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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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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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.
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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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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.
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Commercial Pool Heaters
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.
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Installation and Service Manual
13. Remove the manometer and related fitting from the“inlet”side
of the gas valve, replace 1/8" hex plug in the gas valve and
tighten.
14. Turn on the gas supply at the manual valve, turn on L.P. gas at
the tank if required.
15. Turn the power switch to the “ON” position.
16. Turn the gas valve knobs to the “ON” position.
17. Set the temperature control to call for heat.
ƽ WARNING: After completing any testing on the
gas system, leak test all gas connections. Apply a
soap/water solution to all gas connections while
main burners are operating. Bubbles forming
indicate a leak. Repair all leaks at once. Do not
operate this pool heater with a leak in the gas train,
valves or related piping.
Check burner performance by cycling the system while you observe
burner response. Burners should ignite promptly. Flame pattern
should be stable, see Burner Flames, page 47. Turn system off and
allow burners to cool, then cycle burners again to ensure proper
ignition and flame characteristics.
Figure 30 – Measuring Gas Supply Pressure at Combination
Gas Valve
TABLE - K
Multiple Unit Installations Gas Supply Pipe Sizing
Nominal
Iron Pipe
Size
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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Commercial Pool Heaters
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
30
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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
33
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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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Commercial Pool Heaters
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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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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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 not“air bound”by manually opening the temperature and
pressure relief valve. Leave the valve open until a steady flow of
water is observed at the discharge from the valve. Close the valve
and complete filling the system.
To Turn Off Gas To Pool Heater
1. Open the front access panel to access the control panel.
2. Turn the power switch to the “OFF” position.
3. Turn the manual gas cock clockwise ; to the “OFF” position.
ƽ WARNING: Should overheating occur or the
gas fail to shut off, turn off the manual gas control
valve to the pool heater.
Note: Backwash the filter when the G.P.M. filtration rates are too
low to meet local codes or state code. A high temperature rise across
the pool heater is also an indication of low flow in the filter system.
Sustained low flow to the pool heater will result in cycling of the
heater on the limit controls and possible opening of the relief valve.
39
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Commercial Pool Heaters
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.
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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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Installation and Service Manual
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. This“scouring action” provides greater
cost savings for owners. Tubes are always able to transfer heat at
peak efficiency. Every surface within this water containing section is
of a non-ferrous material, providing clear, clean, rust-free water.
Straight copper tubes-finned on the outside for maximum heat
transfer-coated cast iron one piece cored headers make up an
entirely rust-proof pool heater. A Cupro-Nickel heat exchanger is
standard on 1,800,000 - 2,070,000 Btu/hr models. On all models,
header inspection plugs can be removed for field inspection and
cleaning of copper tubes. The entire heat exchanger may be easily
removed from the pool heater.
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.
48
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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
49
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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.
50
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Installation and Service Manual
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 heater“OFF”and 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).
51
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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 a“call for heat”
cycle. Connection to either of these terminals requires the removal
of a factory-installed jumper located on the terminal strip.
ON/OFF ROCKER SWITCH
The black line voltage wire runs directly to a single pole, single throw
On/Off rocker switch located behind the front cover accessible by a
knurled knob. Turning ON the rocker switch delivers line voltage to
the low voltage transformer and ignition module.
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 turn“OFF”power 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.
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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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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
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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
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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
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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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