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Swimming Pool Heaters 150,000 - 399,999 Btu/hr Models

1. 10 OR LESS FIG 16 Vent Termination from Peaked Roof 10 or Less From Ridge MORE THAN 10 gt lt _____ 10 CHIMNEY LI FIG 17 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 10 OR LESS CHIMNEY WALL OR CHIMNEY PARAPET FIG 18 Vent Termination from Flat Roof 10 or Less from Parapet Wall 13 10 OR MORE 7 NOTE NO HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FOR WALLS OR PARAPETS IS MORE THAN 10 WALL OR PARAPET CHIMNEY FIG 19 Vent Termination from Flat Roof More Than 10 from Parapet Wall 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 The vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The venting system shall terminate at least 3 feet 0 9m above any forced air inlet within 10 feet 3 05m The venting system shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontally from
2. 11 When a pool heater is installed within the pool structure the structure shall be designed such that in the event of a fuel gas leak the leaking gas is vented to the exterior of the pool structure CLEARANCES FROM COMBUSTIBLE CONSTRUCTION 6 Indoor models FIG 4a Clearances from Combustible Construction Back Clearances from Combustible Construction Right Side 3 7 6 cm 24 0 61m suggested for service Rear Outdoor 3 7 6 cm 3 minimum from any surface Rear Indoor 6 15 2 cm 6 minimum from any surface Left Side 3 7 6 cm Front ALCOVE 24 0 61m suggested for service Top 3 7 6 cm 24 0 61m suggested for service Flue 6 15 2 cm Hot Water Pipes 1 25 4mm An ALCOVE is a closet without a door 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 COMBUSTION AND VENTILATION AIR REQUIREMENTS FOR CONVENTIONALLY VENTED APPLIANCES AND SIDEWALL VENTED APPLIANCES 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 CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable prov
3. A dimension for the E Rite Sidewall Vent System TABLE H AIR SHUTTER ADJUSTMENT OPENING FOR E Rite VENT SYSTEMS Chamber Pressure A Dimension Opening Input Btu hr FIG 29 Combustion Air Fan with Air Shutter A Dimension The E Rite Sidewall 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 will be a dedicated system with one air inlet pipe per pool heater The air inlet pipe its connection and location of the combustion air inlet cap will be the same as specified in the Horizontal DirectAire Vent Systems Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation Air OOOO gg 2 ad ae g cB FLUE OUTLET CAP FIG 30 E Rite Sidewall Vent Caps Illustration E Rite Sidewall Vent Cap for 150 000 through 399 999 Btu hr Models The E Rite Sidewall vent caps must be installed on an exterior sidewall The E Rite Sidewall vent cap and accessories are included in a venting kit which must be furnished by the manufacturer in accordance with CSA International requirements This venting kit includes a flue adapter air inlet collar sidewall vent cap air inlet cap and necessary adapters to install a separate combustion air pipe from the pool heater to the outdoors The factory supplied sidewall vent kit MUST be used for sidew
4. PVC CPVC or ABS 4 or 5 I D Dryer Vent not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified below Plastic pipe requires an adapter not provided to transition between the air inlet and cap Sealing of single wall galvanized or Type B double wall vent material used for combustion air supply in a DirectAire Vent System a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of air inlet pipe on the bottom of horizontal runs 16 c 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 air inlet pipe d Ensure that the air inlet pipe is properly supported A CAUTION Using other vent or air intake materials failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the pool heater NOTE The use of double wall vent material for the combustion air inlet pipe is recommended when the pool heater is
5. j Remove the 1 8 hex plug located on outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge Minimum range of scale should be up to 5 w c for natural gas and LP gas k A reference pressure hose is factory installed from the barbed connection on the gas valve regulator to the fan pressurized front chamber All manifold pressure measurements made with the reference hose in place will be the sum of the net manifold pressure and the air pressure in the front chamber 1 Turn the power switch to the ON position m Ensure that the ON OFF switch on the smart valve is in the ON position n Turn the manual gas cock to the ON position 0 Set the electronic temperature control to call for heat p Before the valve opens the manometer or magnahelic gauge will read a positive air pressure of 1 3 w c to 1 5 w c in the jacket as supplied by the combustion air fan on high speed in the pre purge cycle There is no gas flow at this point This air pressure reading is normal q The gas valve will open at the end of the trial for ignition stage and remain open as the burners fire Observe the gas manifold pressure when the valves open If insufficient gas pressure is supplied to the burners the burners will not fire Record the gas pressure indicated on the manometer or magnahelic Subtract the air pressure in the front chamber as recorded in step 7 from the gross mani
