Lochinvar Gas Heater F0600187510 User Manual

CPE-I-S-10  
INSTALLATION AND SERVICE MANUAL  
GAS HEATERS FOR COMMERCIAL  
POOL APPLICATIONS  
500,000 - 2,070,000 Btu/hr MODELS  
Starting Serial #F0600187510  
ƽ WARNING: 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.  
ƽ WARNING: Improper  
installation, adjustment,  
alteration,  
service  
or  
• Immediately call your  
gas supplier from a  
neighbors phone. Follow  
maintenance can cause  
property damage, personal  
injury, exposure to 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.  
the  
gas  
supplier’s  
ƽ WARNING: Do not use  
this pool heater if any part  
has been under water. The  
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  
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.  
ƽ DANGER: Carbon Monoxide poisoning 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. 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.  
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.  
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. 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).  
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.  
4. This pool heater is only for use with the type of gas indicated on  
the rating plate.  
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Commercial Pool Heaters  
5. If you smell gas, shut off the gas supply:  
Do not try to light any appliance;  
Do not touch any electrical switch; do not use any  
telephone in your building;  
Immediately call your gas supplier from a neighbor’s  
telephone. 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  
Clearances from Combustible Construction  
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.  
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)  
6" (15cm) (24" (0.61m) suggested for service)  
Alcove* (30" (0.76m) suggested for service)  
3" (7.5cm)  
LOCATING POOL HEATER  
1. Maintain all clearances from combustible construction when  
locating pool heater. See Clearances from Combustible  
Construction, this page.  
Left Side  
Front  
Top  
Flue  
1" (25.4mm)  
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.  
Hot Water Pipes 1" (25.4mm)  
*An Alcove is a closet without a door.  
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.  
Note: No additional clearances from combustibles are needed for  
3. Install the indoor pool heaters so that the ignition system use of the Direct Vent (DV) air inlet assembly.  
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. Figure 2 – Clearances from Combustible Construction  
See Outdoor Installation Venting, page 25. A wind proof cabinet  
Base for Combustible Floors  
protects the pool heater from weather.  
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.  
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Installation and Service Manual  
TABLE - A  
COMBUSTIBLE FLOOR KITS  
Input Btu/hr  
Kit Number  
500,000  
CFK3302  
650,000  
750,000  
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 equipment 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  
equipment room. Damage to the pool heater by freezing is non-  
warrantable.  
Figure 3 – Draining Pool Heater  
ƽ CAUTION: Under no circumstances should the  
equipment 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.  
COMBUSTION AND VENTILATION AIR  
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.  
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.  
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.  
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.  
3. Location - Indoor pool heaters must be located in a room  
having a temperature safely above freezing [32°F(0°C)].  
Combustion Air Filter  
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.  
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.  
5. Shut-Down and Draining - If for any reason, the pool heater is  
to be shut off, the following precautionary measures must be  
taken:  
a. Shut off gas supply;  
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.  
b. Shut off water supply;  
c. Shut off electrical supply;  
d. 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;  
e. Drain pump and piping.  
ƽ CAUTION: Some pleated filters are too  
restrictive and could cause air flow problems.  
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Commercial Pool Heaters  
Combustion Air Options  
INSTALLATION Continued  
This pool heater has four combustion air options.  
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.  
1. Outside Combustion Air, No Ducts  
You can direct outside combustion air to this pool heater using  
either one or two permanent openings.  
1. Remove the metal panel from the pool heater’s side wall (see  
Figure 4).  
One Opening  
2. Remove screws from the air filter/bracket assembly.  
The opening must have a minimum free area of one square inch  
per 3000 Btu input (7cm2 per kW). You must locate this opening  
within 12" (30cm) of the top of the enclosure.  
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 one  
square inch per 4000 Btu/hr input (5.5cm2 per kW). You must locate  
this opening within 12" (30cm) of the bottom of the enclosure.  
Figure 4 – Metal Panel Covering Side Combustion Air Inlet  
The ventilation air opening must have a minimum free area of one  
square inch per 4000 Btu/hr input (5.5cm2 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  
Figure 7 – Outside Combustion Air - Two Openings  
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Installation and Service Manual  
2. Outside Combustion Air, Using Ducts  
All dimensions are based on net free area in square inches. Metal  
louvers or screens reduce the free area of a combustion air opening  
You can direct outside combustion air to this pool heater using  
two air ducts to deliver the air to the equipment room. Each of  
the two openings must have a minimum free area of one square  
inch per 2000 Btu input (11cm2 per kW).  
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  
equipment 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.  
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 equipment 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 equipment 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 equipment 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  
square inch per 1000 Btu input (22cm2 per kW), but not less  
than 100 square inches (645cm2).  
Figure 9 – Combustion Air from Interior Space  
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Commercial Pool Heaters  
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.  
Figure 10 – Vent Termination from Peaked Roof - 10' or Less  
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.  
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  
Figure 11 – Vent Termination from Peaked Roof More Than 10'  
From Ridge  
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.  
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.  
Keep the vent cap clear of snow, ice, leaves, and debris to avoid  
blocking the flue.  
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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  
Figure 12 – Vent Termination from Flat Roof 10' or Less from  
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 equipment  
room. In cold climates, operate pump continuously  
to help prevent freezing of pool heater water.  
Provide proper freeze protection. See Freeze  
Protection, page 7.  
Parapet Wall  
TABLE - B  
Flue and Air Inlet Pipe Sizes  
Input  
Btu / hr  
Flue  
Size  
Air Inlet  
Size*  
500,000  
650,000  
6"  
8"  
6"  
8"  
750,000  
8"  
8"  
Figure 13 – Vent Termination from Flat Roof More Than 10'  
from Parapet Wall  
990,000  
10"  
12"  
12"  
14"  
14"  
10"  
12"  
12"  
12"  
12"  
1,260,000  
1,440,000  
1,800,000  
2,070,000  
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 assisted appliances.  
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.  
Locate vent termination at least 3 feet (0.91m) from an inside corner  
of an L-shaped structure.  
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Commercial Pool Heaters  
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.  
Combustion Air Inlet Piping  
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.  
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).  
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.  
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.  
Sidewall Air Inlet  
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 Equipment Room  
Combustion Air Source  
Boiler Input  
Outside Air*/2 Openings  
Outside Air*/1 Opening  
Inside Air/2 Openings  
500,000  
125 in2 (806 cm2)  
167 in2 (1,077 cm2)  
500 in2 (3,226 cm2)  
650,000  
750,000  
163 in2 (1,052 cm2)  
188 in2 (1,213 cm2)  
248 in2 (1,600cm2)  
315 in2 (2,032cm2)  
360 in2 (2,323cm2)  
450 in2 (2,903cm2)  
518 in2 (3,342cm2)  
217 in2 (1,400 cm2)  
250 in2 (1,613 cm2)  
330 in2 (2,129 cm2)  
420 in2 (2,710 cm2)  
480 in2 (3,097 cm2)  
600 in2 (3,871 cm2)  
690 in2 (4,452 cm2)  
650 in2 (4,194 cm2)  
750 in2 (4,839 cm2)  
990 in2 (6,388 cm2)  
1260 in2 (8,130 cm2)  
1440 in2 (9,291 cm2)  
1800 in2 (11,614 cm2)  
2070 in2 (13,356 cm2)  
990,000  
1,260,000  
1,440,000  
1,800,000  
2,070,000  
* 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.  
12  
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Installation and Service Manual  
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).  
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  
Figure 15 – Air Inlet Cap for Sidewall Termination  
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.  
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.  
Example: Two 10" air inlet pipes (78.5 in2 area each) have a total  
area of 157 in2 and will require a 15" (176.7 in2 area) 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.  
