. Improper venting of this pool heater could
lead to increased levels of carbon monoxide.
11. Do not use this pool heater if any part has been under
water. Immediately call a qualified service technician to
replace the pool heater. The possible damage to a flooded
pool heater can be extensive and present numerous safety
hazards. Any appliance that has been under water must be
replaced.
12. Do not alter this pool heater in any way. Any change to
this pool heater or its controls can be dangerous.
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Installation and Service Manual
PRODUCT
IDENTIFICATION
Figure 1A - Standard Horizontal Piping Loop
Figure 1B - Optional Vertical Piping Loop
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Commercial Pool Heaters
Left Side
Front
Top
Flue
6" (15cm) (24" (0.61m) suggested for service)
Alcove* (30" (0.76m) suggested for service)
3" (7.5cm)
INSTALLATION
This pool heater meets the safe lighting performance criteria
with the gas manifold and control assembly provided, as
specified in the ANSI Z21.10.3/CSA 4.3 standard for gas-fired
water heaters.
1" (25.4mm)
Hot Water Pipes 1" (25.4mm)
*An Alcove is a closet without a door.
LOCATING POOL HEATER
Note: No additional clearance is needed on the right side of
the pool heater for the observation port. An observation port is
located on both the right and left side of the pool heater.
1. Maintain all clearances from combustible construction
when locating pool heater. See Clearances from
Combustible Construction, this page.
2. Locate the pool heater so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, install a suitable drain pan that is well-
drained under the pool heater. The pan must not restrict
combustion air flow. The pool heater manufacturer is not
responsible for water damage in connection with this pool
heater, or any of its components.
Note: No additional clearances from combustibles are needed
for use of the Direct Vent (DV) air inlet assembly.
3. Install the indoor pool heaters so that the ignition system
components are protected from any water while operating
or during service.
4. You must install the pool heater on a level, non-
combustible floor.
5. Do not install pool heater directly on carpet or other
combustible material. A concrete-over-wood floor is not
considered non-combustible. Maintain required clearances
from combustible surfaces.
If installing the pool heater in an area with a combustible
floor, you must construct a special combustible floor base.
See Base for Combustible Floors, this page.
6. For outdoor models, you must install an optional vent cap.
Instructions for mounting the vent cap are included in the
venting section. Do not install outdoor models directly on
the ground. You must install the outdoor pool heater on a
concrete, brick, block, or other non-combustible pad.
Outdoor models have additional special location and
clearance requirements. See Outdoor Installation Venting,
page 25. A wind proof cabinet protects the pool heater
from weather.
Figure 2 – Clearances from Combustible Construction
Base for Combustible Floors
There are no manufactured combustible floor base kits
available for 990,000 - 2,070,000 Btu models. See Table-A for
floor base kits that are available.
If a manufactured combustible floor base kit is not used, you
must construct a base for combustible floor installation. Install
the pool heater over a base of hollow clay tiles or concrete
blocks from 8" to 12" thick, extending at least 24" beyond the
pool heater sides. Place tiles or blocks so that the holes line up
horizontally to provide a clear passage through the tiles or
blocks. Place a 1/2" fireproof millboard over the top of the tile
or block base. Place a 20-gauge sheet metal cover over the
fireproof millboard. Center the pool heater on the base. Also
follow this procedure if electrical conduit runs through the
floor beneath the pool heater. This base must meet all local fire
and safety codes.
Clearances from Combustible
Construction
Maintain minimum specified clearances for adequate
operation. Allow sufficient space for servicing pipe
connections, pump and other auxiliary equipment, as well as
the pool heater. See rating plate for specific service clearance
requirements.
Right Side
Rear
3" (7.5 cm)
3" (7.5 cm) (3" min. from any surface)
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TABLE - A
COMBUSTIBLE FLOOR KITS
Input Btu/hr
Kit Number
500,000
650,000
750,000
CFK3302
CFK3303
CFK3304
FREEZE PROTECTION
Although this pool heater is CSA design certified for outdoor
installations - such installations are not recommended in areas
where the pool heater will be operated in the winter months
and the danger of freezing exists. Proper freeze protection
must be provided for outdoor installations; pool heaters
installed in unheated mechanical rooms or where temperatures
may drop to the freezing point or lower. If freeze protection
is not provided for the system, a low ambient temperature
alarm is recommended for the mechanical room. Damage to
the pool heater by freezing is non-warrantable.
Figure 3 – Draining Pool Heater
ƽ CAUTION: Under no circumstances should
the mechanical room ever be under a negative
pressure. Particular care should be taken where
exhaust fans, attic fans, clothes dryers,
compressors, air handling units, etc., may take
away air from the pool heater.
1. Pump Operation - MOST IMPORTANT - This pool heater
is designed for continuous operation of the filter system
pump when the burners are firing. If the system pump
does not run continuously, an additional pump must be
installed to provide constant circulation through the pool
heater. The constant flow of warm pool water can help
prevent freezing.
2. Anytime the temperature measured at the sensor drops
below 45°F, the temperature control turns on the pump to
circulate the water, if the pump option is installed.
3. Location - Indoor pool heaters must be located in a room
having a temperature safely above freezing [32°F(0°C)].
4. Outdoor Pool Heater Installation - Use extreme caution to
prevent freezing. A snow screen should be installed to
prevent snow and ice accumulation around the pool heater
or its venting system.
COMBUSTION AND VENTILATION
AIR
Provisions for combustion and ventilation air must be in
accordance with Section 5.3, Air for Combustion and
Ventilation, of the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edition of
CAN/CGA-B149 Installation Code for Gas Burning
Appliances and Equipment, or applicable provisions of the
local building codes.
Provide properly-sized openings to the equipment room to
assure adequate combustion air and proper ventilation when the
pool heater is installed with conventional venting or sidewall
venting.
5. Shut-Down and Draining - If for any reason, the pool
heater is to be shut off, the following precautionary
measures must be taken:
Combustion Air Filter
This pool heater has a standard air filter located at the
combustion air inlet. This filter helps ensure clean air is used
for the combustion process. Check this filter every month and
replace when it becomes dirty. The filter size on the 500,000
- 750,000 units is 12" x 12" x 1" (30.5cm x 30.5cm x 2.5cm)
and 16" x 16" x 1 (40.6cm x 40.6cm x 2.5 cm) on the 990,000
- 2,070,000 units. You can find these commercially available
filters at any home center or HVAC supply store.
1. Shut off gas supply.
2. Shut off water supply.
3. Shut off electrical supply.
4. Drain the pool heater completely. Remove the
threaded drain plugs from the inlet and outlet sides of
the front header on the heat exchanger (see Figure 3).
Blow all water out of the heat exchanger. Leave
drains open until Spring.
Use filters rated for a maximum face velocity of 300 ft/min at
a maximum pressure drop of 0.5" water column (w.c.) Pleated
filters may be used provided they meet these specifications.
5. Drain pump and piping.
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Commercial Pool Heaters
Combustion Air Options
INSTALLATION
Continued
ƽ CAUTION: Some pleated filters are too
This pool heater has four combustion air options.
restrictive and could cause air flow problems.
1. Outside Combustion Air, No Ducts
You can direct outside combustion air to this pool heater using
either one or two permanent openings.
For convenience and flexibility, you can direct the combustion air
inlet from either the back or right side of the pool heater. To
arrange the combustion air inlet for side entry, follow the steps
below.
One Opening
The opening must have a minimum free area of one square
2
1. Remove the metal panel from the pool heater’s side wall
inch per 3000 Btu input (7cm per kW). You must locate this
opening within 12" (30cm) of the top of the enclosure.
(see Figure 4).
2. Remove screws from the air filter/bracket assembly.
3. Move the filter/bracket assembly from the rear of the pool
heater to the side opening (see Figure 5).
4. Attach the filter/bracket assembly to the pool heater’s side
using the pre-drilled screw holes.
5. Attach the metal panel to the rear combustion air opening
to seal it off.
Figure 6 – Outside Combustion Air - Single Opening
Two Openings
The combustion air opening must have a minimum free area of
2
one square inch per 4000 Btu/hr input (5.5cm per kW). You
must locate this opening within 12" (30cm) of the bottom of
the enclosure.
The ventilation air opening must have a minimum free area of
Figure 4 – Metal Panel Covering Side Combustion Air Inlet
2
one square inch per 4000 Btu/hr input (5.5cm per kW). You
must locate this opening within 12" (30cm) of the top of the
enclosure.
Figure 5 – Moving Air Filter/Bracket Assembly from Rear
of Pool Heater to Side
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Figure 7 – Outside Combustion Air - Two Openings
Figure 9 – Combustion Air from Interior Space
All dimensions are based on net free area in square inches.
Metal louvers or screens reduce the free area of a combustion
air opening a minimum of approximately 25%. Check with
louver manufacturers for exact net free area of louvers. Where
two openings are provided, one must be within 12" (30 cm) of
the ceiling and one must be within 12" (30 cm) of the floor of
the mechanical room. Each opening must have a minimum net
free area as specified in TABLE–C, page 12. Single openings
shall be installed within 12" (30 cm) of the ceiling.
2. Outside Combustion Air, Using Ducts
You can direct outside combustion air to this pool heater using
two air ducts to deliver the air to the mechanical room. Each
of the two openings must have a minimum free area of one
2
square inch per 2000 Btu input (11cm per kW).
The combustion air supply must be completely free of any
flammable vapors that may ignite or chemical fumes which
may be corrosive to the pool heater. Common corrosive
chemical fumes which must be avoided are fluorocarbons and
other halogenated compounds, most commonly present as
refrigerants or solvents, such as Freon, trichlorethylene,
perchlorethylene, chlorine, etc. These chemicals, when
burned, form acids which quickly attack the heat exchanger
finned tubes, headers, flue collectors, and the vent system. The
result is improper combustion and a non-warrantable,
premature pool heater failure.
Figure 8 – Outside Combustion Air Through Ducts
Exhaust Fans
Any fan or equipment which exhausts air from the mechanical
room may deplete the combustion air supply and/or cause a
downdraft in the venting system. Spillage of flue products
from the venting system into an occupied living space can
cause a very hazardous condition that must be immediately
corrected. If a fan is used to supply combustion air to the
mechanical room, the installer must make sure that it does not
cause drafts which could lead to nuisance operational problems
with the pool heater.
3. Outside Combustion Air, Using Direct Venting
With this option, you can connect combustion air vent piping
directly to the pool heater. See the information under Direct
Venting starting on page 21 for specific information regarding
this option.
4. Combustion Air from Interior Space
You can direct combustion air to this pool heater using air from
an adjoining interior space. You must provide two openings
from the mechanical room to the adjoining room.
Vertical DirectAire™ and Horizontal DirectAire™ venting
systems have specific requirements for combustion air ducts
from the outside which are directly connected to the pool
heater. See the requirements for combustion air duct in the
venting section starting on page 12.
Each of the two openings must have a net free area of one
2
square inch per 1000 Btu input (22cm per kW), but not less
2
than 100 square inches (645cm ).
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Commercial Pool Heaters
Keep the vent cap clear of snow, ice, leaves, and debris to
avoid blocking the flue.
INSTALLATION
Continued
VENTING
General Information
You must supply adequate combustion and ventilation air to
this pool heater. You must provide minimum clearances for the
vent terminal from adjacent buildings, windows that open, and
building openings. Follow all requirements set forth in the
latest edition of the National Fuel Gas Code, ANSI Z223.1, in
Canada, the latest edition of CAN/CGA Standard B149
Installation Code for Gas Burning Appliances and Equipment
or applicable local building codes. Vent installations for
connection to gas vents or chimneys must be in accordance
with Part 7, “Venting of Equipment” of the above-mentioned
standards.
IMPORTANT: Examine the venting system at
least once each year. Check all joints and vent
pipe connections for tightness. Also check for
corrosion or deterioration. If you find any
problems, correct them at once.
Figure 10 – Vent Termination from Peaked Roof - 10' or
Less From Ridge
IMPORTANT: Vent terminations are not shown in
Figures 10, 11, 12, and 13. Make sure all vertical
vents are installed with vent terminations
recommended by the vent manufacturer.
Venting Support
Support horizontal portions of the venting system to prevent
sagging. Provide an upward slope of at least 1/4 inch per foot
(21mm/m) on all horizontal runs from the pool heater to the
vertical flue run or to the vent terminal on sidewall venting
installations.
Do not use an existing chimney as a raceway if another
appliance or fireplace is vented through the chimney. The
weight of the venting system must not rest on the pool heater.
Provide adequate support of the venting system. Follow all
local and applicable codes. Secure and seal all vent
connections. Follow the installation instructions from the vent
material manufacturer.
Vertical Vent Termination Clearances
and Location
The vent terminal should be vertical and exhaust outside the
building at least 2 feet (0.61m) above the highest point of the
roof within a 10 foot (3.05m) radius of the termination.
Figure 11 – Vent Termination from Peaked Roof More Than 10'
From Ridge
The vertical termination must be a minimum of 3 feet (0.91m)
above the point of exit.
A vertical termination less than 10 feet (3.05m) from a parapet
wall must be a minimum of 2 feet (0.61m) higher than the
parapet wall.
You must locate the air inlet termination elbow at least 12"
(30cm) above the roof or above normal snow levels.
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Provide a minimum clearance of 4 feet (1.2m) horizontally
from electric meters, gas meters, regulators, and relief
equipment. Never locate the vent cap above or below electric
meters, gas meters, regulators, and relief equipment unless a
4 foot (1.2m) horizontal clearance is maintained.
Terminate the venting system at least 3 feet (0.9m) above any
forced air inlet within 10 feet (3.05m).
Terminate the venting system at least 4 feet (1.2m) below,
4 feet (1.2m) beside, or 1 foot (30cm) above any door, window,
or gravity air inlet into any building.
Locate vent termination at least 8 feet (2.4m) horizontally from
any combustion air intake located above the sidewall
termination cap.
ƽ CAUTION: Pool heaters which are shut
down or will not operate may experience freezing
due to convective air flow in the flue pipe,
through the air inlet, or from negative pressure in
the mechanical room. In cold climates, operate
pump continuously to help prevent freezing of
pool heater water. Provide proper freeze
protection. See Freeze Protection, page 7.
Figure 12 – Vent Termination from Flat Roof 10' or Less
from Parapet Wall
TABLE–A
TABLE - B
Flue and Air Inlet Pipe Sizes
Input
Btu/hr
Flue
Size
6"
Air Inlet
Size*
6"
500,000
650,000
750,000
990,000
1,260,000
1,440,000
1,800,000
2,070,000
8"
8"
8"
8"
10"
12"
12"
12"
12"
Figure 13 – Vent Termination from Flat Roof More Than 10'
from Parapet Wall
10"
12"
12"
14"
14"
Sidewall Vent Termination Clearances
and Location
Locate the bottom of the vent terminal at least 12 inches
(30cm) above grade and above normal snow levels. Locate the
bottom of the vent terminal at least 7 feet (2.13m) above grade
when located adjacent to public walkways. Do not terminate
directly above a public walkway.
* Minimum diameter for air inlet pipe. Installer may increase diameter one
pipe size for ease of installation, if needed. Refer to the National Fuel Gas
Code (ANSI Z223.1) Vent Tables for additional guidance on vent sizing of fan
Do not terminate the venting system in a window well,
stairwell, alcove, courtyard, or other recessed area. Do not
terminate the venting system below grade.
assisted appliances.
Locate vent termination at least 3 feet (0.91m) from an inside
corner of an L-shaped structure.
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Note: When the use of the DV box adapter in the following
venting systems is not practical, contact the manufacturer for
an “in-line” filter to address problems.
INSTALLATION
Combustion Air Inlet Piping
Continued
Length of Air Inlet Pipe
ƽ WARNING: Locate and install the
combustion air inlet cap correctly. Failure to do
so can allow the discharge of flue products to be
drawn into the combustion process. This can
result in incomplete combustion and potentially
hazardous levels of carbon monoxide in the flue
products. This will cause operational problems
and the spillage of flue products. Spillage of flue
products can cause personal injury or death due
to carbon monoxide poisoning.
The installed length of air inlet pipe from the pool heater to the
outside air inlet cap must not exceed 50 equivalent feet
(15.2m). Upsizing air inlet pipe diameters is permitted to meet
increased length requirements. Subtract 5 feet (1.5m) of
equivalent length for each 90° elbow. Subtract 2.5 feet (0.7m)
of equivalent length for each 45° elbow.
Do not exceed the limits for the combustion air inlet piping
lengths.
Sidewall Air Inlet
The sidewall or vertical rooftop DirectAire™ combustion air
supply system has specific vent material and installation
requirements. The air inlet pipe connects directly to the pool
heater to supply combustion air. In most installations, the
combustion air inlet pipe will be a dedicated system with one
air inlet pipe per pool heater. You can combine multiple air
inlets if the guidelines in Combined Air Inlet Points, page 13
are followed. The air inlet pipe will be connected to a
combustion air inlet cap as specified in this section.
The sidewall air inlet cap is supplied in the Horizontal
DirectAire™ Vent Kit. Order the kit from the appliance
manufacturer. This sidewall cap supplies combustion air for a
single pool heater only. See TABLE–D, page 17, for kit
numbers.
Locate the pool heater as close as possible to the sidewall
where you will install the combustion air supply system.
For normal installations, this system uses a single-wall pipe to
supply combustion air from outdoors directly to the pool
heater.