6. maintain a negative draft between 0 02 to 0 05 inches water when the powered sidewall vent cap is operating The barometric damper controls draft and provides dilution air to the vent system to prevent condensate formation When a barometric damper is installed the equipment room must have adequate air to supply dilution air to the barometric damper Length of Flue Pipe The maximum total equivalent length of flue pipe connected to the powered sidewall cap cannot exceed 75 equivalent feet 22 9m Subtract 5 feet 1 52m for each elbow in the vent Do not exceed the limit for total equivalent vent pipe length Sidewall Vent Termination 0000 00999 0000 ON 0000 OONN 0000 OO 00 990 00999 0000 00000 0000 00009 0 000 90999 00 009 FIG 25 Powered Sidewall Vent Cap The powered sidewall vent cap must be installed on an exterior sidewall The powered sidewall vent cap and accessories are included in a venting kit which must be furnished by the manufacturer in accordance with CSA International requirements This venting kit includes a flue adapter an air inlet cover the powered sidewall cap barometric damper proving switch and all necessary relays to interlock with the heaters control system The powered sidewall 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 Terminal
7. or 1 foot 30cm above any door window or gravity air inlet into any building Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30cm above grade To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc Flue gases will form a white plume in winter Plume could obstruct window view Flue gas condensate can freeze on exterior surfaces or on the vent cap when a pool heater is operated in the winter months Frozen condensate on the vent cap can result in a blocked flue condition Flue gas condensate can cause discoloration of exterior building surfaces Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate MASONRY CHIMNEY INSTALLATION A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance Venting of a high efficiency appliance 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 appliance 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
8. required to check and adjust the manifold pressure The regulator cover screw on the gas valve must be in place and tight for the appliance to operate properly 1 Turn the power switch to the OFF position a Remove the top front jacket panels FIG 35 Front Chamber Pressure Measurement 28 b Locate the air pressure switch located to the right of the combustion air fan Trace the hose from the air pressure switch to the barb located in the top right front corner of the upper chamber Remove the hose from this barb and connect the hose from the manometer or magnahelic to this barb to measure the air pressure in the front chamber c Turn the power switch to the ON position d Ensure that the ON OFF switch on the smart valve is in the ON position e Set the electronic temperature control to call for heat The fan should start f While the combustion air fan is running for the pre purge cycle and the pressure in the front chamber stabilizes record the pressure in the front chamber This pressure will be used to calculate the net manifold pressure g Turn the power switch to the OFF position h Remove the manometer or magnahelic hose from the front chamber barb and reinstall the hose from the air pressure switch to the barb i Turn the manual gas cock to the OFF position Regulator Adjustment MANOMET El MANIFOLD PRESSURE FIG 36 Manifold Gas Pressure Measurement
9. two 5 air inlet pipes 19 6 in area each have a total area of 39 2 in and will require a single 8 50 3 in area common air inlet pipe The air inlet point for multiple pool heater air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected 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 3m equivalent feet Subtract 5 feet 1 52m for each elbow in the air inlet pipe You must deduct the restriction in 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 metal louvers to 75 wood louvers based on the materials used Air Inlet Pipe Materials The Vertical DirectAire system requires installation of a separate pipe to supply combustion air from outdoors directly to the unit The following air inlet pipe materials and sealing recommendations apply whenever an optional venting system is used to duct combustion air directly to the pool heater Air Inlet Pipe Materials The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from the following specified materials in this section