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. 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 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.  
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.  
13  
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Commercial Pool Heaters  
Barometric Damper Location  
INSTALLATION Continued  
Vent System Options  
This pool heater has six venting options.  
Any venting system option that requires a barometric damper must  
adhere to the following directions for optimum performance.  
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.  
1. Conventional Negative Draft Venting  
This option uses a vertical rooftop flue termination.  
Combustion air is supplied from the equipment room.  
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.  
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 equipment room. See page 17 for venting  
details.  
1. Conventional  
Venting  
Negative  
Draft  
IMPORTANT: Before installing the venting system,  
follow all venting clearances and requirements  
found in the Venting, General Information section,  
page 10.  
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.  
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.  
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.  
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).  
14  
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Installation and Service Manual  
Connect the flue vent directly to the flue outlet opening on the top At the time of removal of an existing pool heater, the following steps  
of the pool heater. No additional draft diverter or barometric shall be followed with each pool heater remaining connected to the  
damper is needed on single unit installations with a dedicated stack common venting system placed in operation, while other appliances  
and a negative draft within the specified range of 0.02 to 0.08 inches remaining connected to the common venting system are not in  
w.c. If the draft in a dedicated stack for a single pool heater operation.  
installation exceeds the maximum specified draft, you must install  
a barometric damper to control draft. Multiple pool heater  
1. Seal any unused opening in the common venting system.  
installations with combined venting or common venting with  
other Category I negative draft appliances require each pool heater  
to have a barometric damper installed to regulate draft within the  
proper range.  
2. Visually inspect the venting system for proper size and horizontal  
pitch. Make sure there is no blockage or 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.  
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.  
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.  
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.  
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.  
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.  
Common venting systems may be too large when an existing pool  
heater is removed.  
15  
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Commercial Pool Heaters  
INSTALLATION Continued  
Masonry Chimney Installations  
You can terminate the combustion air pipe either horizontally 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).  
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 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.  
Figure 19 – Air Inlet Cap for Sidewall Termination  
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.  
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.  
16  
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Installation and Service Manual  
TABLE-D  
DirectAire™ Kits  
Input  
Btu/hr  
Horizontal  
Kit*  
Vertical  
Kit*  
500,000  
650,000  
SVK3047  
SVK3048  
SVK3048  
SVK3040  
SVK3041  
SVK3041  
SVK3041  
SVK3041  
VDK3026  
VDK3027  
VDK3027  
VDK3023  
VDK3024  
VDK3024  
VDK3024  
VDK3024  
750,000  
990,000  
1,260,000  
1,440,000  
1,800,000  
2,070,000  
Figure 20 – Vertical DirectAire Installation with Rooftop  
Combustion Air Inlet  
Vent Kits  
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.  
* 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.  
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 equipment 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.  
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.  
Figure 21 – Sidewall Venting Installation with an Induced  
Draft Fan and Sidewall Vent Cap  
17  
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Commercial Pool Heaters  
INSTALLATION Continued  
Sidewall Fan  
Sidewall Venting Without 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.  
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  
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.  
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.  
Seal all vent joints and seams gas-tight.  
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 Figure 22). 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.  
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.  
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.  
The sidewall fan/powered vent cap must be interlocked with 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.  
18  
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Installation and Service Manual  
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.  
4’ MIN.  
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.  
Figure 22 – 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.  
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.  
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.  
Provide adequate clearance to combustibles for the vent connector  
and firestop.  
Sidewall Vent Termination Clearances and Location  
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.  
Follow all sidewall venting termination information for clearances  
and location under Sidewall Vent Termination Clearances and  
Location, page 11.  
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.  
19  
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Commercial Pool Heaters  
INSTALLATION Continued  
TABLE-E  
Sidewall Vent Kits  
Vent  
Kit*  
Input  
Btu/hr  
Max. Vent  
Length  
Max. Vent  
Length  
Termination Only  
(500,000 - 750,000  
Btu/hr)  
(w/Power  
Fan Assy.)  
500,000 SVK3006 100 ft.  
650,000 SVK3008 100 ft.  
750,000 SVK3008 100 ft.  
990,000 SVK3053 100 ft.  
1,260,000 SVK3054 100 ft.  
1,440,000 SVK3054 100 ft.  
1,800,000 SVK3055 100 ft.  
2,070,000 SVK3055 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  
Figure 23A – Horizontal DirectAire Installation (Illustration  
with Sidewall Venter and Sidewall Combustion Air)  
N/A  
Combustion air supplied from outdoors must be free of contaminants  
(see Combustion and Ventilation Air, page 7).  
N/A  
N/A  
Vent Kits  
*These kits include a sidewall venter assembly, vent termination, and  
barometric damper.  
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.  
4. Horizontal DirectAire™ Venting  
IMPORTANT: Before installing a venting system,  
follow all venting clearances and requirements  
found in the Venting, General Information section,  
page 10.  
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 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.  
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.  
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.  
Venting of Flue Products  
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.  
Termination point for the flue products must follow the clearance  
requirements in Sidewall Vent Termination Clearances and Location  
page 11.  
For proper operation, a barometric damper is provided for  
Horizontal DirectAireTM installations. The damper will help to  
ensure a draft between negative 0.04 to 0.08 inches w.c.  
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 connect the air inlet pipe to a  
combustion air inlet cap as specified in this section.  
20  
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Installation and Service Manual  
Drain Tee Installation  
TABLE-F  
Horizontal DirectAire™ Kits  
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 23B). 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.  
Input  
Kit*  
Btu/hr  
500,000  
650,000  
HDK3031  
HDK3032  
HDK3032  
HDK3037  
HDK3038  
HDK3038  
HDK3039  
HDK3039  
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  
IMPORTANT: Before installing a venting system,  
follow all venting clearances and requirements  
found in the Venting, General Information section,  
page 10.  
Figure 23B – Aire-Lock Direct Vent (Illustration with Sidewall  
Vent and Sidewall Combustion Air)  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
Seal all vent joints and seams gas-tight..  
21  
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Commercial Pool Heaters  
INSTALLATION Continued  
Install the horizontal vent cap from the outside. Mount the vent  
Masonry Chimney Installation  
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.  
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 Horizontal Vent Termination Clearances and Location  
systems (singlewall, doublewall, flexible, or rigid) must be rated for Follow all sidewall venting termination information for clearances  
use with a high efficiency, positive pressure vent system.  
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  
DirectAire™ 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  
DVK3004  
DVK3005  
DVK3005  
DVK3000  
DVK3001  
DVK3001  
DVK3002  
DVK3002  
VDK3026  
VDK3027  
VDK3027  
VDK3023  
VDK3024  
VDK3024  
VDK3024  
VDK3024  
750,000  
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.  
Vertical DV Venting Termination  
You must use the vent termination recommended by the vent  
manufacturer for vertical direct vent terminations. Follow all * 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.  
vertical venting termination information for clearances and location  
under Vertical Vent Termination Clearances and Location, page 10.  
Flue Pipe Materials  
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.  
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.  
Heat-Fab, Inc. Saf-T CI Vent. 1-800-772-0739.  
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.  
Protech Systems, Inc. Fas-N-Seal Vent. 1-800-766-3473.  
Metal-Fab, Inc. Corr/Guard Vent. 1-800-835-2830.  
When installing the vent cap, the wall opening must provide an air  
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.  
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.  
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Installation and Service Manual  
In cold climates, use a Type-B doublewall vent pipe or an insulated Attach the filter/bracket assembly and DV box adapter to the right  
single wall pipe for combustion air. This will help prevent moisture side opening using the pre-drilled screw holes. Make sure you attach  
in the cool incoming air from condensing and leaking from the inlet the metal panel to the rear combustion air opening of the pool heater.  
pipe.  