Where overnight temperatures reach 40°F, use a Type-B
double-wall vent pipe or an insulated single-wall pipe for
combustion air. This will help prevent moisture in the cool
incoming air from condensing and leaking from the inlet pipe.
TABLE-C
Minimum Recommended Combustion Air Supply to Mechanical Room
Combustion Air Source
Boiler Input
500,000
Outside Air*/2 Openings
Outside Air*/1 Opening
Inside Air/2 Openings
2
2
2
2
2
2
125 in (806 cm )
167 in (1077 cm )
500 in (3226 cm )
2
2
2
2
2
2
650,000
750,000
990,000
1,260,000
1,440,000
1,800,000
2,070,000
163 in (1052 cm )
217 in (1400 cm )
650 in (4194 cm )
2
2
2
2
2
2
188 in (1213 cm )
250 in (1613 cm )
750 in (4839 cm )
2
2
2
2
2
2
248 in (1,600cm )
330 in (2,129 cm )
990 in (6,388 cm )
1260 in (8,130 cm )
1440 in (9,291 cm )
1800 in (11,614 cm )
2
2
2
2
2
2
315 in (2,032cm )
420 in (2,710 cm )
2
2
2
2
2
2
360 in (2,323cm )
480 in (3,097 cm )
2
2
2
2
2
2
450 in (2,903cm )
600 in (3,871 cm )
2
2
2
2
2
2
518 in (3,342cm )
690 in (4,452 cm )
2070 in (13,356 cm )
*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings
must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the boiler only, additional gas fired units in the boiler room will require
an increase in the net free area to supply adequate combustion air for all units. Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI
Z223.1, in Canada refer to CAN/CGA-B149 Installation Code. Check all local code requirements for combustion air.
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You must install the combustion air inlet cap and the powered
vent cap on the same wall and in the same pressure zone. Do
not install the combustion air inlet cap closer than 10 feet
(3.05m) from an inside corner of an L-shaped structure.
Vertical Rooftop Air Inlet
Use the vertical air inlet terminations available from the pool
heater manufacturer, recommended and/or supplied by the vent
manufacturer, or use two 90° elbows as described on
page 24.
Figure 14 – Sidewall Combustion Air Inlet
Figure 16 – Roof Top Combustion Air Inlet
Clearances
You must locate the air inlet termination elbow at least 12"
(30cm) above the roof or above normal snow levels.
If the air inlet cap is within a 10 foot (3.05m) radius of the flue
outlet, the point of termination for the combustion air inlet cap
must be at least 3 feet (0.91m) below the point of flue gas
termination (vent cap).
Figure 15 – Air Inlet Cap for Sidewall Termination
To prevent recirculation of flue products from an adjacent vent
cap into the combustion air inlet, follow all applicable
clearance requirements in the latest edition of the National
Fuel Gas Code and/or CAN/CGA-B149 Installation Code and
instructions in the Installation and Service Manual.
Do not install the combustion air inlet cap closer than 10 feet
(3.05m) from an inside corner of an L-shaped structure.
Combined Air Inlet Points
The air inlet pipes from multiple pool heaters can be combined
to a single common connection if the common air inlet pipe
has a cross sectional area equal to or larger than the total area
of all air inlet pipes connected to the common air inlet pipe.
You must install the combustion air inlet cap at least one foot
(0.30m) above ground level and above normal snow levels.
2
The point of termination for the combustion air inlet cap must
be at least 3 feet (0.91m) below the point of flue gas
termination (powered vent cap) if it is located within 10 feet
(3.05m) of the flue outlet from the powered vent cap. Make
sure to properly install the air inlet cap assembly on the air
inlet pipe.
Example: Two 10" air inlet pipes (78.5 in area each) have a
2
2
total area of 157 in and will require a 15" (176.7 in area)
common air inlet pipe.
The air inlet point for multiple pool heater air inlets must be
provided with an exterior opening which has a free area equal
to or greater than the total area of all air inlet pipes connected
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Commercial Pool Heaters
Barometric Damper Location
INSTALLATION
Continued
Any venting system option that requires a barometric damper
must adhere to the following directions for optimum
performance.
to the common air inlet. This exterior opening for combustion
air must connect directly to the outdoors. The total length of
the combined air inlet pipe must not exceed a maximum of 50
(15.2m) equivalent feet. Subtract 5 feet (1.5m) for each 90°
elbow in the air inlet pipe. You must deduct the restriction in
the area provided by any screens, grills or louvers installed in
the common air inlet point. These are common on the sidewall
air inlet openings. Screens, grills or louvers installed in the
common air inlet can reduce the free area of the opening from
25% to 75% based on the materials used.
The preferred location for the barometric damper is in a tee or
collar installed in the vertical pipe rising from the pool heater’s
flue outlet. The barometric damper MUST NOT be installed in
a bull head tee installed on the pool heater’s flue outlet. The
tee or collar containing the barometric damper should be
approximately three feet vertically above the connection to
the pool heater’s flue outlet. This location ensures that any
positive velocity pressure from the pool heater’s internal
combustion fan is dissipated and the flue products are rising
due to buoyancy generated from the temperature of the flue
products. Adjust weights on the damper to ensure that draft is
maintained within the specified range.
Vent System Options
This pool heater has six venting options.
1. Conventional Negative Draft Venting
This option uses a vertical rooftop flue termination.
Combustion air is supplied from the mechanical room.
1. Conventional Negative Draft
Venting
2. Vertical DirectAire™ Venting
This option uses a vertical conventional vent for flue products.
Combustion air is supplied by a pipe from the sidewall or
rooftop. See page 16 for venting details.
IMPORTANT: Before installing the venting
system, follow all venting clearances and
requirements found in the Venting, General
Information section, page 10.
3. Sidewall Venting
This option uses a powered vent assembly to exhaust the flue
products out a sidewall vent termination. Combustion air is
supplied from the mechanical room. See page 17 for venting
details.
4. Horizontal DirectAire™ Venting
This option uses a powered vent assembly to exhaust the flue
products out a sidewall. Combustion air is supplied by a pipe
from the sidewall. See page 20 for venting details.
5. Direct Venting
This option uses a sealed AL29-4C flue and a separate
combustion air pipe to the outdoors. This system terminates
both the flue and combustion air inlet in the same pressure
zone. The flue outlet and combustion air intake may terminate
at either a sidewall (horizontal) or the rooftop (vertical). See
page 21 for venting details.
Figure 17 – Conventional Negative Draft Vertical Venting
with Combustion Air Louvers
This option uses Type-B doublewall flue outlet piping. The
blower brings in combustion air. The buoyancy of the heated
flue products cause them to rise up through the flue pipe. The
flue outlet terminates at the rooftop.
6. Outdoor Installation Venting
This option uses the installation of a special air inlet/vent cap
on top of the pool heater. See page 25 for venting details. All
pool heaters are shipped from the factory equipped for
conventional negative draft venting. All other optional vent
systems require the installation of specific vent kits and
venting materials. The following is a detailed explanation of
the installation requirements for each venting system,
components used and part numbers of vent kits for each model.
Negative Draft
The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper
operation. Make all draft readings while the pool heater is in
stable operation (approximately 2 to 5 minutes).
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Connect the flue vent directly to the flue outlet opening on the Common venting systems may be too large when an existing
top of the pool heater. No additional draft diverter or pool heater is removed.
barometric damper is needed on single unit installations with a
dedicated stack and a negative draft within the specified range At the time of removal of an existing pool heater, the following
of 0.02 to 0.08 inches w.c. If the draft in a dedicated stack for steps shall be followed with each pool heater remaining
a single pool heater installation exceeds the maximum connected to the common venting system placed in operation,
specified draft, you must install a barometric damper to control while other appliances remaining connected to the common
draft. Multiple pool heater installations with combined venting system are not in operation.
venting or common venting with other Category I negative
1. Seal any unused opening in the common venting system.
draft appliances require each pool heater to have a barometric
2. Visually inspect the venting system for proper size and
damper installed to regulate draft within the proper range.
horizontal pitch. Make sure there is no blockage or
Do Not connect vent connectors serving appliances vented by
natural draft (negative draft) to any portion of a mechanical
draft system operating under positive pressure. Connecting to
a positive pressure stack may cause flue products to be
discharged into the living space causing serious health injury.
restriction, leakage, corrosion and other unsafe conditions.
3. If possible, close all building doors and windows. Close all
doors between the space in which the appliances remaining
connected to the common venting system are located and
other building spaces.
4. Turn on clothes dryers and any other appliances not
connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts,
so they will operate at maximum speed. Do not operate a
summer exhaust fan.
Flue Outlet Piping
With this venting option, you must use Type-B doublewall (or
equivalent) vent materials. Vent materials must be listed by a
nationally-recognized test agency for use as vent materials.
Make the connections from the pool heater vent to the outside
stack as direct as possible with no reduction in diameter. Use
the National Fuel Gas Code venting tables for doublewall vent
to properly size all vent connectors and stacks. Follow the vent
manufacturer’s instructions when installing Type-B vents and
accessories, such as firestop spacers, vent connectors,
thimbles, caps, etc.
5. Close fireplace dampers.
6. Place in operation the unit being inspected. Follow the
lighting instructions. Adjust thermostat so pool heater will
operate continuously.
7. Test for spillage of flue gases at the draft hood/relief
openings of all appliances connected to the venting system
after five minutes of main burner operation.
8. After making sure that each appliance remaining
connected to the common venting system properly vents
when tested as above, return doors, windows, exhaust fans,
fireplace dampers and other gas burning appliances to their
previous conditions of use.
9. Correct any improper operation of the common venting
system so that the installation conforms to the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada,
the latest edition of CAN/CGA-B149 Installation Code for
Gas Burning Appliances and Equipment. When resizing
any portion of the common venting system, resize to
approach the minimum size as determined using the
appropriate tables of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CAN/CGA-B149 Installation Code for Gas Burning
Appliances and Equipment.
Provide adequate clearance to combustibles for the vent
connector and firestop.
When planning the venting system, avoid possible contact with
plumbing or electrical wiring inside walls, ceilings, and floors.
Locate the pool heater as close as possible to a chimney or gas
vent.
Avoid long horizontal runs of the vent pipe, 90° elbows,
reductions and restrictions.
No additional draft diverter or barometric damper is required
on single unit installations with a dedicated stack and a
negative draft maintained between 0.02 to 0.08 inches w.c.
Common Venting Systems
You can combine the flue with the vent from any other negative
draft, Category I appliance. Using common venting for multiple
negative draft appliances requires you to install a barometric
damper with each pool heater. This will regulate draft within the
proper range. You must size the common vent and connectors
from multiple pool heaters per the venting tables for Type-B
doublewall vents in the latest edition of the National Fuel Gas
Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
Masonry Chimney Installations
A masonry chimney must be properly sized for the installation
of a high efficiency gas-fired pool heater. Venting of a high
efficiency pool heater into a cold or oversized masonry
chimney can result in operational and safety problems.
Exterior masonry chimneys, with one or more sides exposed to
cold outdoor temperatures, are more likely to have venting
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Commercial Pool Heaters
You can terminate the combustion air pipe either horizontally
INSTALLATION
Continued
with a sidewall air inlet or vertically with a rooftop air inlet. The
installed length of air inlet pipe from the pool heater to the
outside air inlet cap must not exceed 50 equivalent feet
(15.2m).
problems. The temperature of the flue products from a high
efficiency pool heater may not be able to sufficiently heat the
masonry structure of the chimney to generate proper draft.
This will result in condensing of flue products, damage to the
masonry flue/tile, insufficient draft and possible spillage of
flue products into an occupied living space. Carefully inspect
all chimney systems before installation.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to determine
its suitability for the venting of flue products. A clay-tile-lined
chimney must be structurally sound, straight and free of
misaligned tile, gaps between liner sections, missing sections
of liner or any signs of condensate drainage at the breaching or
clean out. If there is any doubt about the condition of a
masonry chimney, it must be relined with a properly-sized and
approved chimney liner system. An unlined masonry chimney
must not be used to vent flue products from this high-
efficiency pool heater. An unlined chimney must be relined
with an approved chimney liner system when a new pool
heater is being attached to it. Metallic liner systems (Type-B
doublewall or flexible or rigid metallic liners) are
recommended. Consult with local code officials to determine
code requirements or the advisability of using or relining a
masonry chimney.
Figure 18 – Vertical DirectAire Installation with Sidewall
Combustion Air Inlet
Vertical Vent Termination Clearances and Location
Follow all vertical venting termination information for
clearances and location under Vertical Vent Termination
Clearances and Location, page 10.
2. Vertical DirectAire™ Venting
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
The Vertical DirectAire™ vent system is the same as the
Conventional Negative Draft vent system, except it pulls
combustion air from the outdoors through a sidewall or vertical
air inlet. Follow all requirements in Conventional Negative
Draft Venting, page 14.
Figure 19 – Air Inlet Cap for Sidewall Termination
The Vertical DirectAire™ vent system requires you to install
two vent pipes directly to the pool heater; one vertical pipe
with a rooftop termination for the flue products and one pipe
for combustion air. For this venting option, you must purchase
the DV box adapter. The DV box attaches to the air inlet of the
pool heater. The pipe for combustion air attaches to the DV
box.
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A barometric damper is not required in the flue on Vertical
DirectAire™ installations if the draft is within the negative
0.04 to 0.08 inches w.c. required for proper operation. If the
draft exceeds this range, install a barometric damper.
TABLE-D
DirectAire™ Kits
T–C
Input
Horizontal
Kit*
SVK3047 VDK3026
SVK3048 VDK3027
SVK3048 VDK3027
SVK3040 VDK3023
Vertical
Kit*
Btu/hr
500,000
650,000
750,000
990,000
1,260,000 SVK3041 VDK3024
1,440,000 SVK3041 VDK3024
1,800,000 SVK3041 VDK3024
2,070,000 SVK3041 VDK3024
Figure 20 – Vertical DirectAire Installation with Rooftop
Combustion Air Inlet
Vent Kits
*The SVK kits include a DV box adapter and sidewall air inlet cap. The
VDK kits include a DV box adapter and a rooftop air inlet cap. See note on
page 12 concerning DV box adapter.
ƽ WARNING: Only use a sidewall air inlet cap
supplied by the appliance manufacturer or a
rooftop air inlet cap supplied by the vent
manufacturer. Using any other air inlet cap for
single-unit installations or using a common air
inlet cap for multiple units with insufficient free
area and/or protections from wind and weather
may result in operational problems and the
spillage of flue products. Spillage of flue
products can cause personal injury or death due
to carbon monoxide poisoning.
3. Sidewall Venting
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
This option uses a powered vent assembly which pulls the flue
products out of the stack. This fan generates a negative draft at
the pool heater. Combustion air is drawn from the mechanical
room (see Combustion and Ventilation Air, page 7).
For single pool heater installations with sidewall air inlet, (see
Figure 18) you must order the sidewall air inlet kit. The part
number for each SVK kit is listed by input size in TABLE–D.
For single pool heater installations with rooftop air inlet (see
Figure 20), you must order the rooftop air inlet kit The part
number for each VDK kit is listed by input size in TABLE-D.
Purchase the flue pipe, rooftop flue termination, and air inlet
pipe locally.
There is no vent kit for combined air supply systems for multiple
pool heaters. Make sure the air inlet cap is properly sized. You
must purchase this cap locally.
Venting of Flue Products
For venting flue products vertically to the outdoors, follow all
requirements in the installation instructions for conventional
venting in this manual. Follow all clearance requirements in
Vertical Vent Termination Clearances and Location, page 10.
Figure 21 – Sidewall Venting Installation with an Induced
Draft Fan and Sidewall Vent Cap
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Commercial Pool Heaters
The sidewall fan/powered vent cap must be interlocked with
INSTALLATION
Continued
the pool heater’s control system to start the fan on a call for
heat and prove fan operation before the pool heater fires. Plug-
in and terminal strip connections are provided on the pool
heater for easy connection of the factory supplied vent kit and
control package for the sidewall vent fan.
Sidewall Fan
The sidewall fan can be mounted on the inside/outside
(depending upon model) with a sidewall vent hood installed on
the exterior wall. The sidewall fan and accessories are included
in a venting kit provided by the appliance manufacturer. See
TABLE–E for kit numbers.
Sidewall Venting Without Fan
For 500,000 - 750,000 Btu/hr models approved for sidewall
venting without an external power vent fan, you must install
specific vent kits and venting materials. The following is a
detailed explanation of Sidewall Venting Without an External
Fan installation requirements.
The venting kit includes the sidewall fan, vent hood, tapered
vent adapter, barometric damper, proving switch and all
necessary relays to interlock with the heaters control system.
The tapered vent adapter reduces the vent size at the inlet to the
fan. There should be no reduction in vent diameter from the
pool heater’s flue outlet to the sidewall fan. The barometric
damper must be installed on the flue and adjusted to supply a
negative draft within the range of 0.04 to 0.08 inches w.c.
while the pool heater is operating.
Flue Outlet Piping
Venting Guidelines
If using this venting option, a sealed AL29-4C venting system
for flue products is required on all models of this pool heater.
This venting system operates with a positive pressure in the
vent. The internal combustion air blowers generate this
positive pressure which operates the combustion process and
also exhausts the flue products from the building.
Flue Outlet Piping
With this venting option, you must use Type-B doublewall (or
equivalent) vent materials. Vent materials must be listed by a
nationally-recognized test agency for use as vent materials.