10. Sensor NTC Thermistor 10k ohms 77 F 25 C Operating Humidity lt 90 RH Non condensing Operating Ambient Temperature 20 to 140 F 30 to 60 C The electronic temperature control is located on the right front side of the pool heater Three programming keys are provided to adjust the temperature set point and differential values and to control the display The three keys are the Select key Up arrow key and Down arrow key Figure 42A VIEW MODE POOL SELECT KEY ti f SELECT A UP amp DOWN ARROW KEYS FIG 42A Select Key Up Arrow and Down Arrow Keys Select Key Allows the user to select the currently displayed temperature set point used for operation of the heater Pool temperature setting Spa temperature setting or Off may be selected by depressing the Select key in normal operation A pointer will move in the display window to indicate the temperature mode selected for operation When the OFF position is selected this will disable the call for heat operation of the pool heater When in the view mode for normal operation the display shows the current inlet water temperature Up and Down Arrow Keys Allows the displayed parameter to be increased or decreased After pressing the Select key a control value can be changed by using the Arrow keys Control values will be increased or decreased by 1 F for each time the Arrow 34 keys are depressed The temperature set p
11. Train Terminal Strip Remote Controls Water Chemistry Heat Exchanger Inspection Freeze Protection Draining the Heat Exchanger IMPORTANT Consult and follow all local Building and Fire Regulations and other Safety Codes that apply to this installation Consult local gas utility company to authorize and inspect all gas and flue connections Your conventionally vented gas unit must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting A 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 turn off the manual gas control valve to the appliance at a location external to the appliance PREVENTION OF FREEZING Heat exchangers and headers damaged by freezing are not covered by warranty Refer to the WINTERIZING section SPA AND HOT TUB SAFETY The following safety rules must be observed while operating a spa or hot tub p Spa or hot tub water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is considered safe for a healthy adult Special caution is suggested for young children N Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning ie Pregnant women beware Soaking in water above 102 F 39 C can cause
12. b Shut off water supply c Shut off electrical supply d Remove the lower side jacket panel below the water connections Figure59 e Locate the three 3 drains on the bottom of the front header Figure 60 f Open all three 3 drains and allow the heat exchanger to drain completely Leave drains open until Spring Drain the pump and related piping 3 DRAINS FIG 59 Drain Locations FRONT HEADER BOTTOM VIEW FIG 60 Front Header Bottom View 47 48 Copyright 8 05 Printed in U S A
13. components Multiple unit outdoor pool heater installations require a minimum of 4 feet 1 22 m clearance between the vent cap and air inlet of adjacent heater to prevent recirculation of flue products Flue gas condensate can freeze on exterior walls or on the vent cap of a pool heater operated in the winter months Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building or unit surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate FIG 10 Outdoor Vent Cap Outside View FIG 11 Outdoor Vent Cap Installed on Unit The Outdoor Vent Cap Kit The required outdoor cap part numbers are listed by unit size The venting kit must be furnished by the manufacturer in accordance with CSA International requirements An outdoor vent cap kit is mounted on the pool heater as shipped from the factory The kit includes the flue outlet combustion air inlet assembly and gasket Since the outdoor vent cap assembly is supplied with each pool heater the following part numbers are provided for service part information TABLE C INSTALLATION OF OPTIONAL VENT KITS OUTDOOR VENT CAP KITS Input Btu hr Outdoor Cap Kit Number 150 000 ODK3040 199 999 ODK3040 250 000 ODK3041 300 000 ODK3042 399 999 ODK3042 A CAUTION Pool heaters which are shut down or will not operate may experience freezing due to convective
14. for venting flue products to the outdoors and general installation instructions The Vertical DirectAire vent system requires the installation of two vent pipes directly to the unit one vertical pipe with a roof top termination for the flue products and one pipe for combustion air The combustion air pipe may terminate horizontally with a sidewall air inlet or vertically with a rooftop air inlet Vent connection is made directly to the unit after the outdoor vent cap assembly is removed and the conventional flue 14 outlet and direct air inlet adapters are installed 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 water The flue may be combined with the vent from any other negative draft Category I appliances Multiple unit installations common vented with other negative draft appliances require that each pool heater MUST have a barometric damper installed to regulate draft within the proper range The common vent and connectors from multiple pool heaters must be sized per the requirements of the venting tables for Type B double wall vents in the latest edition of the National Fuel Gas Code ANSI Z223 1 or in Canada CAN CGA B149 Installation Codes The sidewall or vertical rooftop DirectAire combustion air supply system has specific vent material and installation requirements The air inlet pipe connects directl