The DV box adapter has an air inlet pipe mounting ring. Connect  
combustion air inlet piping to the direct vent box mounting ring.  
ƽ CAUTION: Pool heaters that are shut down or  
will not operate may experience freezing due to  
convective airflow in the air inlet pipe.  
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  
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.  
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.  
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  
1. Seal all joints and seams of the air inlet pipe using either  
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.  
For venting versatility, you can move the air filter assembly and DV  
box adapter to the right side of the pool heater. Remove the metal  
panel on the pool heater’s right side (see Figure 25). Remove the  
filter/bracket assembly from the rear of the pool heater.  
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.  
Note: Modifications to the DV box adapter will be necessary to  
allow installation on the right side of the pool heater. Follow the  
instructions shipped with the vent kit.  
23  
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Commercial Pool Heaters  
INSTALLATION Continued  
ƽ WARNING: Locate and install the 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.  
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.  
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.  
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.  
Purchase and assemble the combustion air inlet cap to protect the  
air inlet from wind and weather.  
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.  
Example: Two 8" (20.3cm) air inlet pipes (50.3 in2 [324.5cm2]  
area each) have a total area of 100.6 in2 (645.2cm2), requiring a  
12" (30.5cm) (113.1 in2 [729.7cm2]) 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  
IMPORTANT: To prevent recirculation of flue  
products into the combustion air inlet, follow all  
instructions in this section.  
Figure 26 – Vertical Rooftop Air Inlet  
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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Installation and Service Manual  
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  
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.  
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.  
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  
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.  
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.  
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.  
6. Outdoor Installation Venting  
Locate the pool heater at least 10 feet (3.05m) away from any forced  
air inlet.  
IMPORTANT: Before installing a venting system,  
follow all venting clearances and requirements  
found in the Venting, General Information section,  
page 10.  
Locate pool heater at least 3 feet (0.91m) outside any overhang.  
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.  
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Commercial Pool Heaters  
INSTALLATION Continued  
TABLE H  
Outdoor Vent Cap Kits  
Input  
Outdoor Vent Kit*  
Btu/hr  
500,000  
650,000  
ODK3075  
ODK3076  
ODK3076  
ODK3077  
ODK3078  
ODK3079  
ODK3080  
ODK3080  
750,000  
990,000  
Figure 27 – Outdoor Vent Cap Installed on Rear of Pool Heater  
1,260,000  
1,440,000  
1,800,000  
2,070,000  
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.  
* These kits include an outdoor vent cap and gasket.  
INLET PRESSURE: Measure inlet pressure at the inlet pressure tap  
located upstream of the combination gas valve(s).  
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.  
See TABLE–I for maximum and minimum inlet pressures. Do not  
exceed the maximum. Minimum inlet pressure is for the purposes  
of input adjustment.  
TABLE-I  
The Outdoor Vent Cap Kit  
Inlet Pressure  
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.  
Maximum  
10.5" w.c.  
13" w.c.  
Minimum  
4.5" w.c.  
Natural Gas  
LP Gas  
Install the outdoor vent cap on the rear of the pool heater, see  
Figure 27.  
8" w.c.  
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.  
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.  
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.  
If you must adjust regulator pressure, follow the instructions under  
Gas Manifold Pressure Adjustment, page 30. Do not increase  
Combustion Air Fan Adjustment (for regulator pressure beyond specified pressure setting.  
startup)  
Gas Pressure Test  
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 section on page 49 of this manual.  
1. Disconnect the unit from the gas supply piping system  
during any piping system pressure testing greater than  
1/2 PSIG (3.5kPa)  
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).  
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.  
3. Test all gas connections for gas leaks before placing the pool  
heater in operation.  
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Installation and Service Manual  
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.  
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.  
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.  
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 and  
spaced a minimum of 6' from the appliance.  
6. Install a sediment trap in the supply line to the pool heater’s gas  
inlet (see Figure 28).  
Connecting Gas Piping to the Pool  
7. Apply a moderate amount of good quality pipe compound (do  
not use Teflon tape) to pipe only, leaving two end threads bare.  
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.  
8. Remove the seal over the gas inlet to the pool heater.  
9. Connect the gas pipe to the inlet of the pool heater. Use a  
wrench to support the gas manifold on the pool heater.  
10. For L.P. gas, consult your L.P. gas supplier for expert installation.  
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.  
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.  
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.  
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.  
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.  
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.  
27  
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The manifold pressure is preset at the factory and adjustment is not  
usually required. If you must adjust regulator pressure, follow the  
instructions under Gas Manifold Pressure Adjustment, page 30.  
INSTALLATION Continued  
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.  
Checking Gas Supply Pressure  
Use the following procedure to check gas supply pressure.  
Figure 29 – Typical Pool Heater Gas Train Drawing  
1. Turn the main power switch to the “OFF” position.  
2. Turn gas valve knobs to the “OFF” position.  
TABLE-J  
Suggested Gas Pipe Size for Single Unit Installations  
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.  
Distance From Meter (in feet)  
Btu/hr  
Input  
0-50  
500,000 1 1/4"  
650,000 1 1/2"  
750,000 1 1/2"  
51-100 101-200 201-300 301-500  
1 1/2"  
2"  
2"  
2"  
2"  
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 1/2"  
2 1/2"  
2 1/2"  
3"  
2"  
2"  
990,000  
2"  
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 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.  
3"  
3 1/2"  
3 1/2"  
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"  
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.  
28  
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13. Remove the manometer and related fitting from theinletside  
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  
Length of Pipe in Straight Feet  
10  
369  
20  
256  
477  
974  
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  
95  
150  
86  
175  
79  
200  
74  
(Inches)  
3/4"  
1"  
697  
179  
369  
564  
164  
333  
513  
974  
149  
308  
472  
871  
138  
287  
441  
820  
1 1/4"  
1 1/2"  
2"  
1,400  
2,150 1,500 1,210 1,020  
4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100  
2 1/2"  
3"  
6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300  
11,200 8.900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340  
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  
4"  
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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6. Remove the 1/8" hex plug from the manifold pressure tap on  
INSTALLATION Continued  
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 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.  
3. Remove the top front jacket access panels to access the gas  
valves.  
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.  
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.  
17. Remove hoses, replace and tighten plugs and caps when  
complete.  
MANIFOLD  
PRESSURE  
CAP  
18. Replace top front upper jacket access panels and control panel  
door in reverse order.  
PRESSURE  
INLET  
REGULATOR  
4
3
2
1
0
1
2
3
4
ADJUSTMENT  
(UNDER CAP SCREW)  
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 Adjustment. Follow the  
procedure to adjust the combustion air fans as necessary.  
BARBED  
FITTING  
CHAMBER  
PRESSURE  
GAS  
VALVE  
CONTROL  
KNOB  
MANOMETER  
1/8" HEX  
MANIFOLD  
PRESSURE  
TAP  
OUTLET  
Figure 31 – Measuring Net Manifold Gas Pressure  
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tighten to seal. Do not over tighten either part into the threaded  
TABLE-L  
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.  
Net Manifold Pressure  
500,000 – 750,000  
Natural Gas  
LP Gas  
1.8" w.c.  
4.6" w.c.  
990,000 – 2,070,000  
Natural Gas  
LP Gas  
1.2" w.c.  
4.6" w.c.  
Pumped Automatic Bypass  
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.  
* Net Manifold Pressure equals the measured manifold pressure minus  
the chamber pressure. See Figure 31 to measure the Net Manifold Pressure.  