Make the connections from the pool heater vent to the sidewall
fan/cap as direct as possible with no reduction in diameter. Use
the National Fuel Gas Code venting tables for doublewall vent
to properly size all vent connectors and stacks. Follow the vent
manufacturer’s instructions when installing Type-B vents and
accessories, such as firestop spacers, vent connectors,
thimbles, caps, etc.
This vent system has specific vent material and installation
requirements. Only use listed sealed AL29-4C vent system
materials.
Follow all installation requirements. See
TABLE–B, page 11 for proper pipe size for your pool heater.
A list of sealed AL29-4C flue pipe manufacturers is located on
page 22.
Seal all vent joints and seams gas-tight.
When planning the venting system, avoid possible contact with
plumbing or electrical wiring inside walls.
The maximum installed length of sidewall vent pipe with an
induced draft fan must not exceed 100 feet (30.5m) on the
500,000 - 2,070,000 Btu/hr models. Note: Models 990,000 -
2,070,000 are not approved for sidewall venting without a fan.
The maximum installed length of sidewall vent pipe without an
induced draft fan must not exceed 50 feet (15.2m) on the
500,000 - 750,000 Btu/hr models. Subtract 5 feet (1.5m) for
each 90° elbow. Subtract 2.5 feet (0.7m) for each 45° elbow.
Drain Tee Installation
A drain tee must be installed in the vent pipe to collect and
dispose of any condensate that may occur in the vent system.
The drain tee must be installed as the first fitting after the
horizontal ell on the top of the unit (see Figures 22A and 22B).
Plastic drain tubing, sized per the vent manufacturer’s
instructions, shall be provided as a drain line from the tee. The
drain tubing must have a trap provided by a 3" (7.6cm)
diameter circular trap loop in the drain tubing. Prime the trap
loop by pouring a small quantity of water into the drain hose
before assembly to the vent. Secure the trap loop in position
with nylon wire ties. Use caution not to collapse or restrict the
condensate drain line with the nylon wire ties. The condensate
drain must be routed to a suitable drain for disposal of
condensate that may occur in the direct vent system. Refer to
the condensate drain installation instructions as supplied by the
manufacturer of the vent material.
Sidewall Venting Termination
The sidewall vent cap must be installed on an exterior sidewall.
The sidewall fan/powered sidewall vent cap and accessories
are included in a venting kit which is furnished by the pool
heater manufacturer in accordance with CSA International
requirements. This venting kit includes the powered sidewall
fan/cap, proving switch and all necessary relays to interlock
with the pool heater’s control system.
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The installed length of flue from the pool heater to the outside
point of termination must not exceed 50 equivalent feet
(15.2m). Subtract 5 feet (1.5m) of equivalent length for each
90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for
each 45° elbow.
Masonry Chimney Installation
Do not use a standard masonry chimney to directly vent the
combustion products from this pool heater.
To use a masonry chimney, the chimney must use a sealed,
corrosion-resistant liner system. Sealed, corrosion-resistant
liner systems (singlewall, doublewall, flexible, or rigid) must
be rated for use with a high efficiency, positive pressure vent
system.
Figure 22A – Direct Vent (Illustration with Sidewall Vent
and Sidewall Combustion Air)
Corrosion-resistant chimney liner systems are typically made
from a high grade stainless steel such as AL29-4C. The liner
must be properly sized and fully sealed throughout the entire
length. Both the top and bottom of the masonry chimney must
be capped and sealed to provide a dead air space around the
liner.
ƽ WARNING: Do not vent this pool heater into
a masonry chimney without a sealed stainless
steel liner system. Any breaks, leaks, or damage
to the masonry flue/tile will allow the positive-
pressure flue products to leak from the chimney
and into occupied living spaces. This could
cause serious injury or death due to carbon
monoxide poisoning and other harmful flue
products.
Figure 22B – Sidewall Venting
ƽ WARNING: Do not combine the flue from
this unit with the vent from any other appliance.
Do not combine flues from multiple appliances
into a common vent. The flue from this unit must
be a dedicated stack.
Connect the flue vent directly to the flue outlet opening on the
top of the pool heater. Make the connections from the pool
heater vent to the outside stack as direct as possible with no
reduction in diameter. Provide adequate clearance to
combustibles for the vent connector and firestop. Follow the
vent manufacturer’s instructions when installing sealed AL29-
4C vents and accessories, such as firestop spacers, vent
connectors, thimbles, caps, etc.
IMPORTANT: Check with local code officials to
determine code requirements or the advisability
of using a masonry chimney with a sealed
corrosion-resistant liner system.
Sidewall Vent Termination Clearances and Location
Follow all sidewall venting termination information for
clearances and location under Sidewall Vent Termination
Clearances and Location, page 11.
Provide adequate clearance to combustibles for the vent
connector and firestop.
When planning the venting system, avoid possible contact with
plumbing or electrical wiring inside walls, ceilings, and floors.
Locate the pool heater as close as possible to the chimney or gas
vent. When a vent system is disconnected for any reason, the
flue must be reassembled and resealed according to the vent
manufacturer’s instructions.
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Commercial Pool Heaters
connect the air inlet pipe to a combustion air inlet cap as
specified in this section.
INSTALLATION
Continued
TABLE-E
Sidewall Vent Kits
Input
Btu/hr
Kit*
(w/Power
Fan Assy.)
Max. Vent
Length
Vent
Max. Vent
Termination Only Length
(500,000 - 750,000 Btu/hr)
500,000 SVK3006
650,000 SVK3008
750,000 SVK3008
990,000 SVK3053
1,260,000 SVK3054
1,440,000 SVK3054
1,800,000 SVK3055
2,070,000 SVK3055
100 ft.
100 ft.
100 ft.
100 ft.
100 ft.
100 ft.
100 ft
100 ft.
SVK3043
SVK3044
SVK3044
N/A
50 ft.
50 ft.
50 ft.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Figure 23 – Horizontal DirectAire Installation (Illustration
with Sidewall Venter and Sidewall Combustion Air)
*These kits include a sidewall venter assembly, vent termination, and barometric damper.
Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air, page 7).
4. Horizontal DirectAire™ Venting
Vent Kits
You must order the Horizontal DirectAire™ Vent Kit for
sidewall installation. See TABLE–F for kit numbers. Each kit
includes a sidewall powered vent cap, proving switch,
controls, combustion air inlet cap to supply air to a single pool
heater, the transition adapter to attach the field supplied single
wall air inlet pipe to the pool heater and installation
instructions. Purchase flue pipe and air inlet pipe locally.
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
The Horizontal DirectAire™ vent system is the same as the
Sidewall Venting system, except it pulls combustion air from the
outdoors through a sidewall air inlet. Follow all requirements in
Sidewall Venting, page 17.
The sidewall air inlet cap supplied in the Horizontal
DirectAire™ Vent Kit is used to supply combustion air to a
single pool heater. Combustion air supply pipes from multiple
pool heaters can not be combined into a single air inlet pipe
and inlet point.
The Horizontal DirectAire™ vent system requires you to
install two vent pipes directly to the pool heater; one pipe for
flue products and one for combustion air. Install both vent
pipes horizontally with a sidewall termination point. For this
venting option, you must purchase the DV box accessory from
the pool heater manufacturer. The DV box attaches to the air
inlet of the pool heater. The pipe for combustion air attaches to
the DV box.
ƽ WARNING: Only use the sidewall air inlet cap
recommended by the appliance manufacturer.
Using another sidewall air inlet cap may result in
operational problems and the spillage of flue
products. Spillage of flue products can cause
personal injury or death due to carbon monoxide
poisoning.
Make vent connection directly to the top of the pool heater. No
additional draft diverter or barometric damper is required on
single unit installations with a dedicated stack and a negative
draft maintained between 0.04 to 0.08 inches w.c.
Venting of Flue Products
Termination point for the flue products must follow the
clearance requirements in Sidewall Vent Termination
Clearances and Location page 11.
The Horizontal DirectAire™ combustion air supply system
has specific vent material and installation requirements. The
air inlet pipe connects directly to the pool heater to supply
combustion air. The combustion air inlet pipe is a dedicated
system with one air inlet pipe per pool heater. You must
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For proper operation, a barometric damper is provided for materials.
Follow all installation requirements. See
TM
Horizontal DirectAire installations. The damper will help to TABLE–B, page 11 for proper pipe size for your pool heater.
ensure a draft between negative 0.04 to 0.08 inches w.c.
A list of sealed AL29-4C flue pipe manufacturers is located on
page 22.
TABLE-F
Seal all vent joints and seams gas-tight.
Horizontal DirectAire™ Kits
Drain Tee Installation
Input
A drain tee must be installed in the vent pipe to collect and
dispose of any condensate that may occur in the vent system.
The drain tee must be installed as the first fitting after the
horizontal ell on the top of the unit (see Figure 22A). Plastic
drain tubing, sized per the vent manufacturer’s instructions,
shall be provided as a drain line from the tee. The drain tubing
must have a trap provided by a 3" (7.6cm) diameter circular
trap loop in the drain tubing. Prime the trap loop by pouring a
small quantity of water into the drain hose before assembly to
the vent. Secure the trap loop in position with nylon wire ties.
Use caution not to collapse or restrict the condensate drain line
with the nylon wire ties. The condensate drain must be routed
to a suitable drain for disposal of condensate that may occur in
the direct vent system. Refer to the condensate drain
installation instructions as supplied by the manufacturer of the
vent material.
Btu/hr
500,000
Kit*
HDK3031
HDK3032
HDK3032
HDK3037
HDK3038
HDK3038
HDK3039
HDK3039
650,000
750,000
990,000
1,260,000
1,440,000
1,800,000
2,070,000
*These kits include a sidewall venter assembly, vent termination, DV box
adapter, sidewall air inlet cap, and a barometric damper. See note on page 12
concerning DV box adapter.
5. Direct Venting
ƽ WARNING: Do not combine the flue from
this unit with the vent from any other appliance.
Do not combine flues from multiple appliances
into a common vent. The flue from this unit must
be a dedicated stack.
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
Connect the flue vent directly to the flue outlet opening on the
top of the pool heater. Make the connections from the pool
heater vent to the outside stack as direct as possible with no
reduction in diameter. Provide adequate clearance to
combustibles for the vent connector and firestop. Follow the
vent manufacturer’s instructions when installing sealed AL29-
4C vents and accessories, such as firestop spacers, vent
connectors, thimbles, caps, etc.
This option uses sealed AL29-4C vent materials for the flue
outlet piping and separate combustion air inlet piping. This
system terminates both the flue and combustion air inlet in the
same pressure zone. The flue outlet and combustion air intake
may terminate at either a sidewall or the rooftop.
To use the optional Direct Vent system, you must install
specific vent kits and venting materials. The following is a
detailed explanation of Direct Vent installation requirements,
including the components used and vent kit part numbers.
Provide adequate clearance to combustibles for the vent
connector and firestop.
Flue Outlet Piping
Venting Guidelines
When planning the venting system, avoid possible contact with
plumbing or electrical wiring inside walls, ceilings, and floors.
Locate the pool heater as close as possible to the chimney or gas
vent. When a vent system is disconnected for any reason, the
flue must be reassembled and resealed according to the vent
manufacturer’s instructions.
If using this venting option, a sealed AL29-4C venting system
for flue products is required on all models of this pool heater.
This venting system operates with a positive pressure in the
vent. The internal combustion air blowers generate this
positive pressure which operates the combustion process and
also exhausts the flue products from the building.
The installed length of flue from the pool heater to the outside
point of termination must not exceed 50 equivalent feet
(15.2m). Subtract 5 feet (1.5m) of equivalent length for each
This vent system has specific vent material and installation
requirements. Only use listed sealed AL29-4C vent system
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When installing the vent cap, the wall opening must provide an air
INSTALLATION
Continued
space clearance of 2 inches (5.1cm) around the flue pipe. The
diameter of the opening for installation of the sidewall cap will be
4 inches (10.2cm) larger (minimum) than the nominal diameter of
the installed vent pipe to the horizontal vent cap.
90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for each
45° elbow.
Masonry Chimney Installation
Do not use a standard masonry chimney to directly vent the
combustion products from this pool heater.
Install the horizontal vent cap from the outside. Mount the vent
cap to the wall using four screws or wall anchors. Seal under the
screw heads with caulking. Install the sealed, AL29-4C vent
pipe from the pool heater to the vent cap.
To use a masonry chimney, the chimney must use a sealed,
corrosion-resistant liner system. Sealed, corrosion-resistant liner
systems (singlewall, doublewall, flexible, or rigid) must be rated
for use with a high efficiency, positive pressure vent system.
Horizontal Vent Termination Clearances and Location
Follow all sidewall venting termination information for
clearances and location under Sidewall Vent Termination
Clearances and Location, page 11.
Corrosion-resistant chimney liner systems are typically made
from a high grade stainless steel such as AL29-4C. The liner
must be properly sized and fully sealed throughout the entire
length. Both the top and bottom of the masonry chimney must
be capped and sealed to provide a dead air space around the liner.
TABLE-G
Direct Vent Kits
Input
Btu/hr
Horizontal
Kit*
Vertical
Kit*
ƽ WARNING: Do not vent this pool heater into a
masonry chimney without a sealed stainless steel
liner system. Any breaks, leaks, or damage to the
masonry flue/tile will allow the positive-pressure
flue products to leak from the chimney and into
occupied living spaces. This could cause serious
injury or death due to carbon monoxide poisoning
and other harmful flue products.
500,000
650,000
750,000
DVK3004
DVK3005
DVK3005
DVK3000
DVK3001
DVK3001
DVK3002
DVK3002
VDK3026
VDK3027
VDK3027
VDK3023
VDK3024
VDK3024
VDK3024
VDK3024
990,000
1,260,000
1,440,000
1,800,000
2,070,000
IMPORTANT: Check with local code officials to
determine code requirements or the advisability of
using a masonry chimney with a sealed corrosion-
resistant liner system.
* The DVK kit includes a DV box adapter, air inlet cap, and a sidewall vent termination. The
VDK kit includes a DV box adapter and an air inlet cap. See note on page 12 concerning
DV box adapter.
Flue Pipe Materials
Vertical DV Venting Termination
The following manufacturers supply flue materials suitable for
these models. All materials are made with AL29-4C stainless
steel. Call the numbers below for the nearest distributor.
You must use the vent termination recommended by the vent
manufacturer for vertical direct vent terminations. Follow all
vertical venting termination information for clearances and
location under Vertical Vent Termination Clearances and
Location, page 10.
Heat-Fab, Inc. Saf-T CI Vent. 1-800-772-0739.
Protech Systems, Inc. Fas-N-Seal Vent. 1-800-766-3473.
Metal-Fab, Inc. Corr/Guard Vent. 1-800-835-2830.
Horizontal DV Venting Termination
Horizontal venting (air inlet and flue outlet on the same wall)
uses the pool heater’s internal combustion air blowers to force
the flue products out of the horizontally-terminated flue.
Combustion Air Inlet Piping
The Direct Vent system requires the installation of a pipe to
supply combustion air from the outdoors directly to the pool
heater. The air inlet piping can either be brought in horizontally
from a sidewall or vertically from the rooftop. Make sure the
combustion air inlet is in the same pressure zone as the vent
terminal.
You must purchase a horizontal direct vent kit from the pool heater
manufacturer to ensure proper operation. See TABLE–G, this
page, to determine which horizontal direct vent kit you need.
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In cold climates, use a Type-B doublewall vent pipe or an Note: Modifications to the DV box adapter will be necessary
insulated single wall pipe for combustion air. This will help to allow installation on the right side of the pool heater. Follow
prevent moisture in the cool incoming air from condensing and the instructions shipped with the vent kit.
leaking from the inlet pipe.
Attach the filter/bracket assembly and DV box adapter to the
right side opening using the pre-drilled screw holes. Make sure
ƽ CAUTION: Pool heaters that are shut down
you attach the metal panel to the rear combustion air opening of
the pool heater.
or will not operate may experience freezing due
to convective airflow in the air inlet pipe.
The DV box adapter has an air inlet pipe mounting ring.
Connect combustion air inlet piping to the direct vent box
mounting ring.
Length of Air Inlet Pipe
The installed length of air inlet pipe from the pool heater to the
outside air inlet cap must not exceed 50 equivalent feet
(15.2m). Subtract 5 feet (1.5m) of equivalent length for each
90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for
each 45° elbow.
Do not exceed the limits for the combustion air inlet piping
lengths.
Connecting the Air Inlet Pipe to the Pool Heater
Connect the air inlet piping directly to the pool heater by
attaching it to the DV box adapter. The DV box adapter is
included in the direct vent kits for horizontal direct vent. For
vertical direct vent, order the DVK3003 kit from the pool
heater manufacturer. The combustion air inlet area of the pool
heater is located at the right rear corner of the pool heater. This
pool heater uses a simple air filter to ensure clean air is used
for the combustion process. Attach the DV box adapter over
the air filter (see Figure 24). Align the screw holes on the DV
box adapter with the screw holes surrounding the air filter
hanger. Insert the sheet metal screws and tighten firmly.
Figure 25 – Moving Air Filter Assembly and DV Box
Adapter
Air Inlet Piping Materials
The air inlet pipe(s) must be sealed. Select the air inlet pipe
material from the following specified materials.
•
•
PVC, CPVC, or ABS (6", 7", or 8" I.D.)
Galvanized steel vent pipe with joints and seams sealed as
specified below.