15. hr 150 000 199 999 LP gas cylinders shall be located outdoors and away from the 250 000 pool structure in accordance with the latest edition of the _ _ Standard for the Storage and Handling of Liquefied Petroleum 300 000 Gases ANSI NFPA 58 or CAN CSA B149 2 and applicable 399 999 local codes For each elbow or tee add equivalent straight pipe to total length from Table N TABLE N MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART Nominal Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of x Btu hr per hour for gas pressures of 14 Inches pressure drop of 0 5 1 1 2 2 150 1 500 1210 f 1020 923 f sso 769 707 00 oss sos sis a2 oar I nch Water Column ia isso io or ei 120 Based on NAT GAS Daia ova sae ein sion ara fa 1025 Buhr per Cubic Foot of Gas and 0 60 3 11 200 7 900 6 400 5 400 4 870 4 410 4 000 3 800 3 540 3 300 3 000 2 720 2 500 2 340 Specific Gravity 4 eso isoo 13 100 11 100 10 000 9 000 8 300 7 090 7 380 6 870 6 130 seso 5 130 4 720 26 TABLE O SINGLE OR SECOND STAGE LOW PRESSURE PROPANE GAS PIPING SINGLE UNIT INSTALLATIONS OTe le Sa Ce E E 74 DISTANCE FROM METER Input Btu hr 51 100 150 000 1 199 999 1 1 4 250 000 1 1 4 300 000 1 1 2 399 999 1 1 2 For each elbow or tee add equivalent straight pipe to total length from Table N TABLE P FIRST STAGE HIGH P
16. if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the unit Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured with rustproof sheet metal screws Vent connectors serving appliances vented by natural draft MUST NOT be connected to any portion of a mechanical draft system operating under positive pressure Connection to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury Common venting systems may be too large when an existing unit is removed At the time of removal of an existing appliance the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while other appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any other appliances not connected
17. installed at least one foot 0 30m above ground level and above normal snow levels Multiple E Rite Sidewall Vent Installations FIG 32 Installation of Multiple E Rite Sidewall Vent Caps The combustion air inlet caps for multiple unit installations must maintain the minimum 3 foot 0 91m radius clearance below or horizontally from the closest flue outlet Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the 3 foot 0 91m radius minimum clearance between air inlet and flue outlet must be maintained All clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple unit installations A CAUTION Pool heaters which are shut down or will not operate may experience freezing due to convective air flow in the flue pipe or from negative pressure in the equipment room If operated in cold climates continuous pump operation is recommended to help Proper freeze prevent freezing of pool water protection must be provided A pool heater that is not in use in the winter season must be properly drained and winterized See Freeze Protection GAS SUPPLY Verify unit is supplied with the type gas specified on the rating plate This unit is orificed for operation up to 2000 feet altitude Consult factory for installations above 2000 feet elevation 25 TABLE J INLET GAS P
18. operated in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Length of Air Inlet Pipe The total equivalent length of the sidewall or vertical rooftop DirectAire combustion air inlet pipe must not exceed a maximum of 50 equivalent feet 15 3m in length Subtract 5 feet 1 52m for each elbow in the air intake system Do not exceed limits for the combustion air inlet piping lengths Vent Kits The Vertical DirectAire Vent Kit for sidewall or rooftop air inlet MUST be ordered from the pool heater manufacturer for single unit installations The part number for each kit is listed by unit size Each kit includes the flue outlet adapter air inlet collar and in sidewall air kits a sidewall combustion air inlet cap to supply air to a single pool heater Each kit includes instructions for proper installation The flue pipe rooftop vent cap for the flue vertical air inlet cap and air inlet pipe are purchased locally You must specify if the air inlet cap is for a vertical rooftop termination or a sidewall termination The air inlet cap for the combined air supply from multiple boilers must be purchased locally TABLE E DIRECTAIRE VENT KITS ae vo O Vertical Air Inlet Kit Conventional Vent Flue Size 5 iy 5 5 6 Minimum diameter installer may increase diameter one pipe size for ease of installation if needed A CAUTION The air inlet c