POOL HEATER PIPING  
INSTALLATION  
Outdoor  
Operation  
-
Outdoor  
3-Way  
Automatic Bypass Valve Cover  
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.  
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.  
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 pipe threads have been cut into the PVC pipe wall, the  
limit and bulbwell can be inserted into the tapped openings. Apply  
a 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  
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.  
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  
Bypass Valve Actuator  
INSTALLATION Continued  
Note: If the wing nut underneath the valve actuator body is loose,  
retighten.  
To manually operate the 3-way automatic bypass valve actuator:  
1. Power must be removed from the unit.  
9. Reinstall the plastic actuator cover and secure with the  
screw loosened in Step 2.  
2. Once power is removed, the de-clutch button located  
on the side of the valve actuator body can be pressed.  
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.  
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  
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MODEL NO.  
BYPASS PIPE SIZE  
CP (N,L) 501 - 751  
CP (N,L) 991 - 2071  
2” MINIMUM  
2 1/2” MINIMUM  
AUTOMATIC  
BYPASS VALVE  
FACTORY POOL  
RETURN SENSOR  
LOCATION  
PVC MINIMUM  
(SEE TABLE)  
RECOMMENDED  
ISOLATION VALVE  
FROM FILTER  
VALVE  
110°LIMIT  
COPPER OR CPVC  
(SEE TABLE)  
20' MAXIMUM  
3'  
MINIMUM  
TO POOL  
ALTERNATE POOL  
RETURN SENSOR  
LOCATION  
Figure 34 - Heater is Within 15 Feet of Pool Piping  
MODEL NO.  
BYPASS PIPE SIZE  
2” MINIMUM  
CP (N,L) 501 - 751  
2 1/2” MINIMUM  
CP (N,L) 991 - 2071  
FACTORY POOL  
RETURN SENSOR  
LOCATION  
AUTOMATIC  
BYPASS VALVE  
PVC (SEE TABLE)  
RECOMMENDED  
ISOLATION VALVE  
FROM FILTER  
12"  
OR FOUR PIPE  
DIAMETERS  
MAXIMUM  
20' MAXIMUM  
COPPER OR CPVC  
(SEE TABLE)  
VALVE  
110°LIMIT  
3'  
MINIMUM  
TO POOL  
ALTERNATE POOL  
RETURN SENSOR  
LOCATION  
Figure 35 - Heater is Beyond 15 Feet of Pool Piping  
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Commercial Pool Heaters  
INSTALLATION Continued  
MODEL NO.  
BYPASS PIPE SIZE  
2” MINIMUM  
CP (N,L) 501 - 751  
FACTORY POOL  
RETURN SENSOR  
LOCATION  
CP (N,L) 991 - 2071  
2 1/2” MINIMUM  
AUTOMATIC  
BYPASS VALVE  
PVC (SEE TABLE)  
FROM FILTER  
COPPER OR CPVC  
(SEE TABLE)  
RECOMMENDED  
ISOLATION VALVE  
VALVE  
COPPER OR CPVC  
(SEE TABLE)  
3'  
110°LIMIT  
MINIMUM  
ALTERNATE POOL  
RETURN SENSOR  
LOCATION  
TO POOL  
Figure 36 - Heaters are within 15 feet Perpendicular of Pool Piping  
MODEL NO.  
BYPASS PIPE SIZE  
2” MINIMUM  
CP (N,L) 501 - 751  
CP (N,L) 991 - 2071  
2 1/2” MINIMUM  
ALTERNATE POOL  
RETURN SENSOR  
LOCATION  
FROM FILTER  
4" PVC  
3'  
MINIMUM  
FLOWMETER  
110°LIMIT  
3" PVC  
FLOWMETER  
3" PVC  
TO POOL  
RECOMMENDED  
ISOLATION VALVE  
FACTORY POOL  
RETURN SENSOR  
LOCATION  
AUTOMATIC  
BYPASS VALVE  
COPPER OR CPVC  
(SEE TABLE)  
Figure 37 - Heaters are Beyond 15 feet of Pool Piping  
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MODEL NO.  
BYPASS PIPE SIZE  
2” MINIMUM  
CP (N,L) 501 - 751  
CP (N,L) 991 - 2071  
2 1/2” MINIMUM  
ALTERNATE POOL  
RETURN SENSOR  
LOCATION  
FROM FILTER  
OPTIONAL  
POOL SUPPLY  
SENSOR LOCATION  
4" CPVC  
3'  
FLOWMETER  
MINIMUM  
110°LIMIT  
4" CPVC  
FACTORY POOL  
RETURN SENSOR  
LOCATION  
TO POOL  
RECOMMENDED  
ISOLATION VALVE  
COPPER OR CPVC  
(SEE TABLE)  
Figure 38 - Multi-Stack Frame - Heaters are Beyond 15 feet from Pool Piping  
Relief Valve  
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.  
IMPORTANT: High chemical concentrations from im-  
properly adjusted feeders and Chlorinator can cause  
rapid corrosion to the heat exchanger. This damage is  
non-warrantable.  
Water Flow Switch  
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.  
Do not place chlorine tablets or bromine sticks in the skimmer.  
High chemical concentrations will result when the pump is not  
running.  
35  
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CONNECTING TO  
INSTALLATION Continued  
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.  
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.  
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.  
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.  
IMPORTANT: Do not block access to the electrical  
cover plate when installing electrical conduit.  
The inactive timer is adjustable from 1 - 99 hours. Selection of a  
time between 4 - 8 hours is recommended.  
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  
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:  
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.  
Service Indicator Option  
- Yellow to terminal #1  
- Blue to terminal #2  
- White with a red stripe to terminal #3  
- Pink to terminal #4.  
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.  
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  
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.  
Terminal StripConnection 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-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).  
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 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.  
A.  
37  
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Commercial Pool Heaters  
INSTALLATION Continued  
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.  
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.  
B.  
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.  
C.  
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).  
Figure 40 (A-C) - Terminal Strip Connection  
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).  
OPERATION  
FOR YOUR SAFETY READ BEFORE  
OPERATING  
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.  
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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Installation and Service Manual  
Figure 42 – ON/OFF Switch  
Figure 43 – Combination Gas Valve  
8. Turn the manual gas cock clockwise ; to the “OFF” position.  
Pre-Start Checklist  
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.  
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.  
10. Turn the manual gas cock counterclockwise : to the “ON”  
position.  
11. Turn the power switch to the “ON” position.  
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.  
12. Slide the control panel assembly back into the pool heater.  
Tighten the knurled screw at the bottom of the control panel  
cover.  
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 notair boundby 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  
flue products. If the boiler 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.  
OPERATION Continued  
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)  
Figure 45 – Horizontal Pool Heater Piping  
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).  
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  
optional pool supply sensor exceeds another limit (default = 100°F).  
In addition, the temperature control will operate a 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 heater from condensation of 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.  
The default display mode is the View mode, indicated in the upper  
right-hand corner of the display.  
The default value shown is the Pool Temperature, indicated by the  
arrow pointing to the POOL text on the overlay. If the pool return  
sensor has been installed and connected, this will be the  
temperature of the water coming from the pool.  
40  
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By pressing the Select key again, the Pool Target will be shown once  
more. To return to the View mode, simply stop pressing any  
buttons for 25 seconds.  
By pressing the Select key, the Pool Target is shown and the text  
TARGET on the display. This is the pool temperature set point.  
By pressing the Select key again, the Boiler Inlet Temperature is  
shown, indicated by the text Boil In. This is the temperature of the  
water going into the pool heater. Note that it is different than the  
temperature of the water coming from the pool.  
Note: The control values programmed into memory will not be  
lost because of a power failure.  