Type-B doublewall vent with joints and seams sealed as
specified below.
•
Check local codes for possible restrictions.
ƽ WARNING: Use only vent or air intake
materials specified in this manual. Follow vent
pipe manufacturer’s instructions. Failure to do so
can result in property damage, personal injury, or
death. Mixing of venting materials will void the
warranty and certification of this pool heater.
Sealing Type-B Doublewall Vent Pipe or Galvanized
Vent Pipe
Follow the steps below to properly seal Type-B doublewall
vent pipe or galvanized vent pipe.
Figure 24 – Attaching DV Box Adapter to Unit
For venting versatility, you can move the air filter assembly and
DV box adapter to the right side of the pool heater. Remove the 1. Seal all joints and seams of the air inlet pipe using either
metal panel on the pool heater’s right side (see Figure 25).
Remove the filter/bracket assembly from the rear of the pool
heater.
aluminum foil duct tape meeting UL Standard 723 or 181
A-P or a high quality UL Listed silicon sealant such as
those manufactured by Dow Corning or General Electric.
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ƽ WARNING: Locate and install the
INSTALLATION
2. On horizontal runs, do not install vent pipe with seams
pointing down. Position vent pipe so that the seams are on
the top side of the vent pipe.
Continued
combustion air inlet termination correctly.
Failure to do so can allow the discharge of flue
products to be drawn into the combustion
process. This can result in incomplete
combustion and potentially hazardous levels of
carbon monoxide in the flue products. This will
cause operational problems and the spillage of
flue products. Spillage of flue products can
cause personal injury or death due to carbon
monoxide poisoning.
3. Secure all joints with a minimum of three sheet metal
screws or pop rivets. Apply aluminum foil duct tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
4. Ensure that the air inlet pipes are properly supported.
You must locate the combustion air cap and the flue gas outlet
on the same rooftop surface (vertical direct vent system) or
sidewall surface (horizontal direct vent system) and in the
same pressure zone as the vent termination. Follow all
clearance requirements listed on pages 8 and 9.
ƽ WARNING: Properly seal all joints and
seams in the inlet vent piping system. Failure to
do so may result in flue gas recirculation,
spillage of flue products, and carbon monoxide
emissions. Carbon monoxide poisoning can
cause severe personal injury or death.
Purchase and assemble the combustion air inlet cap to protect
the air inlet from wind and weather.
Combined Combustion Air Inlet Points
You can combine the air inlet pipes from multiple pool heaters
to a single common connection if the common air inlet pipe
has a cross sectional area equal to or larger than the total area
of all air inlet pipes connected to the common air inlet pipe.
Alternatively, assemble the combustion air inlet cap for the
vertical rooftop air inlet from items purchased locally. The air
inlet cap consists of two 90° elbows installed to the air inlet
pipe (see Figure 26). Install the first 90° elbow on the rooftop
at the highest vertical point of the air inlet pipe. Install the
second 90° elbow on the horizontal outlet of the first elbow.
The outlet of the second 90° elbow will be pointing down. You
may use a 90° elbow and a 90° street elbow to make this
assembly. If you use a straight piece of pipe between the two
90° elbows, it should not exceed 6" (51mm) in length.
2
2
Example: Two 8" (20.3cm) air inlet pipes (50.3 in [324.5cm ]
2
2
area each) have a total area of 100.6 in (645.2cm ), requiring
2
2
a 12" (30.5cm) (113.1 in [729.7cm ]) common air inlet pipe.
The air inlet point for multiple pool heater air inlets must be
provided with an exterior opening which has a free area equal
to or greater than the total area of all air inlet pipes connected
to the common air inlet. This exterior opening for combustion
air must connect directly to the outdoors. The total length of
the combined air inlet pipe must not exceed a maximum of 50
(15.2m) equivalent feet. You must deduct the restriction in area
provided by any screens, grills, or louvers installed in the
common air inlet openings and some rooftop terminations.
Screens, grills, or louvers installed in the common air inlet can
reduce the free area of the opening from 25% to 75% based on
the materials used.
Vertical and Sidewall Combustion Air Inlet
Figure 26 – Vertical Rooftop Air Inlet
IMPORTANT: To prevent recirculation of flue
products into the combustion air inlet, follow all
instructions in this section.
For horizontal direct vent termination of combustion air, you
must use the termination cap from the pool heater
manufacturer. The sidewall air inlet cap is available as part of
a direct vent kit. See TABLE–G for Horizontal Direct Vent
Kits.
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Vertical Combustion Air Inlet Clearances
ƽ WARNING: Only install outdoor models
outdoors and only use the vent cap supplied by
the pool heater manufacturer. Personal injury or
product damage may result if any other cap is
used or if an outdoor model is used indoors.
Properly install all covers, doors and jacket
panels to ensure proper operation and to prevent
a hazardous condition.
You must locate the air inlet termination elbow at least 12"
(30cm) above the roof or above normal snow levels.
If the air inlet cap is within a 10 foot (3.05m) radius of the flue
outlet, the point of termination for the combustion air inlet cap
must be at least 3 feet (0.91m) below the point of flue gas
termination (vent cap).
Do not install the combustion air inlet cap closer than 10 feet
(3.05m) from an inside corner of an L-shaped structure.
Combustion air supply must be free of contaminants (see
Combustion and Ventilation Air, page 7). To prevent
recirculation of the flue products into the combustion air inlet,
follow all instructions in this section.
Horizontal Combustion Air Inlet Clearances
You must locate the horizontal air inlet termination point at
least 12" (30cm) above grade and above normal snow levels.
Outdoor Vent/Air Inlet Location
Keep venting areas free of obstructions. Keep area clean and
free of combustible and flammable materials. Maintain a
minimum clearance of 3" (76mm) to combustible surfaces and
a minimum of 3" (76mm) clearance to the air inlet. To avoid a
blocked air inlet or blocked flue condition, keep the outdoor
cap air inlet, flue outlet and drain slot clear of snow, ice, leaves,
debris, etc.
If the air inlet cap is within a 10 foot (3.05m) radius of the flue
outlet, the point of termination for the combustion air inlet cap
must be at least 3 feet (0.91m) horizontally and 12 inches
(30cm) below the point of flue gas termination (vent cap). Do
not install the horizontal combustion air inlet cap above the
flue outlet.
Do not install the combustion air inlet cap closer than 10 feet
(3.05m) from an inside corner of an L-shaped structure.
Do not install outdoor models directly on the ground. You must
install the outdoor pool heater on a concrete, brick, block, or
other non-combustible pad.
Multiple Sidewall Direct Vent Installations
Do not locate the pool heater so that high winds can deflect off
of adjacent walls, buildings or shrubbery causing recirculation.
Recirculation of flue products may cause operational
problems, bad combustion or damage to controls. Locate unit
at least 3 feet (0.91m) from any wall or vertical surface to
prevent wind conditions from affecting performance.
The combustion air inlet caps for multiple pool heater
installations must maintain the same minimum clearance from
the closest flue vent cap as specified in single pool heater
installations. You may install multiple flue outlet caps side-by-
side and multiple combustion air inlet caps side-by-side, but
the air inlet must always be at least 3 feet (0.91m) horizontally
and 12 inches (30cm) below the closest flue outlet. Do not
install combustion air inlet caps above the flue outlets.
Multiple pool heater outdoor installations require 48" (1.22m)
clearance between each vent cap. Locate the outdoor cap at
least 48" (1.22m) below and 48" (1.22m) horizontally from
any window, door, walkway or gravity air intake.
Maintain all clearances and installation requirements for
multiple pool heater installations.
Locate the pool heater at least 10 feet (3.05m) away from any
forced air inlet.
6. Outdoor Installation Venting
Locate pool heater at least 3 feet (0.91m) outside any
overhang.
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
Clearances around outdoor installations can change with time.
Do not allow the growth of trees, shrubs or other plants to
obstruct the proper operation of the outdoor vent system.
These pool heaters are self-venting and can be used outdoors
when installed with the optional outdoor cap. This cap mounts
directly to the top of the pool heater and covers the flue outlet
and combustion air inlet openings. No additional vent piping is
required.
Do not install in locations where rain from building runoff
drains will spill onto the pool heater.
E–G
Outdoor Vent Cap Kit
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INSTALLATION
Continued
TABLE-H
Outdoor Vent Cap Kits
Input
Btu/hr
Outdoor Vent Kit*
500,000
650,000
ODK3075
ODK3076
ODK3076
ODK3077
ODK3078
ODK3079
ODK3080
ODK3080
750,000
990,000
1,260,000
1,440,000
1,800,000
2,070,000
Figure 27 – Outdoor Vent Cap Installed on Rear of Pool
Heater
* These kits include an outdoor vent cap and gasket.
CONNECTING TO GAS SUPPLY
Only supply gas type specified on the pool heater’s rating
plate. This pool heater is orificed for operation up to 2000 feet
altitude. If installing above 2000 feet elevation, consult the
pool heater manufacturer.
Flue gas condensate can freeze on exterior walls or on the vent
cap. Frozen condensate on the vent cap can result in a blocked
flue condition. Some discoloration to exterior building or pool
heater surfaces can be expected. Adjacent brick or masonry
surfaces should be protected with a rust resistant sheet metal
plate.
INLET PRESSURE: Measure inlet pressure at the inlet
pressure tap located upstream of the combination gas valve(s).
The Outdoor Vent Cap Kit
The optional outdoor vent cap kit is available from the pool
heater manufacturer. The outdoor cap part numbers are listed
by input size. See TABLE–H for kit numbers.
See TABLE–I for maximum and minimum inlet pressures. Do
not exceed the maximum. Minimum inlet pressure is for the
purposes of input adjustment.
Install the outdoor vent cap on the rear of the pool heater, see
Figure 27.
TABLE-I
Inlet Pressure
The air filter bracket will need to be rotated as shown in
Figure 27 to allow proper access to the filters with the outdoor
vent cap in place.
TABLE–H
Inlet Pressure
Max.
Min.
Nat. Gas 10.5" w.c. 4.5" w.c.
LP Gas 13" w.c. 8" w.c.
The 3-Way Valve Cover Installation
The 3-way bypass valve requires a cover for outdoor use. This
cover is provided with the outdoor vent kits listed in Table-H.
See page 31 for 3-way valve cover installation instructions.
MANIFOLD PRESSURE: Measure manifold pressure at the
pressure tap on the downstream side of the combination gas
valves. The gas regulator on the pool heater’s combination gas
valves is preset at the factory to supply proper manifold
pressure for normal operation. See TABLE–L, page 31 for net
manifold pressure settings.
Combustion Air Fan Adjustment
(for startup)
For startup, the combustion air fan shutter may require
adjustment. Should the combustion air fan shutter need
adjusting refer to the Adjusting Differential Air Pressure
instructions located under the Cleaning and Maintenance
If you must adjust regulator pressure, follow the instructions
under Gas Manifold Pressure Adjustment, page 30. Do not
increase regulator pressure beyond specified pressure setting.
section on page 49 of this manual.
Note: The manifold gas pressure can affect the differential air
pressure. Once the combustion air fan shutter has been
adjusted, confirm manifold gas pressure as described in the
Gas Manifold Pressure Adjustment section on page 30 of this
manual.
Gas Pressure Test
1. Disconnect the unit from the gas supply piping system
during any piping system pressure testing greater than 1/2
PSIG (3.5kPa).
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2. Isolate the pool heater from the gas supply piping system
by closing a manual shutoff valve during any piping
system pressure testing that is equal to or less than 1/2
PSIG (3.5kPa).
3. Test all gas connections for gas leaks before placing the
pool heater in operation.
Gas Piping
To safely operate this pool heater, you must properly size the
gas supply piping. See Tables- J and K for piping and fitting
requirements. Gas pipe size may be larger than pool heater
connection.
On models 500,000 - 750,000 Btu/hr the gas connection to the
pool heaters are 1 1/4" NPT and on models 990,000 -
2,070,000 Btu/hr the gas connections to the pool heaters are
2" NPT.
Figure 28 – Gas Line Connection
5. Run pipe or tubing to the pool heater’s gas inlet. If you use
tubing, obtain a tube to pipe coupling to connect the tubing
to the pool heater’s gas inlet.
IMPORTANT: Do not block access to the
electrical cover plate when installing the
sediment trap. The sediment trap must be a
minimum of 12 inches from the pool heater.
6. Install a sediment trap in the supply line to the pool
heater’s gas inlet (see Figure 28).
7. Apply a moderate amount of good quality pipe compound
(do not use Teflon tape) to pipe only, leaving two end
threads bare.
Optional gas controls may require routing of bleeds and vents
to the atmosphere, outside the building when required by local
codes.
Note: All secondary regulators MUST BE of the lock-up type
8. Remove the seal over the gas inlet to the pool heater.
and spaced a minimum of 6' from the appliance.
9. Connect the gas pipe to the inlet of the pool heater. Use a
wrench to support the gas manifold on the pool heater.
Connecting Gas Piping to the Pool
10. For L.P. gas, consult your L.P. gas supplier for expert
installation.
Heater
All gas connections must be made with pipe joint compound
resistant to the action of liquefied petroleum (L.P.) and natural
gases. All piping must comply with local codes and
ordinances. Piping installations must comply with approved
standards and practices.
11. Ensure that all air is completely bled from the gas line
before starting the ignition sequence. Start up without
properly bleeding air from the gas line may require
multiple reset functions of the ignition control module to
achieve proper ignition.
1. Make sure the gas line is a separate line direct from the
meter unless the existing gas line is of sufficient capacity.
Verify pipe size with your gas supplier.
ƽ WARNING: Do not have any open flame in
proximity to the gas line when bleeding air from
the gas line. Gas may be present.
2. Use new, properly threaded black iron pipe free from chips.
If you use tubing, make sure the ends are cut square,
deburred and clean. Make all tubing bends smooth and
without deformation. Avoid flexible gas connections.
Internal diameter of flexible lines may not provide the pool
heater with the proper volume of gas.
Gas Train and Controls
Note: The gas train and controls assembly provided on this
pool heater have been tested under the applicable American
National Standard to meet minimum safety and performance
criteria such as safe lighting, combustion and safety shutdown
operation.
3. For ease of service, install a union.
4. Install a manual main gas shutoff valve at the pool heater’s
gas inlet, outside of the pool heater in accordance with the
National Fuel Gas Code, ANSI Z223.1, this must be
installed within 6 feet of the pool heater.
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The manifold pressure is preset at the factory and adjustment
INSTALLATION
Continued
is not usually required. If you must adjust regulator pressure,
follow the instructions under Gas Manifold Pressure
Adjustment, page 30.
Figure 29 shows a typical pool heater gas train.
Venting of Combination Gas Valves
The combination gas valve/regulator used on these pool
heaters is equipped with an integral vent limiting orifice per
ANSI Z21.78. The vent limiter ensures that the volume of gas
emitted from the valve in the event of a failed gas diaphragm
does not exceed the maximum safe leakage rate allowed by
agency requirements. Combination gas valve/regulators
equipped with integral vent limiters are not required to have
vent or relief lines piped to the outdoors.
Figure 29 – Typical Pool Heater Gas Train Drawing
Checking Gas Supply Pressure
Use the following procedure to check gas supply pressure.
TABLE-J
1. Turn the main power switch to the “OFF” position.
2. Turn gas valve knobs to the “OFF” position.
Suggested Gas Pipe Size for Single Unit Installations
Btu/hr
Input
Distance From Meter (in feet)
51-100 101-200 201-300 301-500
3. Shut off gas supply at the field-installed manual gas cock
in the gas piping to the pool heater. If fuel supply is L.P.
gas, shut off gas supply at the tank.
0-50
500,000 1 1/4"
650,000 1 1/2"
750,000 1 1/2"
1 1/2"
2"
2"
2"
2"
2 1/2"
2 1/2"
2 1/2"
3"
2 1/2"
2 1/2"
3"
4. Remove the 1/8" hex plug, located on the “inlet” side of
any gas valve. You may also use a tapping on the field-
installed main manual gas cock or gas piping. Install a
fitting in the inlet pressure tapping suitable to connect to a
manometer or magnahelic gauge. Range of scale should be
14" w.c. or greater to check inlet pressure.
2"
2"
990,000
2"
2"
2 1/2"
2 1/2"
3"
3"
5. Turn on gas supply at the manual gas cock, turn on L.P. gas
at the tank if required.
1,260,000 2"
2 1/2"
2 1/2"
3"
3"
1,440,000 2 1/2"
1,800,000 2 1/2"
2,070,000 2 1/2"
3"
3 1/2"
3 1/2"
4"
6. Turn the power switch to the “ON” position.
7. Turn the gas valve knobs to the “ON” position. Set the
temperature control to call for heat. See Operating
Temperature Control on page 40 for programming
instructions.
3"
3 1/2"
3 1/2"
3"
3"
8. Observe the gas supply pressure as all burners are firing.
Ensure that inlet pressure is within the specified range. See
Connecting To Gas Supply, page 26 for minimum and
maximum gas supply pressures.
Combination Gas Valves
These pool heaters fire in a single stage of operation.
Note: This pool heater incorporates a “soft start” feature
which lights approximately half of the burners before lighting
the remaining burners. Each combination valve consists of a
gas regulator and two valve seats to meet the requirements for
redundant gas valves. The valve has a gas control knob that
must remain in the open position at all times when the pool
heater is in service. The gas control valve has pressure taps
located on the inlet and discharge sides of the valve. Manifold
pressure is adjusted using the regulator located on the valve. A
manifold gas pressure tap for each burner stick is located on
the discharge side of the valve.