19. point on the valve to connect the bias pressure hose from the fan pressurized chamber to the regulator The bias hose connection prevents stoppage of the vent limiter by foreign material The termination of the vent limited opening on the combination gas valve regulator complies with the safety code requirements of CSD 1 CF 190 a as shipped from the manufacturer without the installation of additional vent lines ELECTRICAL CONNECTIONS This appliance is wired for 120 VAC service The unit when installed must be electrically grounded and bonded in accordance with the requirements of the local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the CSA C22 2 No 3 Electric Features of Fuel Burning Equipment and or local Electrical Codes 1 The electrical power circuit to this pool heater shall be installed with a ground fault circuit interrupter Local codes shall govern the installation of this device 2 All wiring between the unit and field installed devices shall be made with type T wire 63 F 35 C rise 3 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 4 The filter pump must run continuously when the pool heater is being fired 5 To avoid serious damage DO NOT energize or operate the pool heater until the pool filter system and related pip
20. to the appliance 37 11 Set the digital thermostat to the desired settings 12 If the appliance will not operate follow the instructions below To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Set the digital thermostat to the lowest setting j N Turn off all electric power to the appliance if service is to be performed ies Remove the control access panel 4 Push the gas control switch to the OFF position 5 Replace the control access panel A WARNING Should overheating occur or the gas fail to shut off turn off the manual gas control valve to the appliance IGNITION SYSTEM CHECKOUT Turn off gas supply to unit _ N Turn electric power on U Program the temperature control to a setting above pool water temperature or to highest safe setting amp The igniter will cycle on trial for ignition Nn The ignition module will make a total of four tries for ignition and then lock out for one hour before retrying for ignition or until main power is turned off and back on to reset the control a Program the temperature control to desired temperature set point sf Turn on gas supply oo Turn main power switch OFF and then ON 9 Ifignition system fails to operate properly repair work must be performed by a qualified serviceman or installer HOT SURFACE IGNITION SYSTEM OPERATIO
21. 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 Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after five minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system 12 properly vents when tested as above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use g Any improper operation of the common venting system should be corrected 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 Codes for Gas Burning Appliances and Equipment When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment VERTICAL VENTING TERMINATION
22. 00 000 SVK3033 399 999 SVK3033 A CAUTION Pool heaters which are shut down or will not operate may experience freezing due to convective air flow into the equipment room If operated in cold climates continuous pump operation is recommended to help prevent freezing of pool water Proper freeze protection must be provided A pool heater that is not in use in the winter season must be properly drained and winterized See Freeze Protection The Powered Horizontal DirectAire Vent System FIG Illustration 26 Power Horizontal DirectAire Installation 19 POWER HORIZONTAL DIRECTAIRE WITH A SIDEWALL FLUE AND SIDEWALL AIR INLET Follow all requirements in the General Venting section and Sidewall Venting for venting flue products to the outdoors and general installation instructions The Power Horizontal DirectAire vent system requires the installation of two vent pipes directly to the pool heater one pipe for flue products and one for combustion air Both vent pipes are installed horizontally with a sidewall termination point Vent connection is made directly to the pool heater Flue products are carried to the sidewall by a powered sidewall cap fan assembly A barometric damper is supplied with each Horizontal DirectAire Vent Kit and MUST be installed in the flue of each unit The barometric damper must be adjusted to maintain a negative draft between 0 02 to 0 05 inches water when the powered sidewall vent cap is ope
23. DANGER Failure to properly seal all joints and seams as required in the flue piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death Follow all requirements in the General Venting and Sidewall Vent Terminations sections for venting flue products to the outdoors See the Combustion and Ventilation Air Requirements section to insure that adequate combustion and ventilation air is supplied to the mechanical room All other general installation requirements must be followed E Rite Sidewall Vent Termination The sidewall vent cap shall terminate at least 3 feet 0 91m above any forced air inlet within 10 feet 3 05m The sidewall vent shall terminate at least 4 feet 1 22m below 4 feet 1 22m horizontally from or 1 foot 0 30m above any door window or gravity air inlet to the building Do not terminate the sidewall vent in a window well stairwell alcove courtyard or other recessed area The sidewall vent can not terminate below grade 24 The sidewall vent system shall terminate at least 1 foot 0 30m above grade above normal snow levels and at least 7 feet 2 13m above grade when located adjacent to public walkways The sidewall vent shall not terminate directly above a public walkway The sidewall vent terminal shall not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure The sidewall vent cap