Error Messages Displayed by the  
Temperature Controller  
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.  
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 key Select 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.  
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.  
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 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.  
Programming Mode  
E03 - The inlet temperature into the pool heater was below its target  
temperature for more than 15 minutes. Check the mixing valve.  
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.  
By pressing the Select key again, the Temperature Units will be  
displayed, indicated by the text °F or °C. This is the units in which  
the temperatures are shown. The default is °F.  
41  
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Commercial Pool Heaters  
Hot Surface Ignition Control Module  
OPERATION Continued  
Ignition Module Lockout Functions  
HOT SURFACE IGNITION SYSTEM  
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 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  
42  
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Installation and Service Manual  
circuit, circuit breaker for the control circuit, switching relays for  
TABLE-N  
Ignition Control Diagnostic Codes  
component operation and wiring harness connections to the pool  
heater’s components. The control panels are common and may be  
switched between pool heaters for troubleshooting.  
Code Sequence  
Condition  
Removing the Control Panel  
1. Pull the control panel out as far as it will go.  
Constant ON  
Constant OFF  
System OK, no faults present.  
Possible control fault, check power;  
LED may be effective, do not  
replace control if all operational  
2. Remove the multi-pin connector blocks from the top and right  
side of the control panel.  
sequences  
TroubleShooting Guide.  
function  
properly,  
see  
3. Use a 1/2" box wrench or socket wrench to remove the bolt on  
the right side of the control panel.  
One Flash  
Low Air, check air pressure switch and  
hoses to pressure sensing points, fan,  
venting and sealing of pressurized  
chamber.  
4. Remove the entire control panel.  
5. Reinstall the control panel in the reverse order.  
Note: Brief flashing normal on fan start-up/proving.  
ƽ CAUTION: Control panel is heavy and awkward  
to handle when removed. Carefully support the  
control panel when removing.  
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.  
Ignition and Control Timings  
Three Flashes  
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.  
Proven Pilot Hot Surface Ignition System F-9 on 500,000 through  
2,070,000 Btu/hr models with One Hot Surface Ignition Module.  
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  
Four Flashes  
Igniter failure, igniter will not maintain  
minimum 2.75 amp current draw, caused  
by low voltage, bad wiring/continuity,  
high resistance or igniter failure.  
Failure Response Time: 0.8 Seconds at less than 0.5 µA flame  
current  
Flame Current: 5 - 15 µA  
Five Flashes  
Six Flashes  
Power supply problem, check for low  
supply voltage or transformer output less  
than 18VAC.  
Post-purge:  
30 Seconds  
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 24 VAC control  
43  
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Commercial Pool Heaters  
Water Chemistry  
OPERATION Continued  
Factors which affect pool water and, more importantly, the  
efficiency of your new pool heater are:  
OPERATION AND DIAGNOSTIC  
INDICATORS  
1. Proper Filtration  
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.  
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.  
Figure 50 – pH Scale  
Trial for Ignition  
Hot surface igniter 1 preparing to light  
burners.  
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.  
Heating  
Burners operating.  
Service (if equipped) Service  
purchased.  
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.  
Damage to the pool heater, including the pumped bypass, due to  
improper chemical water balance is non-warrantable. Proper  
chemical water balance, as indicated by use of the calcium  
saturation and Ryznar indexes, is required to maintain warranty  
status of the pool heater and its components. These indexes are  
designed to help prevent scaling and corrosive damage to the pool  
and all associated equipment. We recommend the use of a  
commercial or professional grade test kit to maintain chemical  
water balance. See your local pool professional for assistance.  
The display indicators on the Operating Temperature Control point  
to text on the overlay (Figure 46). They indicate the following:  
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.  
Active - This indicator appears when the pool heater supplies heat  
to the pool.  
44  
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Refer to Circulating Pump on page 46 for information relating to Pipe Size Requirements  
pump wiring.  
The pipe sizing chart provides the minimum pipe size for common  
manifold piping to ensure adequate flow.  
TABLE-P  
TABLE-Q  
AMP Draw Data  
Pipe Sizing Chart  
Btu/Hr  
Input  
Approximate  
Total Amps  
Controls  
Fans Pump  
500,000 - 750,000 Btu/hr Models  
Number of Units  
Common Pipe  
Size (Min.)  
500,000  
650,000  
3.6  
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  
1
2
3
4
5
6
2"  
5.4  
5.4  
7.3  
7.3  
7.3  
7.3  
7.3  
3"  
750,000  
3 1/2"  
4"  
990,000  
1,260,000  
1,440,000  
1,800,000  
2,070,000  
5"  
5"  
990,000 - 2,070,000 Btu/hr Models  
Number of Units  
Common Pipe  
Size (Min.)  
1
2
3
4
5
6
2 1/2"  
4"  
4"  
5"  
6"  
6"  
45  
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Commercial Pool Heaters  
TABLE-R  
Minimum Pump Performance  
OPERATION Continued  
Btu/Hr Input  
GPM  
Ft.Hd.  
Circulating Pump  
1. This pool heater is factory supplied with a properly sized pump  
that circulates water between the pool heater and system.  
500,000 – 750,000  
990,000 – 1,440,000  
1,800,000 – 2,070,000  
55  
10  
15  
18  
90  
2. The pump is sized to pool heater input and water hardness. See  
Water Chemistry on page 44.  
115  
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.  
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.  
4. Standard pool heaters are furnished with the following  
circulating pump mounted in the factory supplied pool loop.  
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. Thisscouring 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.  
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  
This pump is sized based on installation of a single pool heater 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.  
The standard pump selection is based on the following pipe and  
fittings from the pool heater to the system:  
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.  
6 - 90° elbows  
2 - unions  
2 - ball valves  
1 - cold water tee  
Not more than 45 feet of straight pipe.  
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.  
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.  
46  
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Installation and Service Manual  
CLEANING AND  
MAINTENANCE  
Listed below are items that must be checked to ensure safe reliable Normal Flame: A normal flame is blue with slight yellow tips, has  
operations. Verify proper operation after servicing.  
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.  
ƽ
CAUTION: Label all wires prior to  
disconnection when servicing controls. Wiring  
errors can cause improper and dangerous  
operation.  
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.  
Appliance Area  
Lifting Flames: The usual causes for lifting flames are over firing  
the burner(s), excessive primary air, or high draft.  
Keep appliance area clear and free from combustible materials,  
gasoline and other flammable vapors and liquids.  
If you observe improper flame patterns, examine the venting  
system, ensure proper gas supply, and ensure adequate supply of  
combustion and ventilation air.  
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.  
Flue Gas Passageways Cleaning Procedures  
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.  
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.  
ƽ WARNING: The areas around the burner view  
ports are hot. Direct contact with the pool heater  
could result in burns.  
IMPORTANT: All gaskets on disassembled  
components must be replaced with new gaskets on  
reassembly. Gasket kits are available from your  
distributor.  
Figure 51 - Flame Pattern Illustration  
47  
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Commercial Pool Heaters  
CLEANING AND  
MAINTENANCE Continued  
Burner Removal and Cleaning  
pool heater, a garden hose can be used to wash the tubes to ensure  
that all soot is removed from the heat exchanger surfaces.  
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.  
Note: Do not wet the pool heater’s refractory.  
8. Ensure that all burner ports are cleaned to remove any soot. See  
Burner Removal and Cleaning, this page.  
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.  
5. Remove the mounting nuts from the manifold mounting  
brackets. Pull the manifold/orifice assembly away from the  
burners. Repeat for each manifold assembly.  
Note: Make sure frame runners seal securely where they contact the  
front and rear compartment refractory.  
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.  
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.  
13. Cycle the pool heater and check for proper operation.  
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  
Heat Exchanger Cleaning  
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.  