9. If gas pressure is out of range, contact gas utility, gas
supplier, qualified installer or service agency to determine
necessary steps to provide proper gas pressure to the pool
heater.
10. If gas supply pressure is within normal range, turn the
power switch to the “OFF” position.
11. Turn gas valve knobs to the “OFF” position.
12. Shut off gas supply at the manual gas cock in the gas
piping to the pool heater. If fuel supply is L.P. gas, shut off
gas supply at the tank.
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13. Remove the manometer and related fitting from the “inlet”
side of the gas valve, replace 1/8" hex plug in the gas valve
and tighten.
14. Turn on the gas supply at the manual valve, turn on L.P.
gas at the tank if required.
15. Turn the power switch to the “ON” position.
16. Turn the gas valve knobs to the “ON” position.
17. Set the temperature control to call for heat.
ƽ WARNING: After completing any testing on
the gas system, leak test all gas connections.
Apply
a
soap/water solution to all gas
connections while main burners are operating.
Bubbles forming indicate a leak. Repair all leaks
at once. Do not operate this pool heater with a
leak in the gas train, valves or related piping.
Check burner performance by cycling the system while you
observe burner response. Burners should ignite promptly.
Flame pattern should be stable, see Burner Flames, page 47.
Turn system off and allow burners to cool, then cycle burners
again to ensure proper ignition and flame characteristics.
Figure 30
–
Measuring Gas Supply Pressure at
Combination Gas Valve
TABLE - K
Multiple Unit Installations Gas Supply Pipe Sizing
Nominal Iron
Pipe Size,
(Inches)
Length of Pipe In Straight Feet
10
369
20
256
30
205
384
789
40
174
328
677
50
155
292
595
923
60
141
267
543
830
70
128
246
502
769
80
121
256
472
707
90
113
210
441
666
100
106
200
410
636
125 150 175 200
3/4"
1"
95
179
369
564
86
79
74
697
477
164
333
513
974
149 138
308 287
472 441
871 820
1 1/4"
1 1/2"
2"
1,400
2,150
4,100
6,460
11,200
974
1,500
2,820
4,460
7,900
1,210 1,020
2,260 1,950
3,610 3,100
6,400 5,400
1,720 1,560 1,440 1,330 1,250 1,180 1,100
2-1/2"
3"
2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300
4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340
4"
23,500 16,100
13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720
Maximum capacity of pipe in thousands of BTU’s per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a total system
pressure drop of 0.5 Inch Water Column (Based on NAT GAS, 1025 BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity).
29
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Commercial Pool Heaters
6. Remove the 1/8" hex plug from the manifold pressure tap
INSTALLATION
Continued
on the gas valve (see Figure 31). Retain plug for future
use.
Gas Manifold Pressure Adjustment
7. Install a fitting in this tap that is suitable for connection of
a hose to a manometer, or (+) side of a magnahelic gauge
(see Figure 31).
IMPORTANT: The gas valves are referenced to
the fan pressurized chamber by
a
hose
connected from the vent of the gas valve
regulator to the chamber pressure tap located on
the front inside portion of the jacket. Reference
the drawings in this section for component and
connection points for pressure measurement.
The procedure for connecting a manometer or
magnahelic must be followed to obtain actual net
manifold pressure for normal operation. A
manometer or magnahelic gauge legible in 0.1"
increments up to 10 inches w.c. is required to
check and adjust the manifold pressure. The
regulator cover screw on the gas valve must be
in place and tight at all times for the pool heater
to operate properly.
8. Turn the power switch to the “I” or “ON” position.
9. Push the reset button(s) for the ignition control(s), if
necessary.
10. Set the temperature control to call for heat (see
Programming Temperature Control, page 41).
11. Once the pool heater is firing the manometer/magnahelic
will reflect the Manifold Gas Pressure. Compare this
reading to the respective value in TABLE-L, page 31 for
Natural Gas or Propane Gas.
12. If adjustment is necessary, remove the regulator cover
screw on the gas valve.
1. Remove the thumbscrew that fastens the control panel
access door and pull out the control panel.
Note: If the gas valve under adjustment is located on a
manifold assembly monitored by an igniter, the pool heater
may shut down and recycle when the regulator cover screw is
removed. This is normal.
2. Turn the power switch located in the lower left corner
behind the control panel access door to the “O” or “OFF”
position.
13. Turn the regulator adjustment screw “clockwise” ꢀ to
raise the regulator gas pressure. Turn the regulator
adjustment screw “counterclockwise” ꢁ to lower the
regulator gas pressure.
3. Remove the top front jacket access panels to access the gas
valves.
4. Locate the reference hose on the second gas valve which
goes from the vent fitting on the gas valve to a barbed
fitting on the deck of the pool heater (see Figure 31).
14. Replace the regulator cover screw and make sure it is tight
for proper operation.
5. Remove the flexible cap from the barbed fitting on the
“tee” located in this line and hook one side of the
manometer, or (-) side of a magnahelic gauge, to this “tee”.
Retain this cap for future use.
15. Read the value on the manometer/magnahelic and compare
it to the values in TABLE-L.
16. Repeat this adjustment procedure for each gas valve as
necessary to adjust to the proper manifold gas pressure.
MANIFOLD
PRESSURE
17. Remove hoses, replace and tighten plugs and caps when
complete.
CAP
PRESSURE
INLET
18. Replace top front upper jacket access panels and control
panel door in reverse order.
REGULATOR
4
ADJUSTMENT
(UNDER CAP SCREW)
3
2
1
0
19. If proper ignition and burner operation is not achieved after
checking gas supply pressure, see Cleaning and
Maintenance, page 49 for Combustion Air Fan
BARBED
1
FITTING
CHAMBER
PRESSURE
2
3
4
GAS
VALVE
CONTROL
KNOB
Adjustment.
Follow the procedure to adjust the
combustion air fans as necessary.
MANOMETER
1/8" HEX
MANIFOLD
PRESSURE
TAP
OUTLET
Figure 31 – Measuring Net Manifold Gas Pressure
30
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pipe threads have been cut into the PVC pipe wall, the limit
and bulbwell can be inserted into the tapped openings. Apply a
TABLE-L
Net Manifold Pressure
small amount of a high quality RTV silicone sealant to the
threads to prevent leaks and install the limit and bulbwell into
the threaded openings in the pipe. Install the limit control and
bulbwell and tighten to seal. Do not over tighten either part
into the threaded openings in the PVC pipe. Over tightening
can damage the parts and/or strip the threads cut into the
plastic pipe. Install the pool supply sensor into the bulbwell
and connect it to the pool heater circuit as shown in the wiring
diagram for your model. Wire the limit into the pool heater
control circuit as shown in the wiring diagram. If additional
wire length is needed, use 18 GA wire for distances up to 30 ft.
For longer distances, size the wire per Table M, page 37. Use
weatherproof connections for outdoor installation.
500,000 - 750,000
Nat. Gas
1.8" w.c.
4.6" w.c.
LP Gas
990,000 - 2,070,000
Nat. Gas
LP Gas
1.2" w.c.
4.6" w.c.
* Net Manifold Pressure equals the measured manifold pressure minus the chamber
pressure. See Figure 31 to measure the Net Manifold Pressure.
Pumped Automatic Bypass
POOL HEATER PIPING
INSTALLATION
This is a high efficiency pool heater which requires a special
pumped bypass for proper operation. The bypass assembly
supplied with the pool heater includes a pump and a 3-way
mixing valve. All piping to connect the filter system to the
pool heater is made directly to the bypass piping on the pool
heater.
Install piping from the filter system to the pool heater as shown
in the pool heater piping diagrams. See Figures 34 - 38.
Minimum pipe diameter to and from the installed pool heater
to the filter system piping on models 500,000 - 750,000 Btu/hr
is 2" and on models 990,000 - 2,070,000 Btu/hr the minimum
is 2-1/2". The piping from the filter system to the pool heater
may be PVC, CPVC or Copper Pipe. The piping from the
pool heater back to the filter system will carry water with
temperatures in excess of 110°F and must be CPVC or
Copper Pipe. The temperature of the heated water from the
pool heater will be substantially cooled as it is mixed back into
the pool water from the filter system and returned to the pool.
The mix of heated water and pool water from the filtration
system should only be slightly warmer than the pool water
before the connections from the pool heater.
Outdoor Operation - Outdoor 3-Way
Automatic Bypass Valve Cover
The pump supplied on the pool heater bypass has a sealed
motor suitable for outdoor installations. When installing the
3-way automatic bypass valve outdoors, an outdoor valve
cover is required. An outdoor valve cover is supplied with an
optional outdoor vent kit (see Table H, page 26 of this manual).
To install the outdoor valve cover, follow the steps below:
1. Turn off power to the unit.
2. Remove the plastic actuator cover from the 3-way
automatic bypass valve by loosening the screw above the
conduit fitting (Figure 32).
3. Grasp the cover on the screw side and lift the cover up and
away from the valve.
4. Disconnect the wires at the terminal block (if connected).
5. Unscrew the plastic conduit cap from the conduit fitting
(Figure 32) and pull the plastic conduit hose and wires
from the valve.
6. Feed the plastic conduit hose through the opening of the
valve cover end cap (JKD6654) (see Figure. 32) and slide
the end cap approximately one foot up the conduit.
7. Reconnect the wires to the 3-way valve circuit board as
shown in Figure 33.
Auxiliary Mixed Water Limit Control
Ensure that the auxiliary 110°F mixed water limit control (and
optional pool supply sensor, if used) are installed in the filter
system piping. Install the auxiliary limit a minimum of three
feet downstream from the point where the heated water from
the pool heater is added to the filtration system. See Figures
34 - 38. The limit and sensor may be mounted in 3/8" NPT
tapped fittings installed in the filtration system piping or they
may be installed directly into tapped openings in the PVC filter
system piping. Turn off the filter system pump when installing
the auxiliary limit and sensor in the filtration system piping.
Tapped openings can be added to the PVC pipe by first drilling
9/16" pilot holes in the PVC pipe at least three feet
downstream of the point where the heated water from the pool
heater is added to the filter piping. The drilled pilot holes can
now be carefully threaded with a 3/8" NPT taper tap. After the
8. Feed the conduit hose into the conduit fitting and
reinstall the conduit cap.
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Manual Operation of the 3-Way Automatic
INSTALLATION
Continued
Note: If the wing nut underneath the valve actuator body is
Bypass Valve Actuator
To manually operate the 3-way automatic bypass valve
actuator:
loose, retighten.
9. Reinstall the plastic actuator cover and secure with the
screw loosened in Step 2.
1. Power must be removed from the unit.
10. Place the valve cover (JKD6653) over the 3-way
automatic bypass valve. Install the end caps (JKD6653
and JKD6654) using the four screws provided in the kit
(BLT7901) as shown in Figure 32.
2. Once power is removed, the de-clutch button located
on the side of the valve actuator body can be pressed.
CAUTION: Failure to remove power from the
actuator prior to attempting to manually operate
the valve can result in irreparable damage to the
actuator mechanism.
11. Turn the power on to the unit and resume operation.
Note: The actuator handle is not used when the outdoor cover
is installed. The handle is attached to the underside of the
actuator for storage.
Figure 32 – 3-Way Valve Cover
*
Figure 33 – 3-Way Valve Cover Connection Diagram
32
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Figure 34 - Heater is Within 15 Feet of Pool Piping
Figure 35 - Heater is Beyond 15 Feet of Pool Piping
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Commercial Pool Heaters
INSTALLATION
Continued
Figure 36 - Heaters are within 15 feet Perpendicular of Pool Piping
Figure 37 - Heaters are Beyond 15 feet of Pool Piping
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Installation and Service Manual
Relief Valve
Figure 38 - Multi-Stack Frame - Heaters are Beyond 15 feet from Pool Piping
Do not place chlorine tablets or bromine sticks in the skimmer.
High chemical concentrations will result when the pump is not
running.
This pool heater is supplied with a relief valve(s) sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV. The relief valve(s) is installed in the vertical
position and mounted in the hot water outlet. Place no other
valve between the relief valve and the pool heater. To prevent
water damage, pipe the discharge from the relief valve to a
suitable floor drain for disposal when relief occurs. Do not
install any reducing couplings or other restrictions in the
discharge line. The discharge line will allow complete drainage
of the valve and line. Manually operate the relief valves at least
once a year.
Chlorinator must feed downstream of the pool heater and
have an anti-siphoning device to prevent chemical back-up in
the pool heater when the pump is shut off.
Water Flow Switch
IMPORTANT: High chemical concentrations from
improperly adjusted feeders and Chlorinator can
cause rapid corrosion to the heat exchanger. This
damage is non-warrantable.
ƽ CAUTION: Avoid contact with hot discharge
A water flow switch is standard equipment. The wiring
connection installs the flow switch in the 24 VAC safety circuit
to prove water flow before main burner ignition. The standard
flow switch is installed in the outlet side of the piping loop
when shipped from the factory. These pool heaters require a
sufficient flow of 26 GPM to make the flow switch and start
burner operation.
water.
Automatic Chlorinator and
Chemical Feeders
All chemicals must be diluted into the pool water being
circulated through the pool heater. Any concentration of
chlorine in the pool heater can cause damage to the pool heater.
35
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Commercial Pool Heaters
CONNECTING TO
INSTALLATION
Ensure that the pump installed on the pool heater will supply
adequate flow to make the flow switch contacts and operate the
pool heater. A water flow switch meets most code
requirements for a low-water cut off device on appliances
requiring forced circulation for operation.
Continued
ELECTRICAL SUPPLY
This pool heater is wired for 120 VAC service. The pool heater,
when installed, must be electrically grounded in accordance
with the requirements of the authority having jurisdiction or in
the absence of such requirements, with the latest edition of the
National Electrical Code ANSI/NFPA No. 70. When the pool
heater is installed in Canada, it must conform to the CAE
C22.1, Canadian Electrical Code, Part 1 and/or local Electrical
Codes.
PUMP PURGE /
MAINTENANCE TIMER
OPTION
1. Use only Type-T wire [63°F (35°C) rise] on all wiring
between the pool heater and field-installed devices.
2. Enclose line voltage wire exterior to the pool heater in
approved conduit or approved metal-clad cable.
3. The pump must run continuously when the pool heater is
being fired.
4. To avoid serious damage, do not energize the pool heater
until the system is filled with water.
5. Provide the pool heater with the proper overload
protection.
Pump Purge Delay Option
An electronic pump purge option is available for this pool
heater. During extended periods of inactivity during which
pumping may have been turned off to conserve energy, air can
become entrapped in the piping. The pump purge option
delays pool heater operation until the pump has been on for
sufficient time to remove air from piping. Both the inactivity
time and pump purging time are adjustable.
The inactive timer is adjustable from 1 - 99 hours. Selection
of a time between 4 - 8 hours is recommended.
IMPORTANT: Do not block access to the
electrical cover plate when installing electrical
conduit.
The purge timer is adjustable from 1 - 60 minutes. Selection
of a time between 10 to 30 minutes is recommended.
3-Way Automatic Bypass Valve Wiring
An override toggle switch is provided to turn off the pump
purge feature for testing or should the option no longer be
desired. When turned off, the call for heat will not be delayed.
If the piping loop was disassembled for shipping or needs to be
fitted with an outdoor enclosure, connection or disconnection
of the 3-way automatic bypass valve will be required. Wiring
connections should be made to the appropriately numbered
terminals on the 3-way automatic bypass valve as follows:
Service Indicator Option
A service indicator option is available for this pool heater. The
Service Indicator light on the Diagnostic Information Panel
will light up indicating that the pre-programmed hours/cycles
have elapsed. Contact a qualified serviceperson to perform
service on the pool heater.
- Yellow to terminal #1
- Blue to terminal #2
- White with a red stripe to terminal #3
- Pink to terminal #4.
Note: Orientation of the valve connections may vary from
what is shown. Care should be taken to ensure wires are
connected to the appropriate terminals, see Figure 33 on
page 32 of this manual.
ƽ WARNING: Power must be removed and the
clutch button must be depressed before
attempting to manually operate the valve or
damage to the 3-way valve may occur.
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Figure 39 - Control Panel Component Location Drawing
also an external pool temperature control, adjust the pool
heater’s pool return set point a few degrees higher than the
external pool temperature control’s set point. The pool heater
temperature control will then act as a backup to the external
pool temperature control.
TABLE-M
Remote Wire Connection
Wire
Gauge
Maximum
Allowable Length
12 GA
14 GA
16 GA
18 GA
100 ft
75 ft
50 ft
30 ft
Figure 40-C shows the Continuous and Intermittent terminals.
External safety devices connected to these terminals will
function to protect the pool heater. Devices connected to the
Intermittent terminals (B1 and B2) are monitored only when
there is an active Call for Heat. Devices connected to the
Continuous terminals (A1 and A2) are monitored continuously
and will activate and alarm (if the pool heater is equipped with
the alarm option) anytime the safety device senses an
abnormal condition. An additional wire may be field installed
from these safety devices to terminals A3 or B3 (as
appropriate) to activate an audible alarm (if the pool heater is
equipped with the alarm option).
TABLE–N
Terminal Strip Connection Options
The scenarios shown in Figures 40 A - C represent typical
terminal strip connection requirements. The terminal strips are
located on the left side of the pool heater under the electrical
access panel. Other applications may be accommodated, but
must be addressed individually.