24. DirectAire Roof Top Air Kit which must be ordered from the manufacturer This roof top cap will supply combustion air for a single unit only FIG 23 Air Inlet Cap for Rooftop Termination 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 if it is located within 10 feet 3 05m of the flue outlet The combustion air inlet cap must not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure The air inlet point for the combustion air inlet cap must be installed at least one foot 0 30m above the roof top and above normal snow levels Incorrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the pool heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the pool heater and possible spillage of flue products which can cause personal injury death or property damage Combined Air Inlet Points The air inlet pipes from multiple pool heaters installed with the DirectAire venting system can be combined to a single common connection The common air inlet pipe must have a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe Example
25. ER2 I amp S 04 INSTALLATION AND SERVICE MANUAL CERTIFIED Swimming Pool Heaters 150 000 399 999 Btu hr Models IMPORTANT This is a gas appliance and should be installed by a licensed electrician and or certified gas supplier Service must be performed by a qualified service installer service agency or the gas supplier A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death This pool heater 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 e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbors phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARRANTY Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Improper maintenance of pool water chemistry r
26. N AND DIAGNOSTIC LED INDICATOR Top View Side View y g eke afa an 5 FIG 45 SmartValve with Hot Surface Ignition Control Module Service Parts This unit uses a SmartValve electronic ignition control module and a hot surface igniter The electronic ignition module SmartValve is not repairable Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty hot surface igniter flame rod or ignition module MUST be replaced with a new OEM unit only An OEM specification igniter flame rod and ignition control module SmartValve for this specific unit are available from your local distributor DO NOT use general purpose field replacement ignition modules SmartValves or igniters Each pool heater has one ignition module one hot surface igniter and a flame rod Flame Sensing The SmartValve uses a separate flame rod to sense the presence of main burner flame The flame rod is mounted just above the burner adjacent to the hot surface igniter The flame rod is connected to the SmartValve with a pink wire The minimum flame current required to sustain burner operation is 0 5 microamps In normal burner operation the flame current should be steady and in the range of 4 to 6 microamps An unsteady or constantly changing microamp signal u
27. RESSURE Measured at the inlet pressure tap located upstream of the combination gas valve Btu hr Input 150 000 399 999 Btu hr Max Inches Water Column 150 000 300 000 Btu hr Min Inches Water Column 399 999 Btu hr Min Inches Water Column Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment MANIFOLD PRESSURE Measured at the pressure tap on the downstream side of the combination gas valve If adjustment of regulator pressure is required see Manifold Adjustment Procedure Do not increase regulator pressure beyond specified pressure setting TABLE K NET MANIFOLD PRESSURE Btu hr Input Natural and LP Gas Regulator Setting 1 8 w c Net for the Referenced gas valve GAS PRESSURE TEST 1 The pool heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5kPa 150 000 399 999 2 The pool heater must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5kPa 3 The pool heater and its gas connection must be leak tested before placing the heater in operation GAS CONNECTION Safe operation of the unit requires properly sized gas supply pipi
28. RESSURE PROPANE GAS PIPING SINGLE UNIT INSTALLATIONS SUGGESTED GAS PIPE SIZE Length Tubing Size 0 70 Feet 71 250 Feet 5 8 Copper Tubing Capacity based on 5 PSIG inlet with 1 PSIG pressure drop GAS PIPING 1 2 Copper Tubing FIG 33 Gas Line Connection to unit w sediment trap and manual main gas shut off valve All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gasses All piping must comply with local codes and ordinances Tubing installations must comply with approved standards and practices Install Piping to Control The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are square deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide unit with proper volume of gas Install a manual main gas shutoff valve at the pool heater s gas inlet outside of the pool heater and before the gas valve When the pool heater is installed in under or directly attached to the pool or spa structure the manual main gas shutoff valve must be located outside the pool structure Run pipe or tubing to the pool heater s gas inl