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.  
Air Flow  
7. The heat exchanger can be removed by sliding towards the front  
of the pool heater. Once the heat exchanger is removed from the  
Check frequently to be sure the flow of combustion and ventilation  
air to the pool heater is not obstructed.  
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Installation and Service Manual  
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 (ΔP) 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  
AIR  
E
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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Commercial Pool Heaters  
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 Air Adjustment with a Manometer to  
Set Differential Pressures  
Adjustment Procedure  
Servicing Hot Surface Igniter and Ignition  
Module  
1. Remove the upper front jacket panels from the unit to access  
the upper chamber.  
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.  
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.  
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.  
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.  
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.  
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. Attach one manometer hose to the barb located on the back of  
the pressure switch. Attach the other manometer hose to the  
capped tee barb spliced into the rubber hose running into the  
combustion chamber (see Figure 55).  
Ignition System Checkout  
1. Turn “OFF” the gas supply to the pool heater.  
2. Turn the electric power “ON.  
6. Adjust the air shutter on the right fan until the differential  
pressure is nominally 1.1-1.3 inches water column.  
3. Program the temperature control to settings above water  
temperature or to the highest safe setting.  
7. Once the adjustment procedure is complete, reattach the cap to  
the tee in the hose and the pressure switch and check all tubing  
and wire connections for snug fit. Test fire the unit. Install  
upper panels.  
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.  
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 switch.  
As the low air switch makes, power is supplied to the optional  
ENERGY SAVING  
RECOMMENDATIONS  
louver/venter enable contact relay.  
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.  
12. 24VAC is then supplied to the PS terminals on the ignition  
module.  
13. The combustion air fan operates for the pre-purge period.  
2. Reduce pool thermostat to 78°F or lower.  
14. At the end of the pre-purge period, 120VAC is applied to the  
hot surface igniter and the trial for ignition light.  
3. Use an accurate pool thermometer to monitor water  
temperature.  
15. The hot surface igniter proves 1800°F (982°C) ignition  
temperature by the current draw through the ignition module.  
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.  
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.  
5. Turn the pool heaterOFFand drain during long periods when  
the pool will not be used (winter, vacations, etc).  
18. The gas/air mixture is forced into the burner and out of the  
burner ports under pressure.  
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.  
19. The hot surface igniter lights the gas/air mixture and then  
serves as a flame sensor to prove main burner flame by  
rectification.  
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.  
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.  
SEQUENCE OF OPERATION  
OVERVIEW  
22. 24VAC is supplied to a digital temperature control which times  
out and then energizes the next 50% of the gas valves.  
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.  
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.  
HEAT TRANSFER PROCESS  
1. Place the POWER switch in the “ON” position.  
26. Heated products of combustion pass over the heat exchanger  
transferring heat to the water.  
2. 120VAC power is supplied to the control transformer along with  
L1 and F1 on the ignition module.  
27. The rate of flue product movement is controlled by “V” baffles  
on the heat exchanger to maximize heat transfer.  
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.  
28. Flue products pass into the flue collector and are exhausted  
from the unit.  
5. If equipped, 24VAC is supplied to a low water cut-off and then  
to the optional high and low gas pressure switches.  
END OF SEQUENCE  
6. 24VAC is supplied to the terminal strip and onto the switching  
contacts of the digital temperature control.  
29. Set point temperature for the pool water is satisfied.  
30. Power to the gas valves is turned “OFF.  
7. The digital temperature control will then call for heat.  
31. The combustion air fan runs for a 30 second post purge timing  
and turns “OFF.  
8. 24VAC is then supplied to the water pressure switch and the  
flow switch (if equipped).  
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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Commercial Pool Heaters  
SAFETY DEVICE TERMINALS  
GLOSSARY  
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  
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  
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 acall 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.  
TEMPERATURE CONTROLLER  
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 turnOFFpower to these  
items before attempting to service the pool heater.  
(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)  
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.  
24VAC CIRCUIT BREAKER  
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.  
PRESSURE SWITCH  
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.  
(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.  
PREPURGE  
EMS/SEQUENCER/REMOTE AQUASTAT  
(Ignition Module Function)  
TERMINALS  
Once the ignition module sees a 24VAC input from its pressure  
switch, it runs the blowers for approximately 15 seconds in order  
to purge the combustion chamber of any unburned fuel/air  
mixture.  
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 by routing through dry  
contacts from external devices. Connection of the external dry  
contacts to these terminals requires the removal of one or more  
factory-installed jumpers located on the terminal strip.  
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Installation and Service Manual  
IGNITER WARM-UP AND PROVING  
(Ignition Module Function)  
HEAT TRANSFER PROCESS  
(Gas Valves, Burner and Heat Exchanger)  
Once the ignition module has completed its prepurge period, it  
turns on the hot surface igniter. Once the hot surface igniter’s  
current draw reaches a proper level, the ignition module begins an  
additional period of approximately 25 seconds for the igniter to  
ensure the ignition temperature is attained to ignite the fuel/air  
mixture.  
Once flame has been proven, the ignition module will hold the gas  
valves open as long as there is proof of flame and a call for heat is  
present. When the temperature of the water reaches that of the  
programmed set point, the pool heater will be shut down.  
POST-PURGE  
(Ignition Module Function)  
IGNITER  
When 24VAC is removed from the ignition module’s thermostat  
input, the module turns “OFF” the gas valves and maintains the  
blowers for approximately 25 seconds in order to allow the  
combustion chamber to be purged of all combustion by-products.  
(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.  
IGNITION AND FLAME PROVING  
(Ignition Module Function)  
IDLE  
(Temperature Controller 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.  
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.  
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.  
53  
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Commercial Pool Heaters  
WIRING BOX CONNECTIONS  
WIRING BOX CONNECTIONS  
SENSOR  
WIRING BOX  
FACTORY  
CONNECTOR  
B
C
CONNECTOR  
FLOW SWITCH  
A
3
2
1
6
5
4
PR  
BR  
O
C
O/  
BK  
AC POWER  
6
9
8
7
12  
11  
10  
15  
3
2
1
NO  
NC  
O/BK  
BR/W  
CONNECTOR  
PR  
PR/  
BK  
5
14  
13  
O
BR/W  
4
12  
1
2
3
4
WATER  
BR  
5
FLOW&PRESS  
BK  
W
BK/  
W
O
1
2
3
1
2
3
3
G
PR  
PR  
9
6
4
GAS  
B
A
11  
13  
T
10  
O/BK  
O/BK  
7
PRES  
BR  
8
BR  
PR  
1
BR/W  
T
O/W  
BL/  
BK  
1
2
1
O
T/  
W
Outlet Inlet  
SensorSensor  
T
15  
Y
14  
BL  
2
2
PR  
O/BK  
P
P
3
3
O
BL/BK  
BL/BK  
PR  
BL  
BR  
BR/  
W
1
C 2  
O/  
NC C NO  
BK  
B
A
25' X 2  
HeatDem1  
HeatDem2  
MANUAL RESET  
STAGE 1 STAGE 2 STAGE 3 STAGE 4  
18AWG  
HI-LIMIT  
T
1C  
1NO 2C 2NO 3C 3NO 4C 4NO  
CONTINUOUS INTERMITTENT  
BLBL  
BR  
BL/BK  
P
P
BR  
PR  
PR BL  
Y
A1  
A2 A3  
B1 B2  
B3  
N1CACUNOX  
C 2  
T/W  
PR  
B
R
BK/  
W
T
3
3
2
1
O/BK  
PR  
O
PR  
Y
2
~~~~  
~~~~  
W
2
ALARM  
O/W  
PR  
O/W  
1
1
4
5
HI-LIMIT  
110°F  
REMOTE  
POOL  
LOUVERS  
OPTIONAL  
SHUTOFF/SOLENOID  
& NORMALLY OPEN  
VENT VALVE  
REMOVE FACTORY TEST  
JUMPER WHEN INSTALLING  
LOUVER OR VENTER.  