Figure 40-A shows the position of the jumpers as shipped from
the factory for stand-alone operation of the pool heater.
Figure 40-B shows connections to the terminal strip for
Remote ON/OFF control of the pool heater. The 1C-1NO
jumper must be removed when making these wiring
connections. This remote ON/OFF control will provide an
Enable/Disable signal to the pool heater and allow the pool
heater to operate based on the set point, until the remote
ON/OFF signal is cancelled. If the remote ON/OFF control is
A.
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WHAT TO DO IF YOU SMELL GAS
INSTALLATION
Continued
•
•
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 turn the gas control lever. Never use
tools. If the lever will not turn by hand, don’t 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 pool heater if any part has been under
water. Immediately call a qualified service technician to
replace the pool heater. The possible damage to a flooded
pool heater can be extensive and present numerous safety
hazards. Any appliance that has been under water must be
replaced.
B.
Lighting Instructions
1. STOP! Read the safety information.
2. Program the temperature control to the desired settings
(see Operating Temperature Control, page 40).
3. Loosen knurled screw at the bottom of control panel cover
(see Figure 41).
4. Grasp the bottom of the control panel cover and pull out.
5. Locate the ON/OFF switch inside control area. Switch is
located to the left of the pull out control circuitry tray (see
Figure 42).
C.
Figure 40 (A-C) - Terminal Strip Connection
6. Turn the power switch to the “OFF” position.
7. This pool heater is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
OPERATION
FOR YOUR SAFETY READ BEFORE
OPERATING
ƽ WARNING: If you do not follow these
instructions exactly, a fire or explosion may
result causing property damage, personal injury
or loss of life.
A. This pool heater does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
B. BEFORE OPERATING, smell around the pool heater area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle to the floor.
Figure 41 – Control Panel Cover
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Figure 43 – Combination Gas Valve
Figure 42 – ON/OFF Switch
Pre-Start Checklist
8. Turn the manual gas cock clockwise ꢀ to the “OFF”
position.
Before attempting to start the pool heater verify that the
following items have been checked:
9. Wait five (5) minutes to clear out any gas. If you smell gas,
STOP! Follow What To Do If You Smell Gas in the safety
information. If you don’t smell gas, go on to the next step.
10. Turn the manual gas cock counterclockwise ꢁ to the “ON”
position.
11. Turn the power switch to the “ON” position.
12. Slide the control panel assembly back into the pool heater.
Tighten the knurled screw at the bottom of the control
panel cover.
1. Verify proper location and installation of the pool heater.
2. Check gas piping and ensure the gas line is purged of all
air.
3. Ensure that the pool is properly filled.
4. DO NOT operate pool heater if improperly filled.
5. Check to ensure that all water connections are tight.
6. Relief valve has been piped to a suitable floor drain.
7. Combustion air openings are not obstructed in any way.
13. If the pool heater will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
Starting the Filter System
Verify proper installation of the pool heater temperature
controls and the installation of the 110°F auxiliary limit and
pool supply sensor in the mixed discharge water from the filter
piping to the pool. Clean the filter. Start the filter pump. Be
sure all air is out of all the lines including the pressure
connection. Ensure that the pool heater is not “air bound” by
manually opening the temperature and pressure relief valve.
Leave the valve open until a steady flow of water is observed
at the discharge from the valve. Close the valve and complete
filling the system.
To Turn Off Gas To Pool Heater
1. Open the front access panel to access the control panel.
2. Turn the power switch to the “OFF” position.
3. Turn the manual gas cock clockwise ꢀ to the “OFF”
position.
ƽ WARNING: Should overheating occur or the
gas fail to shut off, turn off the manual gas
control valve to the pool heater.
Note: Backwash the filter when the G.P.M. filtration rates are
too low to meet local codes or state code. A high temperature
rise across the pool heater is also an indication of low flow in
the filter system. Sustained low flow to the pool heater will
result in cycling of the heater on the limit controls and possible
opening of the relief valve.
39
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Commercial Pool Heaters
heater from condensation of the flue products. If the boiler
OPERATION Continued
inlet temperature is not satisfied within 15 minutes the
controller will shut the unit down. To reset the unit, press any
key. No manual valve adjustments are required.
An LCD is provided to display various readings and operating
parameters. Three (3) pushbuttons are available to change the
display and to program parameters (Figure 46).
Figure 44 – Vertical Pool Heater Piping
Figure 46 - Temperature Control Display and
Programming Keys
Specifications
• Set Point Adjustment Range:
OFF, 55°F up to 105°F (13°C up to 41°C).
• Differential Adjustment Range:
1°F up to 20°F (1°C-11°C)
• Temperature Accuracy: +/- 1°F.
• Display Resolution: 1°F via Liquid Crystal Display (LCD).
• Sensor: NTC Thermistor, 10k ohms @ 77°F (25°C).
• Operating Humidity: < 90% RH Non-condensing.
• Operating Ambient Temperature:
-20° to 140°F (-30° to 60°C).
Figure 45 – Horizontal Pool Heater Piping
OPERATING TEMPERATURE CONTROL
The pool heater is equipped with a microprocessor based
adjustable digital temperature control to provide ON/OFF
operation. The temperature control is located behind the
overlay on the front of the control panel. Operation is based
on temperature inputs from immersion sensors, and, if desired,
an external thermostat. The temperature control will turn on
and off based upon the temperature measured by the pool
return sensor. This sensor is factory installed in a bulbwell
located in the inlet piping to the pool heater, upstream of the
3-way automatic bypass valve. The temperature control will
turn on and off based upon an external thermostat connected
between terminals R1 and W1 on the terminal board. The
temperature control will also turn off if the temperature
measured by the pool heater output sensor exceeds a limit
(default = 200°F) or if the temperature measured by the
The programming keys are as follows:
Select - Allows the user to select the reading or parameter
being displayed. Each time the key is pressed, a different
indicator will appear which describes the value being shown.
These are detailed as follows:
Up and Down Arrows - While in the Adjust mode, the user
can increase or decrease the parameter being shown.
optional pool supply sensor exceeds another limit (default = The default display mode is the View mode, indicated in the
100°F). In addition, the temperature control will operate a upper right-hand corner of the display.
factory installed 3-way automatic bypass valve. This is done
to maintain a minimum temperature at the inlet to the pool
heater (default = 130°F), automatically protecting the pool
The default value shown is the Pool Temperature, indicated by
the arrow pointing to the POOL text on the overlay. If the
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pool return sensor has been installed and connected, this will By pressing the Select key again, the Temperature Units will
be the temperature of the water coming from the pool.
be displayed, indicated by the text °F or °C. This is the units
in which the temperatures are shown. The default is °F.
By pressing the Select key, the Pool Target is shown and the
text TARGET on the display. This is the pool temperature set By pressing the Select key again, the Pool Target will be
point.
shown once more. To return to the View mode, simply stop
pressing any buttons for 25 seconds.
By pressing the Select key again, the Boiler Inlet Temperature
is shown, indicated by the text Boil In. This is the temperature Note: The control values programmed into memory will not
of the water going into the pool heater. Note that it is different be lost because of a power failure.
than the temperature of the water coming from the pool.
Error Messages Displayed by the
By pressing the Select key again, the Boiler Outlet
Temperature is shown, indicated by the text Boil Out. This is
the temperature of the water coming out of the pool heater,
before it is mixed with the water from the pool.
Temperature Controller
There are six error messages that can be displayed in response to
software or hardware problems with the pool heater's internal
temperature control. The error codes that may be seen on the
display are:
By pressing the Select key again, the Boiler Rise is shown,
indicated by the text Boil ΔT. This is the difference between
the inlet and outlet temperatures at the pool heater.
E01 - The internal memory of the microprocessor in the
temperature control has a read error at power up. This error
cannot be field repaired. Replace the pool heater's temperature
control if the error persists.
SHr - There is a short in the temperature sensor. Make sure
sensors are properly installed, wired and connected to the
control. Correct sensor installation or replace sensor.
If the pool supply sensor has been installed and connected, by
pressing the Select key, the Pool Supply Temperature is shown,
indicated by the text SUP. This will show the actual
temperature of the water returning to the pool.
If in the Advance mode (rear dip switch set to “0” position),
the Boiler On hours will be displayed, indicated by the text
BOIL ON in the display. This is the total number of hours the
pool heater has been heating the pool. To clear the Boiler On
hours press the Up and Down Arrow keys simultaneously.
For a detailed explanation of the advance settings, see
Appendix B on page 59 of this manual.
OPn - There is a break in the wiring to the temperature sensor.
Make sure sensors are properly installed, wired and connected
to the control. Correct sensor installation or replace sensor.
FP - The burner is not running 2 minutes after the start of the
call for heat. Check ignition control codes.
By pressing the Select key again, the display returns to the
Pool Temperature display.
E02 - The outlet temperature from the pool heater reached its
maximum setting. Check the bypass pump and mixing valve.
E03 - The inlet temperature into the pool heater was below its
target temperature for more than 15 minutes. Check the
mixing valve.
Programming Mode
In order to adjust any of the settings, it is necessary to enter the
Adjust mode. This is done by pressing all three buttons
simultaneously for one second and it will change from View to
Adjust. The setting shown can be adjusted (within it’s
acceptable range) by pressing the Up or Down Arrow key.
The default display shows the Pool Target temperature
indicated by the arrow pointing to the text POOL on the
overlay, and the text TARGET on the display. This is the
temperature of the water from the pool at which the pool heater
will turn off. The default is 85°F/27°C.
By pressing the Select key again, the Pool Differential
temperature is shown, indicated by the arrow pointing to the
text POOL on the overlay, and the text DIFF on the display.
This is the number of degrees below the Pool Target
temperature that the pool temperature must drop before the
pool heater will turn on. The default is 4°F/2°C.
41
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Commercial Pool Heaters
Hot Surface Ignition Control Module
Ignition Module Lockout Functions
OPERATION Continued
The ignition module may lockout in either a hard-lockout
condition, requiring pushing of the reset button to recycle the
control, or a soft-lockout condition which may recycle after an
approximate five-minute waiting period. This soft-lockout
condition is intended to allow self-correcting faults to correct
themselves and permit normal operation. A typical hard-
lockout fault is a flame failure condition. An ignition module
that is in a hard-lockout condition may only be reset by
pushing the reset button for the ignition control. The reset
button is located on the front of the control panel. Upon a
flame failure, the reset button is only active after the control
module has completed its post-purge cycle. Turning main
power “OFF” and then “ON” or cycling the thermostat will not
reset a hard-lockout condition. Wait five seconds after turning
on the main power before pushing the reset button when the
ignition module is in a hard lockout.
HOT SURFACE IGNITION SYSTEM
Hot Surface Igniter and Ignition Control
Module
This unit has one ignition module and one hot surface igniter.
ƽ CAUTION: The igniter is extremely fragile, be
very careful when removing. A faulty or damaged
hot surface igniter MUST BE replaced with a
Lochinvar PLT3400 igniter. DO NOT use general
purpose field replacement igniters.
The ignition module will go into a soft lockout in conditions of
low air, low voltage or low hot surface igniter current. A soft-
lockout condition will operate the combustion air fans for the
post purge cycle and then the ignition module will pause for
approximately five minutes. At the end of this timed pause, the
ignition module will attempt a new trial for ignition sequence.
If the soft-lockout fault condition has subsided or has been
corrected at the end of the timed pause, main burner ignition
should be achieved with the resumption of the normal trial for
ignition sequence. If the control sensed fault is not corrected,
the ignition module will continue in the soft-lockout condition.
If the thermostat opens during the soft-lockout period, the
ignition module will exit soft lockout and wait for a new call
for heat from the thermostat. A soft-lockout condition may
also be reset by manually cycling the thermostat or turning the
main power switch “OFF” and then “ON” after the control
sensed fault has been corrected.
Figure 47 – Hot Surface Igniter
Diagnostic Status Indication
The ignition module has an LED which indicates the status of
the safety circuits. A remote Ignition Module Status indicating
light is wired from the ignition module Status LED and
mounted on the front control panel. The flashing operation of
this light/LED indicates the diagnostic status of the ignition
control module. The status LED, mounted on the ignition
module, flashes a code sequence from the Ignition Module to
indicate the status of the ignition process. See TABLE– N, on
page 43 for the flashing diagnostic status codes as signaled by
the ignition module.
Figure 48 – Hot Surface Ignition Control Module
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24 VAC control circuit, circuit breaker for the control circuit,
TABLE-N
switching relays for component operation and wiring harness
Ignition Control Diagnostic Codes
connections to the pool heater’s components. The control
panels are common and may be switched between pool heaters
for trouble shooting.
Code Sequence
Condition
Constant ON
Constant OFF
System OK, no faults present.
Removing the Control Panel
Possible control fault, check power;
LED may be effective, do not
replace control if all operational
sequences function properly, see
TroubleShooting Guide.
Low Air, check air pressure switch and
hoses to pressure sensing points, fan,
venting and sealing of pressurized
chamber.
1. Pull the control panel out as far as it will go.
2. Remove the multi-pin connector blocks from the top and
right side of the control panel.
3. Use a 1/2" box wrench or socket wrench to remove the bolt
on the right side of the control panel.
4. Remove the entire control panel.
5. Reinstall the control panel in the reverse order.
One Flash
ƽ CAUTION: Control panel is heavy and
awkward to handle when removed. Carefully
support the control panel when removing.
NOTE: Brief flashing normal on fan start-up/proving.
Two Flashes
Flame without call for heat, check for a
gas valve stuck in the open position, air,
venting, burners and the combustion
process. Fan will remain on.
Lockout due to flame failure, push reset
button on outer control panel after
correcting ignition problem. Initial heater
start up without properly bleeding air
from the gas line may require multiple
reset functions to achieve proper ignition.
Igniter failure, igniter will not maintain
minimum 2.75 amp current draw, caused
by low voltage, bad wiring/continuity,
high resistance or igniter failure.
Power supply problem, check for low
supply voltage or transformer output less
than 18VAC.
Ignition and Control Timings
Proven Pilot Hot Surface Ignition System F-9 on 500,000
through 2,070,000 Btu/hr models with One Hot Surface
Ignition Module.
Three Flashes
Hot Surface Ignition Module Timings (Nominal)
Prepurge:
15 Seconds
Hot Surface Igniter Heat-up Time: 25 - 35 seconds
Main Burner Flame Establishing Period: 4 Seconds
Failure Response Time: 0.8 Seconds at less than 0.5 μA
flame current
Four Flashes
Flame Current: 5 - 15 μA
Post-purge:
30 Seconds
Five Flashes
Six Flashes
Optional Pump Delay Timing: 30 Seconds after burner
shutdown
Replace ignition module, internal fault.
Access to Internal Control Panel
The control panel is accessed by turning the knurled knob
located at the bottom center of the exterior control panel. Pull
the panel out at the bottom. The door will tilt into unit until it
comes free from the outer top. The outer control panel has an
overlay attached to the exterior surface which indicates the
function of each of the pool heater’s indicating lights and a
clear window to view the digital temperature display from the
temperature control. The thermostat and diagnostic light board
are mounted to the back of the control panel door.
The control panel assembly is mounted on a slide out chassis
to allow easy access to the components on the panel. The
control panel contains the ignition module, transformer for the
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Commercial Pool Heaters
Water Chemistry
OPERATION Continued
OPERATION AND DIAGNOSTIC
INDICATORS
The control panel has up to six indicating and diagnostic lights
to show all major steps of operation and control sensed
malfunctions. There are display indicators on the Operating
Temperature Control that give status information as well.
Factors which affect pool water and, more importantly, the
efficiency of your new pool heater are:
1. Proper Filtration
2. Proper Circulation
3. Disinfection and Oxidation
4. pH Control and Total Alkalinity
5. Algae Control
6. Water Balance
The water chemistry of your pool changes daily due to natural
evaporation of the water and the addition of chemicals.
Chemicals are used to sanitize and control algae growth in the
pool. Their addition must be carefully monitored. The
accumulation of minerals or scale in the pool heater due to
a chemical imbalance will cause a non-warrantable failure
of the heat exchanger and its components. pH is an
important factor in maintaining proper balance in your pool
water. pH is the measurement of the acidity or alkalinity of
water. The following chart shows the recommended pH range
and what can happen when the pH increases or decreases from
the ideal of 7.2 to 7.8.
Figure
49
–
Exterior Control
Panel
with
Operation/Diagnostic Lights and LCD Display
TABLE-O
Status LED Diagnostic Codes
Code
Sequence
Condition Lights
Prepurge
Operation of combustion air fans before
ignition.
Trial for Ignition
Heating
Service (if equipped) Service
purchased.
Hot surface igniter 1 preparing to light
burners.
Burners operating.
Figure 50 – pH Scale
If the pH becomes too high, it lowers the ability of chlorine to
destroy bacteria and algae, water can become cloudy, filter
elements may become blocked, and scale formation will occur
in the pool and heat exchanger. If the pH becomes too low the
water becomes acidic. You can have eye burn and skin
irritation, etching of the plaster, corrosion of metal fixtures and
the resulting stains on the plaster, degradation of sand and
gravel filters and corrosion of the copper tubes in the heat
exchanger.
Indicator
when
option
Alarm
Indicates flame failure on either ignition
module and will indicate additional
alarms if the alarm of any failure option
is purchased.