L/V CONT ALARM  
VENT /SOLE4NOID  
5
5
HI-LIMIT  
FIELD  
EXT.  
PR-SW  
2
2
3
3
1
1
RUNTIME  
BELL  
INSTALLED  
1
2
4
OPTIONAL  
ALARM  
1
0
B
R
1
P
2
3
4
5
6
7
8
9
11  
Y
LOUVERS  
2
POOL  
R
SUET  
PPLY  
URN  
3
4
5
1
3
2
1
SENSOR  
Y
FID  
PR BL  
Y
BR/  
W
P
BR BR/W PR GY GY  
R
R
BL  
BL  
W
BL/  
BK  
PR  
BK/  
W
BK  
W
R
ON/OFF  
POWER  
SWITCH  
BR  
/W  
PUMP  
DELAY  
BR  
G
BL/  
BK  
BK  
BR  
W
Y
BK  
Y
W
G
BK  
120VAC FIELD  
BK  
24V  
PR  
TD RLY  
24VAC  
CONNECTIONS  
FOR UNIT  
DASHED LINE INDICATES  
OPTIONAL EQUIPMENT.  
24VAC PUMP  
RELAY  
OPTIONAL  
LOUVER/VENTER  
120V RELAY  
OPTIONAL  
INTERNALLY  
MOUNTED  
2X4 "J" BOX  
ALARM / TIME DELAY  
24V TIME DELAY RELAY  
CHASSIS  
GROUND  
C
CONNECTION DIAGRAM B  
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Installation and Service Manual  
WIRING BOX CONNECTIONS  
MAIN UNIT CONNECTIONS  
C B A  
D
MAIN UNIT  
H
E
CONNECTOR  
IGNITER  
3
2
1
6
5
4
9
8
7
12  
11  
10  
15  
14  
13  
LWCO  
CONNECTOR  
F
3
2
1
AS  
ESS  
GY G GY  
D
E
O
G
PR  
10  
13  
15  
12  
3
6
2
5
2
1
7
1
R/  
O/BK  
O
W
W
BK  
BK  
T
R
Y
BK or R  
CHASSIS  
GROUND  
CHASSIS  
GROUND  
R
BK  
1
W G  
BK W G  
2
2
3
3
4
4
1
1
2
2
3
3
4
4
OPTIONAL  
1
LOW  
HIGH  
O/  
BK  
O
BK R W G  
BK R W G  
GAS  
GAS  
PR  
NO COM NC  
NO COM NC  
2
2
1
1
3
3
O
O/  
O
O/  
PR  
O
O/BK  
PR  
BK  
BK  
3
PR  
BLOWER  
#1  
501-2071  
BLOWER #2  
991-2071  
ONLY  
2
2
2
2
1
1
3
3
1
1
3
O/BK  
O
ALR  
PR  
PR  
O/BK  
-24  
S2  
S1  
R/  
BK  
R/  
BK  
R/  
BK  
T
O
STAGE #1  
STAGE #1  
STAGE #1  
STAGE #2  
STAGE #2  
STAGE #2  
R
O
R
R
R
R
R
1
1
1
2
2
2
AIR SW  
Y
Y
Y
Y
Y
Y
BURNER  
GROUND  
PR  
HSI  
O/BK  
LOW GAS  
651-2071  
991-2071  
991-2071  
2071  
GY  
GY  
G
501-2071  
501-2071  
CP  
LBL2296 Rev -  
A
55  
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Commercial Pool Heaters  
LADDER DIAGRAM  
LINE  
BK  
NEUTRAL  
GROUND  
OPTIONAL  
ALARM  
INPUT 4  
120 VAC 15AMPS  
60Hz  
PR  
W
MAN. RESET  
ADJ. HI-LIMIT  
AUX. HI-LIMIT  
1
2
WARNING :  
THIS HEATER MAY BE  
ON/OFF  
POWER  
SWITCH  
G
BL  
BR  
CONNECTED TO ONE OR MORE BRANCH  
CIRCUITS. TO PREVENT ELECTRICAL SHOCK,  
ENSURE ALL BRANCH CIRCUITS ARE DE -  
ENERGIZED BEFORE ATTEMPTING TO SERVICE  
THIS EQUIPMENT.  
CIRCUIT BREAKER  
T
T
PROBE  
T
TEST SWITCH  
+
BL  
BK  
CHASSIS  
GROUND  
PR  
RESET  
PR  
O.C.  
J
3
BL  
Y
BL/  
BK  
24 VAC  
G
120 VAC BK  
BL/  
BK  
BL  
CHASSIS  
GROUND  
W
W
PR  
PR  
1
P
O
PR  
-
PR  
4
5
6
7
J2  
3
4
5
6
7
2
O
Y
Y
J4  
Y
SILENCE  
PR  
GND  
PR  
BL/  
BK  
Y
Y
PR  
Y
OPTIONAL ALARM  
BELL24V OUTPUT  
BL/  
BK  
BL  
9
GND  
9
O
BL  
BL  
O
BL  
R
C
C
PR  
PR  
NO  
NO  
LOW  
HIGH  
O/  
BK  
Y
ALARM  
O
Alarm Delay Connection  
CONTACTS  
BL  
BL  
23  
R
PR  
Y
PR  
ALARM  
PR  
PR  
A
D
+
OPTIONAL HIGH-LOW GAS  
PRESSURE SWITCHES  
-
12  
PR  
Y
Y
24  
OPTIONAL  
ALARM DELAY  
PR  
FIELD CONNECTION FOR  
REMOTE OPERATOR  
991-2071  
2
1
FLAME  
BL/  
BK  
HD  
CURRENT  
TEST PINS  
BLOWER #2  
BR/W  
O/BK  
Y
~~~~  
~~~~  
PR  
P
Y
AL  
O/  
BK  
15  
16  
NO  
Y
C
O/W  
STAGE #1  
BK  
-
+
S1  
F1  
F2  
BLOWER #1  
5
GY  
1
3
1
O
~~~~  
~~~~  
JUMPER  
LINE  
BK/W  
1C  
BR1NO  
PR  
O/W  
GY  
GY  
4
3
2
1
PR  
W
BK  
3
6
O
-
TRIAL  
STATUS  
+
NEU  
S2/  
FS  
PR  
W
A1  
A2  
A3  
B1 B2  
B3  
W
6
IGNITER  
GY  
BURNER  
FLOW  
SWITCH  
OR  
IGNITION  
MODULE  
11  
BL/  
BK  
Y
Y
10  
O/BK  
TH  
O
O
9
8
7
6
5
4
3
PI  
P
RESET  
O
C
24COM  
RESET  
24VAC  
MV  
Y
Y
PURGE  
BL/  
BK  
BL/W  
BL  
BL  
MV  
R
R
Y
NO  
T
FIELD INSTALLED  
SAFETY DEVICES  
T/W  
PS  
BL  
OPTIONAL  
RUN TIME  
RELAY  
VALVE(S)  
R
2
1
M/S  
FF  
CONTINUOUS INTERMITTENT  
PRESSUR  
E SWITCH  
PV  
PV  
CONTACTS  
991-2071  
ONLY  
A1 A2 A3 B1 B2 B3  
PR/BK  
3
Y
OK  
OK  
FLAME  
110°F  
FFR  
BL  
PR/  
BK  
NO  
NC  
NO  
PRESENCE  
HI-LIMIT  
FAIL  
FAIL  
C
C
VALVE(S)  
Y
P
PR  
COM  
COM  
P
BL  
P
FIELD  
LOCATED  
IN POOL  
PIPING  
C
MV  
CONTINUOUSLY INTERMITTENTLY  
Delay  
NO  
MONITORED MONITORED  
Y
R
RT  
ALARM  
R/BK  
NOTE: SHOWN WITH SHORTING  
17  
18  
OPTIONAL  
BARS REMOVED AND ATTACHED  
DEVICES IN NON-ALARM STATE.  