The display indicators on the Operating Temperature Control
point to text on the overlay (Figure 46). They indicate the
following:
Damage to the pool heater due to improper water balance
is non-warrantable.
Speed - This indicates that the speed setting is being displayed.
The speed setting controls the responsiveness of the 3-way
valve.
Open, Close - These indicators appear when the Operating
Temperature Control adjusts the position of the 3-way valve.
We recommend using a commercial or professional test kit to
monitor the following levels to ensure proper operation of your
pool heater:
Active - This indicator appears when the pool heater supplies
heat to the pool.
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TABLE-P
Recommended Water Chemistry
TABLE-Q
AMP Draw Data
Test
Recommended Level
Btu/Hr
Input
Approximate
Controls Fans Pump Total Amps
Correct pH
7.2 - 7.8
Chlorine Residual
Total Alkalinity
Calcium Hardness
1.0 - 5.0 PPM
80 - 120 PPM
175 - 350 PPM
500,000
650,000
3.6
5.4
5.4
7.3
7.3
7.3
7.3
7.3
2.7
3.4
3.4
3.2
3.2
6.7
6.7
6.7
5.0
5.0
5.0
7.4
7.4
7.4
8.8
8.8
11.3
13.8
13.8
17.9
17.9
21.4
22.8
22.8
750,000
990,000
1,260,000
1,440,000
1,800,000
2,070,000
Chlorine residual is the chlorine remaining in the pool water
after it is consumed in the process of destroying bacteria, algae
and other oxidizable materials. Total alkalinity is the
measurement of the total amount of alkaline chemicals in the
water. Alkalinity controls pH. Sodium bicarbonate is used to
raise total alkalinity. Calcium hardness can be raised by the
addition of calcium chloride, and lowered by the addition of
Tri-sodium Phosphate or its equivalent. The corrosive level of
pool water can also be measured by the Ryznar Stability Index.
This index is calculated by a formula which uses operating
temperatures, total alkalinity, pH, calcium hardness and total
dissolved solids. The Ryznar Stability Index is able to predict
more accurately the scaling or corrosive tendencies of
swimming pool water. Balanced water within the guidelines of
the Ryznar Stability Index are from 6.3 - 6.7. Use of the
Ryznar Stability Index may help prolong the service life of
pool equipment, which in turn will be a cost savings to the
commercial pool owner. Your pool dealer can provide
additional data and equipment to make this measurement if a
problem exists.
Refer to Circulating Pump on page 46 for information relating
to pump wiring.
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Commercial Pool Heaters
This pump is sized based on installation of a single pool heater
OPERATION Continued
in close proximity with the system. If the number of fittings
and straight pipe exceeds the quantities shown in this section,
a larger pump will be required. As an alternative to changing
the pump in these circumstances, the piping can be changed to
a sub-loop. Check pump for correct pump rotation.
Pipe Size Requirements
The pipe sizing chart provides the minimum pipe size for
common manifold piping to ensure adequate flow.
TABLE-R
The standard pump selection is based on the following pipe
and fittings from the pool heater to the system:
Pipe Sizing Chart
Number of Units
Common Pipe
Size (Min.)
6 - 90° elbows
2 - unions
2 - ball valves
1 - cold water tee
500,000 - 750,000 Btu/hr Models
1
2
2"
3"
Not more than 45 feet of straight pipe.
3
4
5
6
3 1/2"
4"
5"
IMPORTANT: For every elbow and tee in excess
of those shown above, deduct 5 feet from the
maximum allowable straight pipe in the pool
heater to the system circulating loop.
5"
Number of Units
Common Pipe
TABLE-S
Minimum Pump Performance
990,000 - 2,070,000 Btu/hr Models Size (Min.)
1
2
2 1/2"
4"
Btu/hr Input
GPM
Ft.Hd.
500,000 - 750,000
990,000 - 1,440,000
1,800,000 - 2,070,000 115
55
90
10
15
18
3
4
5
6
4"
5"
6"
6"
Minimum Pump Performance
Pump performance is based on providing adequate flow and
temperature rise to prevent scale accumulation in the heat
exchanger. See Water Chemistry on page 44.
Circulating Pump
1. This pool heater is factory supplied with a properly sized
pump that circulates water between the pool heater and
system.
Heat Exchanger
This is a highly sophisticated heat exchanger, designed to carry
water in such a way that it generates a scouring action which
keeps all interior surfaces free from build-up of impurities. The
straight-line, two pass design of the tubes sends water into the
headers at a properly rated velocity. The configuration of the
headers, in turn, creates a high degree of turbulence which is
sufficient to keep all contaminants in suspension. This
“scouring action” provides greater cost savings for owners.
Tubes are always able to transfer heat at peak efficiency. Every
surface within this water containing section is of a non-ferrous
material, providing clear, clean, rust-free water. Straight
copper tubes-finned on the outside for maximum heat transfer-
coated cast iron one piece cored headers make up an entirely
rust-proof pool heater. A Cupro-Nickel heat exchanger is
standard on 1,800,000 - 2,070,000 Btu/hr models. On all
models, header inspection plugs can be removed for field
inspection and cleaning of copper tubes. The entire heat
exchanger may be easily removed from the pool heater.
2. The pump is sized to pool heater input and water hardness.
See Water Chemistry on page 44.
3. Lubricate the pump to the
manufacturer’s
recommendations. Pump damage due to inadequate
lubrication is non-warrantable. Use SAE 30 non-detergent
oil or lubricant specified by the pump manufacturer.
4. Standard pool heaters are furnished with the following
circulating pump mounted in the factory supplied pool
loop.
500,000 - 750,000 Btu/hr Models
1/4 HP, 120 VAC, 5.8 Amp
990,000 - 1,440,000 Btu/hr Models
1/2 HP, 120 VAC, 7.4 Amp
1,800,000 - 2,070,000 Btu/hr Models
3/4 HP, 120 VAC, 8.8 Amp
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ƽ WARNING: The areas around the burner
view ports are hot. Direct contact with the pool
heater could result in burns.
ƽ WARNING: Should overheating occur or the
gas supply fail to shut off, do not turn off or
disconnect the electrical supply to the pump.
Instead, shut off the gas supply at a location
external to the pool heater.
High Water Temperature Limit Control
This pool heater is equipped with a fixed setting, auto reset
high water temperature limit control that is screwed into the
outlet head in the heat exchanger. This temperature limit
control has a maximum limit setting of 200°F (93°C). It is also
equipped with an adjustable setting, manual reset high water
temperature limit control. This temperature limit control has a
maximum limit setting of 230°F (110°C). If water temperature
exceeds the set point, the limits will break the control circuit
and shut down the pool heater. The auto reset limit control will
only be reset after the water temperature has cooled below the
set point of the limit. The manual reset limit control will
require an operator to push the reset button (located
immediately below the high limit dial) if this limit has tripped.
Figure 51 - Flame Pattern Illustration
Normal Flame: A normal flame is blue with slight yellow tips,
has a well-defined inner cone, and displays no lifting flames.
Yellow Tips: The usual causes for yellow tips on the burner
flame are burner air flow blockage or partial obstruction.
CLEANING AND
MAINTENANCE
Yellow Flames: The usual causes for yellow flames are
primary air flow blockage to the burner(s) or excessive gas
input. Correct this condition immediately.
Listed below are items that must be checked to ensure safe
reliable operations. Verify proper operation after servicing.
Lifting Flames: The usual causes for lifting flames are over
firing the burner(s), excessive primary air, or high draft.
ƽ CAUTION: Label all wires prior to
disconnection when servicing controls. Wiring
errors can cause improper and dangerous
operation.
If you observe improper flame patterns, examine the venting
system, ensure proper gas supply, and ensure adequate supply
of combustion and ventilation air.
Flue Gas Passageways Cleaning
Appliance Area
Procedures
Keep appliance area clear and free from combustible materials,
gasoline and other flammable vapors and liquids.
Any sign of soot around the refractory, at the burners or in the
areas between the fins on the copper heat exchanger indicates
a need for cleaning. The following cleaning procedures must
only be performed by a qualified serviceman or installer.
Proper service is required to maintain safe operation. Properly
installed and adjusted pool heaters seldom need flue cleaning.
Water Circulating Pump
Inspect the pump every six months and oil as necessary.
Use SAE 30 non-detergent oil or lubricant specified by the
pump manufacturer.
IMPORTANT: All gaskets on disassembled
components must be replaced with new gaskets
on reassembly. Gasket kits are available from
your distributor.
Burner Flames
Visually check the main burner flames at each start up after
long shutdown periods or at least every six months. Burner
view ports are located on the right and left sides of the pool
heater.
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from the pool heater, a garden hose can be used to wash the
tubes to ensure that all soot is removed from the heat
exchanger surfaces.
CLEANING AND
MAINTENANCE Continued
Note: Do not wet the pool heater’s refractory.
Burner Removal and Cleaning
8. Ensure that all burner ports are cleaned to remove any soot.
See Burner Removal and Cleaning, this page.
1. Turn “OFF” the main power to the pool heater.
2. Turn “OFF” the main manual gas shutoff to the pool
heater.
3. Remove the front outer jacket panels.
4. Disconnect the manifold from the gas train using the
union(s) just below each gas valve(s).
9. Carefully reinstall the heat exchanger, “V” baffles, and
frame runners if removed from the pool heater.
Note: Make sure frame runners seal securely where they
contact the front and rear compartment refractory.
5. Remove the mounting nuts from the manifold mounting
brackets. Pull the manifold/orifice assembly away from
the burners. Repeat for each manifold assembly.
6. Remove two mounting screws from the burner and slide
the burner out toward the front of the pool heater. Use
caution to prevent damage to burners, refractory, hot
surface igniter or wiring.
10. Carefully reinstall inner jacket panels, burners, manifolds,
wires and hoses. Use new gasket material to ensure a
proper air seal.
11. Reassemble all gas and water piping. Test for gas leaks.
12. Reassemble outer jacket panels.
13. Cycle the pool heater and check for proper operation.
7. Remove soot from the burners with a stiff bristle brush.
Dirt may be removed from the burner ports by rinsing the
burner thoroughly with water. Drain and dry burners
before re-installing. Damaged burners must be replaced.
Electrical
This pool heater uses a transformer to supply a low voltage
control circuit. The voltage on the secondary side should be 24
to 28VAC when measured with a voltmeter. This unit has a 7
AMP circuit breaker provided on the secondary side of the
transformer. A tripped circuit breaker indicates a short in the
24VAC controls that must be corrected.
When installed in a dusty and dirty location, the burners may
require cleaning on a 3 to 6 month schedule or as needed,
based on severity of contamination. Contaminants can be
drawn in with the combustion air. Non-combustible particulate
matter such as dust, dirt, concrete dust or dry wall dust can
block burner ports and cause non-warrantable failure. The
standard inlet air filter will help eliminate dust and dirt from
entering the pool heater.
Combustion and Ventilation Air
Combustion Air Filter
This unit has a standard air filter located at the combustion air
inlet. This filter helps ensure clean air is used for the
combustion process. Check this filter every month and replace.
The filter size on the 500,000 - 750,000 Btu/hr models is 12" x
12" x 1" (30.5cm x 30.5cm x 2.5cm) and 16" x 16" x 1"
(40.6cm x 40.6cm x 2.5cm) on the 990,000 - 2,070,000 Btu/hr
models. You can find these commercially available filters at
any home center or HVAC supply store.
Heat Exchanger Cleaning
1. While burners are removed, check the heat exchanger
surface for sooting. If present, the heat exchanger must be
cleaned and the problem corrected. Proceed as follows.
2. Remove gas manifold(s)/orifice assemblies as described in
steps 1 through 5 in Burner Removal and Cleaning, this page.
3. Disconnect the wiring from the hot surface igniter and the
hoses from the burner pressure tap.
4. Remove inner jacket panel mounting screws and slide the
door assembly out toward the front of the pool heater. Use
caution to prevent damage to the refractory and hot surface
igniter.
Venting System
Examine the venting system at least once a year. Check more
often in the first year to determine inspection interval. Check
all joints and pipe connections for tightness, corrosion or
deterioration. Clean screens in the venting air intake system as
required. Have the entire system, including the venting system,
periodically inspected by a qualified service agency.
5. Check “V” baffles along the front and back edges of the heat
exchanger. Remove and clean if necessary.
6. Remove soot from the heat exchanger with a stiff bristle
brush. Use a vacuum to remove loose soot from the surfaces
and inner chamber.
7. The heat exchanger can be removed by sliding towards the
front of the pool heater. Once the heat exchanger is removed
Air Flow
Check frequently to be sure the flow of combustion and
ventilation air to the pool heater is not obstructed.
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Combustion Air Fans
Both the 500,000 - 750,000 Btu/hr models and the 990,000 -
2,070,000 Btu/hr models use a fan-assisted combustion
process. The 500,000 - 750,000 Btu/hr models have one fan
and the 990,000 - 2,070,000 Btu/hr models use two fans to
supply combustion air to the burners.
Fan Cleaning
Check each combustion air fan every six months. Clean the
fan as required when installed in a dusty or dirty location.
Oiling is not required.
Combustion Air Fan Adjustment
The combustion air fans are factory pre-set and should not
need adjustment in most cases. Follow the steps below to
adjust the fan if a continuous Low Air status code occurs.
Figure 53 – Loosening Fan Transition Box Screws
Note: On the 500,000 - 750,000 Btu/hr models the air shutter
is adjusted on the side of the fan duct as depicted in Figure 52.
On the 990,000 - 2,070,000 Btu/hr models the air shutter is
adjusted on the rear of the fan duct as depicted in Figure 54.
1. Check for proper installation and draft in the venting
system. Correct as required.
2. The following pressure settings are for installations up to
4000 feet altitude. Contact the factory for high altitude air
pressure settings.
Adjusting Differential Air Pressure
The following is a recommended method for setting the
differential air pressure (ꢂP) for each fan.
Figure 54 – Adjusting Air Shutter 990,000 - 2,070,000
Btu/hr Models
Set-Up Procedure
Beside the fan duct is an air pressure switch with a large and a
small tube delivering pressure from points inside the pool
heater (see Figure 55). The pressure in the large tube is the
chamber pressure. The pressure in the small tube is the burner
pressure. They act together to make the pressure switch. By
disconnecting the caps from the tees in the pressure switch
hoses and connecting them to either side of a manometer, you
can read the differential pressure to the switch.
LESS AIR
E AIR
R
O
M
The left pressure tapping connection on the manometer
connects to the tee in the tubing from the pool heater front
chamber and the right pressure tapping connection on the
manometer connects to the tee in the small tubing from the
burner.
AIR SHUTTER
Figure 52 – Adjusting Air Shutter 500,000 - 750,000 Btu/hr
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CLEANING AND
MAINTENANCE Continued
If the air pressure switch does not make within 60 seconds
from the time the fans turn ON, the ignition module will go
into a soft lockout period (approximately 5 minutes in
duration) during which time the fans are turned off and the
module shows the Low Air flash code. If necessary, soft
lockout can be circumvented by cycling power using the
ON/OFF switch to cycle power to the unit.
Note: If the pool heater has been firing recently, allow the
pool heater to cool for five minutes with the fans
running before beginning the adjustment procedure.
Retain the plastic caps removed from the tees for
reinstallation when complete.
Figure 55 – Combustion AirAdjustment with a Manometer
to Set Differential Pressures
Adjustment Procedure
Servicing Hot Surface Igniter and Ignition
Module
This pool heater uses a proven hot surface ignition control
module and a hot surface igniter. The hot surface ignition
module is not repairable. Any modification or repairs will
invalidate the warranty.
1. Remove the upper front jacket panels from the unit to
access the upper chamber.
2. Slightly loosen screws that attach fan transition box to
metal base (see Figure 53).
3. Depending on model, the air shutter(s) may be located
either on the side or the rear of the fan duct. Locate the air
shutter at the side/rear of the fan duct (see Figure 52 and
54). Move the air shutter towards the rear or left side of the
unit to increase air pressure. Move the air shutter towards
the front or right side of the unit to decrease air pressure.
4a. The 500,000 - 750,000 Btu/hr models have one fan with a
side mounted air shutter. The differential for these models
is nominally 1.5 - 1.65 inches water column.
4b. On the 990,000 - 2,070,000 Btu/hr models adjust the air
shutter on the left fan until the differential pressure is
nominally 1.1 - 1.3 inches water column. Note: The air
chamber pressure is 1.2 inches water column for
liquefied petroleum (L.P.) and 1.4 inches water column
for natural.
5. Reattach the hoses to the pressure switch and locate the air
switch adjacent to the right fan and connect the tubes to
either side of your manometer.
ƽ WARNING: Do not attempt to repair a faulty hot
surface igniter or ignition module. Any modification
or repairs may create hazardous conditions that
result in property damage, personal injury, fire,
explosion and/or toxic gases.
A faulty hot surface igniter or ignition module must be
replaced with an identical part. A specification igniter and
ignition control module for this specific pool heater is
available from your local distributor. Do not use general
purpose field replacement ignition modules or igniters.
Ignition System Checkout
1. Turn “OFF” the gas supply to the pool heater.
2. Turn the electric power “ON”.
3. Program the temperature control to settings above water
temperature or to the highest safe setting.
4. The igniter will cycle on trial for ignition.
5. The ignition module will lock out and turn the alarm light
on.
6. Program the temperature control to the desired temperature
set point.