2
2
5
4
4
BL  
MAINT  
RESET  
EXAMPLE DEVICES:  
HIGH/LOW GAS, AUX. HI-LIMIT  
AUX. LIMITS, EXT. FLOW SWITCH  
PURGE SW  
BL  
5
OFF  
ON  
PUMP ON/OFF RELAY  
24VAC  
13  
14  
N.O.  
P
PR  
BR  
PU  
Y
FIELD SUPPLIED LOUVER/  
POWER VENTER CONNECTIONS  
PUMP  
BK  
-24V  
5
Y
R
BL  
NO  
C
BK  
BURN ON  
+24V  
4
2
1
3
6
CLOSED  
OPEN  
COM  
T/W  
MOTOR  
SERVICE/  
MAINT  
PUMP  
PURGE  
PROVING  
SWITCH  
BL  
O
O
BK  
CONTACTS  
W
T
TH IN  
O
O/BK  
BK  
G
REMOVE  
JUMPER  
Y
1
2
3
4
1
2
3
4
Y
BL  
W/R  
P
1
2
3
4
5
COM  
24V  
CLOSE  
OPEN  
TH OUT  
CLOSE  
PR  
BL  
PUMP OUT  
BR  
120 VAC  
15AMPS  
21  
22  
NOT USED  
W/R  
PR  
5
4
3
2
1
5
4
3
2
1
5
5
4
3
2
1
OPEN  
P
BR  
BL  
ALARM  
DELAY  
SER/MAINT  
GY  
GY  
C2  
BL  
BR/W  
BL/BK  
4
3
2
1
19  
20  
Y
T
3-WAY VALVE ACTUATOR  
W
NO2  
C1  
W
BK/W  
ITEM  
INDICATES  
JUNCTION POINT  
(ELECTRICALLY SAME)  
CLOSED END SPLICE  
BR  
NO1  
BR/W  
BR/W  
5
6
5
6
BR  
BR  
4
6
8
T
BR/W  
PR/BK  
BR/W  
PR  
Pool System/Return  
Pool Supply  
Outlet Sensor  
Inlet Sensor  
5
7
9
PR/BK  
BR/W  
PR  
BR/W  
BR/W  
4
3
4
3
LE  
BK/W  
W
DOTTED LINE  
INDICATES OPTIONAL  
EQUIPMENT  
PR  
BR  
1
2
1
2
BR  
W
BR  
BR  
BK  
W
= WHITE  
T=TAN  
LOUVER /VENTER  
SHUTOFF/  
SOLENOID VALVE  
BK = BLACK  
PR=PURPLE  
BL=BLUE  
Y=YELLOW  
BR=BROWN  
G=GREEN  
GY=GRAY  
R=RED  
W
ENABLE/CONTACT RELAY  
OPTIONAL  
P=PINK  
BK  
NORMALLY OPEN  
VENT VALVE  
O=ORANGE  
W
Y/G = YELLOW WITH GREEN STRIPE  
= RELAYS LOCATED ON CONTROL PANEL  
R
R
NOTES:  
(1) WHERE POSSIBLE, ALL SWITCHES AND CIRCUITRY ARE SHOWN IN THEIR AT REST STATE.S  
(2) ADDITION OF ENERGY MANAGEMENT SYSTEMS OR OPTIONAL LIMIT SWITCHES TO THE TERMINAL  
STRIP REQUIRE THE REMOVAL OF SOME OF THE SHORTING B ARS FROM THE TERMINAL STRI.P  
(3) REFER TO ACTUAL COMPONENTS FOR EXACT TERMINAL L OCATIONS.  
CP  
= RELAYS LOCATED IN WIRING BOX  
= LEDS LOCATED ON DISPLAY BOARD  
= OPTIONAL DIN RAIL CONNECTORS  
LOCATED IN ELECTRICAL WIRING BOX .  
(4) WHEN REPLACING DAMAGED WIRING, USE EQUIVALENT TYPE AND GAUGE.  
LBL20010 REV A  
56  
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Installation and Service Manual  
CONTROL BOX CONNECTIONS  
J 1  
T N I M A  
- E C I V R S E  
L A N O I T O P  
B L  
1 3  
B R  
1 4  
Y
1
2
3
4
5
6
7
8
9
W
R
B R /  
K B O /  
1 5  
1 6  
1 7  
1 8  
1 9  
2 0  
2 1  
2 2  
2 3  
2 4  
W O /  
T
B K  
R
K B R /  
B L  
/
/
P R  
W
B R  
P R  
B R  
W
P
B L  
W /  
P R  
B L  
R
a
n /  
a
n /  
Y
2  
57  
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Commercial Pool Heaters  
Appendix A  
Unit Start Up Checklist  
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.  
4. For negative draft vent systems, measure the draft in 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.  
58  
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Installation and Service Manual  
Appendix B  
Adjust Menu Settings for Operating Modes  
User  
Advanced  
Item  
Description  
Default  
Range  
X
X
X
X
X
TARGET  
DIFF  
BOIL IN MIN  
BOIL MAX  
SUP TARGET  
SUP DIFF  
Pool target temperature  
85˚F  
4˚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  
15 to 30 sec  
ON, 0:20 to 9:55 min  
0 to 999 hr  
Differential setting for return sensor  
Minimum inlet water temperature  
Maximum outlet temperature  
Supply water temperature  
130˚F  
200˚F  
100˚F  
20˚F  
20 sec  
20 sec  
0 hr  
X
X (*)  
X (*)  
X
X
X
Differential setting for supply sensor  
MOTOR SPEED Setting other than 20 may void warranty.  
DLY  
BOIL ON  
F/C Units  
Time at which purging stops  
*Accumulated runtime of unit  
Set temperature at °F or °C  
X
X
˚F  
˚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  
Pool return sensor temperature  
Pool temperature set point  
Inlet sensor temperature  
BOIL IN  
BOIL OUT  
Outlet sensor temperature  
Heater differential temperature  
Pool supply sensor temperature  
Accumulated runtime hours  
BOIL ΔT  
SUP (If equipped pool supply sensor)  
BOIL ON (Advanced switch set to “0”)  
Advanced settings:  
heater whenever the pool supply temperature exceeds this setting.  
The default value is 100°F.  
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.  
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 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 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.  
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 control will shut off the  
59  
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Lochinvar Corporation • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax 615-547-1000  
Revision Notes: Revision 6 (CPE-i&s-06) reflects  
changes made to LBL2296.  
Revision 9 (ECO C02822) reflects moving FIG. 22A (page 19) to page 21 and  
adding Aire-Lock to the title.  
Revision 7 (CPE-i&s-07) reflects changes made to the  
pressure switch, page 50.  
Revision 10 (ECO #C03002) updated images to reflect the CPVC bypass (pgs.  
1, 5, 33-35, and 40) along with updating the Ladder and Connection Box  
diagrams (LBL20010 and 20011).  
Revision 8 (CPE-i&s-08) reflects deletion of Table P and  
changes to associated paragraph on pages 44 & 45.  
CPE-I-S-10  
CP-5M-2/09  
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