7. Turn “ON” the gas supply.
6. Adjust the air shutter on the right fan until the differential
pressure is nominally 1.1-1.3 inches water column.
7. Once the adjustment procedure is complete, reattach the
caps to the tees in the hoses to the pressure switches and
check all tubing and wire connections for snug fit. Test fire
the unit. Install upper panels.
8. Press the module reset button (located on the front of the
unit) to reset the module.
9. If ignition system fails to operate properly, repair work
must be performed by a qualified serviceperson or
installer.
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11. 24VAC is supplied to the C terminal of the air pressure
ENERGY SAVING
switch. As the low air switch makes, power is supplied to
the optional louver/venter enable contact relay.
12. 24VAC is then supplied to the PS terminals on the ignition
module.
RECOMMENDATIONS
1. Keep the pool covered when not in use. This will cut
heating cost, reduce water evaporation, conserve
chemicals and reduce load on the filtering system.
2. Reduce pool thermostat to 78°F or lower.
3. Use an accurate pool thermometer to monitor water
temperature.
4. Use a time clock to start filter pump no earlier than 6 a.m.
during pool season. This is the time when nightly heat loss
stabilizes.
5. Turn the pool heater “OFF” and drain during long periods
when the pool will not be used (winter, vacations, etc).
6. Follow a regular program of preventative maintenance for
your pool heater each new swimming season. Check heat
exchanger, controls, burners and operation of the pool
heater.
7. For pools used only on weekends, the thermostat may be
set lower than 78ºF during the week. Lower setting to a
range that can be easily achieved in one day's operation of
the pool heater.
13. The combustion air fan operates for the pre-purge period.
14. At the end of the pre-purge period, 120VAC is applied to
the hot surface igniter and the trial for ignition light.
15. The hot surface igniter proves 1800°F (982°C) ignition
temperature by the current draw through the ignition
module.
16. The ignition module supplies voltage to the MV terminals
onto the gas valve(s).
17. The first stage gas valve opens and supplies gas to the
orifice inlet to pre-mix.
18. The gas/air mixture is forced into the burner and out of the
burner ports under pressure.
19. The hot surface igniter lights the gas/air mixture and then
serves as a flame sensor to prove main burner flame by
rectification.
20. Burners for all stages are now firing at rated input on the
500,000 through 750,000 Btu/hr models.
21. On the 990,000 through 2,070,000 Btu/hr models
approximately 50% of the input is now energized.
22. 24VAC is supplied to a digital temperature control which
times out and then energizes the next 50% of the gas
valves.
23. The remaining gas valves open and supply gas to the
orifice inlet to pre-mix.
24. The gas/air mixture is forced out of the burner ports and
light by carry-over from the burners currently firing.
25. The heater is now firing at full rated input.
SEQUENCE OF OPERATION
OVERVIEW
This sequence of operation can be considered the order of
events in sequential order that occur after the pool heater has
received a call for heat. The process begins with 120VAC
power entering the pool heater and ends with the pool heater
going into an idle state after completion of a successful call for
heat. Note: The following descriptions do not include
remotely connected devices that may be connected to the pool
heater. Refer to the wiring diagram for actual point to point
wiring connections that show power delivery.
1. Place the POWER switch in the “ON” position.
2. 120VAC power is supplied to the control transformer
along with L1 and F1 on the ignition module.
3. 24VAC is supplied to the adjustable high limit control.
4. 24VAC is then supplied to the 110°F mixed water limit
control and onto the 200°F fixed limit control.
5. If equipped, 24VAC is supplied to a low water cut-off and
then to the optional high and low gas pressure switches.
6. 24VAC is supplied to the terminal strip and onto the
switching contacts of the digital temperature control.
7. The digital temperature control will then call for heat.
8. 24VAC is then supplied to the water pressure switch and
the flow switch (if equipped).
HEAT TRANSFER PROCESS
26. Heated products of combustion pass over the heat
exchanger transferring heat to the water.
27. The rate of flue product movement is controlled by “V”
baffles on the heat exchanger to maximize heat transfer.
28. Flue products pass into the flue collector and are
exhausted from the unit.
END OF SEQUENCE
29. Set point temperature for the pool water is satisfied.
30. Power to the gas valves is turned “OFF”.
31. The combustion air fan runs for a 30 second post purge
timing and turns “OFF”.
32. The unit is now in a Standby Mode waiting for the next
“Call for Heat”.
9. 24VAC is then supplied to the TH terminals on the ignition
module.
10. As power is applied to the TH terminals on the ignition
module, 120VAC is switched from the F2 terminal to start
the combustion air fan(s).
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by routing through dry contacts from external devices.
GLOSSARY
Connection of the external dry contacts to these terminals
requires the removal of one or more factory-installed jumpers
located on the terminal strip.
POWER SUPPLY
120VAC/60Hz/1PH power connects to black (line) and white
(neutral) wires located within an electrical wiring box located
on the left side of the pool heater. A green chassis grounding
wire is also provided for connection to earth ground.
SAFETY DEVICE TERMINALS
The safety device terminals ensure that no power can be
delivered to the ignition module unless factory/field-installed
safety devices such as flow switches and gas pressure switches
are closed. These safety device terminals are located below
the EMS/Sequencer/Remote Aquastat terminals located within
the electrical wiring box. Two types of connections are
offered: Continuous terminals provide for connection of safety
devices that are desired to be constantly monitored.
Intermittent terminals are provided for devices that are only
monitored during a “call for heat” cycle. Connection to either
of these terminals requires the removal of a factory-installed
jumper located on the terminal strip.
ON/OFF ROCKER SWITCH
The black line voltage wire runs directly to a single pole, single
throw On/Off rocker switch located behind the front cover
accessible by a knurled knob. Turning ON the rocker switch
delivers line voltage to the low voltage transformer and
ignition module.
Note: The On/Off switch does not provide for disconnection
of power being supplied to any remotely connected devices
that may be connected to the pool heater (i.e. pumps, louvers,
power venters, etc.). As such, it may be necessary to locate
and turn “OFF” power to these items before attempting to
service the pool heater.
TEMPERATURE CONTROLLER
(Operator) A single-stage temperature controller is provided on
the pool heater and it serves to maintain a user selectable
temperature set point. In addition to maintaining a set point, it
can provide for desired differential setting. Ultimately, the
temperature controller delivers 24VAC to the ignition module
and pressure switch when it senses heat mode is desired.
LOW VOLTAGE SUPPLY TRANSFORMER
A 120VAC to 24VAC transformer located within the control
panel provides 24VAC/60Hz to many of the components
located on the pool heater. One of its 24VAC outputs (blue) is
connected to a circuit breaker and the other (yellow) is
connected to chassis ground.
IGNITION MODULE
(Controlled by Temperature Controller)
24VAC CIRCUIT BREAKER
One ignition module is provided on the pool heater. Upon
sensing the 24VAC delivered to it by the temperature
controller, the ignition module checks for a shorted pressure
switch and then, provided the air switch isn’t shorted, supplies
120VAC to its blower output relay and waits for a pressure
switch signal.
A circuit breaker is provided for protection of the low voltage
supply transformer from overloads and short circuits. The
breaker is located inside the pool heater on the right rear of the
control panel. Power from this breaker goes to the temperature
controller, ignition module and various other components
and/or options on the pool heater. When tripped, all factory-
installed 24VAC components will lose their 24VAC power.
BLOWERS
(Controlled by Ignition Module and Relay Board)
Two blowers serve to provide combustion air to the pool
heater. Both blowers operate in tandem anytime the ignition
module is given a call for heat signal.
MANUAL RESET HIGH-LIMIT THERMOSTAT
A manual reset high limit thermostat is provided as backup for
the auto reset high limit. This is an adjustable dial, bulb-
capillary style thermostat that will trip and require resetting
should water temperature exceed its settings. When tripped,
all controls remain powered, but 24VAC is prevented from
being delivered to the ignition module’s thermostat input.
PRESSURE SWITCH
(Activated by Blower Turning On)
One pressure switch is provided to monitor its On/Off
operation. Upon a call for heat, 24VAC is delivered to the
pressure switch. If the blower generates adequate air pressure,
the pressure switch closes to deliver 24VAC to the ignition
module’s pressure switch monitoring input terminal.
EMS/SEQUENCER/REMOTE AQUASTAT
TERMINALS
The EMS/sequencer/remote aquastat terminals are provided
for connection of the pool heater to an external energy
management system or sequencer and are located along the top
edge of the terminal strip located within the electrical wiring
box. In addition to providing a means to externally fire the
pool heater, these terminals also provide for remote shutdown
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PREPURGE
(Ignition Module Function)
HEAT TRANSFER PROCESS
(Gas Valves, Burner and Heat Exchanger)
Once the ignition module sees a 24VAC input from its pressure Once flame has been proven, the ignition module will hold the
switch, it runs the blowers for approximately 15 seconds in gas valves open as long as there is proof of flame and a call for
order to purge the combustion chamber of any unburned heat is present. When the temperature of the water reaches that
fuel/air mixture.
of the programmed set point, the pool heater will be shut down.
IGNITER WARM-UP AND PROVING
(Ignition Module Function)
POST-PURGE
(Ignition Module Function)
Once the ignition module has completed its prepurge period, it When 24VAC is removed from the ignition module’s
turns on the hot surface igniter. Once the hot surface igniter’s thermostat input, the module turns “OFF” the gas valves and
current draw reaches a proper level, the ignition module begins maintains the blowers for approximately 25 seconds in order to
an additional period of approximately 25 seconds for the allow the combustion chamber to be purged of all combustion
igniter to ensure the ignition temperature is attained to ignite by-products.
the fuel/air mixture.
IDLE
IGNITER
(Controlled by Ignition Module)
One igniter is provided in order to ignite the fuel/air mixture
and its operation and timings are controlled by the ignition
module.
(Temperature Controller Function)
After completion of the post-purge cycle, the pool heater will
go into an idle state whereby the temperature controller
continuously monitors the water temperature until the water
temperature drops to levels that require additional heat.
IGNITION AND FLAME PROVING
(Ignition Module Function)
Once the warm-up and proving period has been completed, the
ignition module sends 24VAC to the gas valves on
approximately half of the pool heater. These gas valves should
open and allow gas to flow to the burners. The fuel/air mixture
should ignite from the hot surface igniter. Once this voltage
has been sent to the valves, the hot surface igniter is turned
“OFF”. The ignition module then monitors and proves the
presence of the flame and will either allow operation to
continue or shut down the gas valves should flame not be
proven and proceed to a Flame Failure condition. If flame was
proven briefly during the ignition period, the module may not
proceed to Flame Failure, but rather post-purge and then go
into another trial for ignition.
SOFT-START
MODELS 990,000 - 2,070,000 BTU/HR ONLY
(Controlled by Temperature Controller)
A small time delay is provided to delay the opening of
approximately half of the valves until the first half of the
valves have opened and the gas has successfully ignited and
established flame on the burners.
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WIRING BOX CONNECTIONS
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Installation and Service Manual
WIRING BOX CONNECTIONS
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LADDER DIAGRAM
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CONTROL BOX CONNECTIONS
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Appendix A
Unit Start Up Checklist
4. For negative draft vent systems, measure the draft in
Ensure that the location and installation of the equipment is in
accordance with the installation manual, all local installation
requirements, and with the latest edition of the National Fuel
Gas Code, ANSI 223.1 and/or CAN/CGA-B149 Installation
Code.
the vent stack. The negative draft should be between
-.02 w.c. to -.08 w.c. Reference pages 10 - 26 of this
manual to determine which venting system is in use.
Note: For positive pressure venting systems a draft
measurement is not required. Ensure that the vent length does
not exceed the maximum lengths listed in the Installation and
Service Manual.
1. Measure the supply gas pressure. For natural gas
models, the supply gas pressure should be between
4.5" w.c. to 10.5" w.c. For LP gas models, the supply gas
pressure should be between 8" w.c. to 13" w.c. For a
detailed procedure on measuring the supply gas pressure,
reference page 28 of this manual.
5. Adjust the temperature set point on the digital
temperature control to the desired pool temperature.
Reference pages 40 and 41 of this manual for information
regarding the operation and adjustment of the digital
temperature control.
2. Measure the differential air pressure. The differential
air pressure for the 500,000 - 750,000 Btu/hr models
should be between 1.5" w.c. to 1.65" w.c. The differential
air pressure for 990,000 - 2,070,000 Btu/hr models should
be between 1.1" w.c. to 1.3" w.c. Reference pages 49 and
50 of this manual for the proper procedure for measuring
the differential air pressure. If an adjustment is necessary
follow the procedure on page 50 of this manual.
6. A 3-way automatic bypass valve is factory installed to
maintain a minimum temperature of 130° to the inlet of the
pool heater to protect against flue gas condensation.
Manual adjustment of the valve is not required.
Note: If the inlet temperature of the pool heater can not be
maintained at 130°, reference pages 33, 34, and 46 of this
manual to ensure that the pipe size and piping arrangements
are correct.
Note: The combustion air fan(s) is factory preset and should
not need adjustment. However, due to installation and
environmental conditions adjustment of the air fan shutter(s)
may be necessary at start up.
If problems arise during the start up, reference the Installation
and Service Manual and/or consult the factory.
3. Measure the net manifold gas pressure. For 500,000 -
750,000 Btu/hr models the net manifold gas pressure for
natural gas models should be 1.8" w.c For LP gas models
the net manifold gas pressure should be 4.6" w.c. For
990,000 - 2,070,000 Btu/hr models the net manifold gas
pressure for natural gas models should be 1.2" w.c. For LP
gas models the net manifold gas pressure should be
4.6" w.c. For the proper procedure for measuring net
manifold gas pressure, reference page 30 of this manual. If
an adjustment of the net manifold gas pressure is
necessary, follow the procedure on page 30 of this manual.
Note: The gas valves are factory preset and should not need
adjustment. However, due to installation and environmental
conditions adjustment of the gas valves may be necessary for
start up.
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Appendix B
Adjust Menu Settings for Operating Modes
User
Advanced
Item
Description
Default
Range
X
X
X
X
TARGET
DIFF
Pool target temperature
85°F
4°F
130°F
200°F
100°F
20°F
OFF, 55 to 105°F
1 to 20°F
130 to 150°F
120 to 200°F
OFF, 70 to 110°F
2 to 20°F
Differential setting for return sensor
Minimum inlet water temperature
Maximum outlet temperature
Supply water temperature
X
BOIL IN MIN
BOIL MAX
SUP TARGET
SUP DIFF
MOTOR SPEED
DLY
X
X(*)
X(*)
X
Differential setting for supply sensor
Setting other than 20 may void warranty 20 sec
15 to 30 sec
ON, 0:20 to 9:55 min
0 to 999 hr
X
Time at which purging stops
*Accumulated runtime of unit
Set temperature at °F or °C
20 sec
0 hr
°F
X
BOIL ON
F/C Units
X
X
°C or °F
User Settings: Rear dip switch set to “1” position.
Advanced Settings: Rear dip switch set to “0” position.
(*) If equipped with optional pool supply sensor.
View Menu Information
View Menu Item
Menu Description
Current Temperature
TARGET Set point
BOIL IN
Pool return sensor temperature
Pool temperature set point
Inlet sensor temperature
Outlet sensor temperature
Heater differential temperature
Pool supply sensor temperature
Accumulated runtime hours
BOIL OUT
BOIL ΔT
SUP (If equipped pool supply sensor)
BOIL ON (Advanced switch set to “0”)
control will shut off the heater whenever the pool supply
temperature exceeds this setting. The default value is 100°F.
If a Pool Supply sensor is connected, then by pressing the
Select key again, the Supply Differential setting will be
displayed, indicated by the text SUP DIFF in the display.
After the control has turned off the heater because the pool
supply temperature exceeded the Pool Supply setting, the pool
supply temperature must drop by this amount before the
control will allow the heater to start up again. The default
value is 20°F.
By pressing the Select key again, the Valve Speed setting will
be displayed, indicated by the arrow pointing to the text
SPEED on the overlay. This setting is used to control the
responsiveness of the 3-way automatic bypass valve, and
should only be adjusted under the direction of Lochinvar’s
Technical Services personnel. The default setting is 20
seconds.
Advanced settings:
By pressing the Select key in the View mode while viewing the
Boiler ΔT reading (or the Supply Sensor temperature if the
Pool Supply sensor is connected), the Boiler On hours will be
displayed, indicated by the text BOIL ON in the display. This
is the total number of hours the pool heater has been heating
the pool.
By pressing the Select key in the Adjust mode while viewing
the Pool DIFF setting, the Boiler Inlet Minimum setting will be
displayed, indicated by the text BOIL IN MIN in the display.
The control will adjust the position of the 3-way automatic
bypass valve in order to maintain the inlet temperature at this
setting. The default is 130°F.
By pressing the Select key again, the Boiler Maximum setting
will be displayed, indicated by the text BOIL MAX in the
display. The control will shut off the heater whenever the
outlet temperature from the heater exceeds this setting. The
default value is 200°F.
By pressing the Select key again, the pump Delay setting is
displayed, indicated by the DLY on the display. This is the
time that the heater pump will continue to run after the control
turns the heater off. The default value is 20 minutes.
If a Pool Supply sensor is connected, then by pressing the
Select key again, the Supply Target setting will be displayed,
indicated by the text SUP TARGET in the display. The
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Lochinvar Corporation • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax 615-547-1000
6/06-Printed in U.S.A.
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