29. TIBLE FLOOR KITS Kit Number CFK3300 CFK3300 CFK3301 CFK3301 CFK3302 Input Btu hr 150 000 199 999 250 000 300 000 399 999 8 Outdoor models require the use of the factory supplied outdoor vent cap assembly The outdoor vent cap is mounted on the flue outlet of the pool heater as shipped Outdoor models must not be installed directly on the ground The outdoor unit must be installed on a concrete brick block or other non combustible pad Outdoor models have additional special location and clearance requirements These are specifically addressed in the Venting Section under Outdoor Installation Do not install in locations where rain from building runoff drains or sprinkler systems will spill onto the pool heater A windproof cabinet protects the unit from weather 9 Indoor installations require that the factory installed outdoor vent cap be removed from the pool heater to allow the installation of a flue pipe Specific instructions for the removal of the outdoor cap are addressed in the venting section Indoor installations require adequate supplies of clean combustion air for proper operation Optional venting arrangements may allow direct pipe connection from the unit to the outside for combustion air See the Venting Options section of this manual 10 This pool heater must be installed at least five feet from the inside wall of a pool unless separated from the pool by a solid fence wall or permanent barrier
30. acid 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 Damage to the pool heater due to improper pH is non warrantable We recommend using a four way test kit to monitor the following levels to insure proper operation of your pool heater TABLE V RECOMMENDED POOL CHEMISTRY LEVELS Test Recommended Level Correct pH 7 2 7 8 Chlorine Residual 1 0 5 0 ppm Total Alkalinity 80 120 ppm Calcium Hardness 175 350 ppm Chlorine residual is the chlorine remaining in the pool water after it is consumed in the process of destroying bacteria algae and other oxidizable materials Total alkalinity is the measurement of the total amount of alkaline chemicals in the water Alkalinity controls pH Sodium bicarbonate is used to raise total alkalinity Calcium hardness can be raised by the addition of calcium chloride and lowered by the addition of Tri sodium Phosphate or its equivalent The corrosive level of pool water can also be measured by the Langlier Saturation Index This index is calculated by a formula which uses operating temperatures total alkalinity pH calcium hardness and total dissolved solids The optimum Saturation Index value is zero A negative value indicates a corrosive condition Your pool spa dealer can provide additio
31. air flow through the vent cap installed on the unit Proper freeze protection must be provided see Freeze Protection A pool heater that is not in use in the winter season must be properly drained and winterized GREY SPONGE GASKET ROUND GASKET INLET AIR COLLAR A CAUTION An Outdoor Installation DirectAire Vent or an E Rite Vent into dead air spaces such as alleys A atriums and inside corners can cause recirculation of flue gases Recirculation of flue gases will cause incomplete combustion sooting premature failure of the jacket vent and heat exchanger as well as icing of the combustion air intake during operation in severe cold weather Minimum clearances between the combustion air intake and exhaust vent terminal are specified in the installation instructions To prevent recirculation of the flue gases maintain as much distance as possible between the combustion air intake and the exhaust vent terminal INLET AIR COVER GREY SPONGE GASKET FLUE ADAPTER FIG 14 Installation of Flue Adapter and Inlet Air Cover 10 Whenever a vent option other than outdoor installation is desired the outdoor vent cap assembly MUST be removed and an optional vent kit must be installed on the pool heater The vent kit allows connection of the flue and or a combustion air pipe The vent kit includes the flue adapter and an air inlet collar to allow connection of an air inlet pipe or an air i
32. all venting installation E Rite Sidewall Vent Kits The E Rite Sidewall Vent Kit MUST be ordered from the pool heater manufacturer The part number for each kit is listed by unit size Each venting kit includes the sidewall caps necessary adapters to install a separate combustion air pipe from the pool heater to the outdoors and instructions for proper installation 22 TABLE E RITE SIDEWALL VENT KITS Inlet amp Outlet Vent Diameter E Rite Sidewall Vent Kit Input Btu hr 150 000 HDK3024 199 999 HDK3024 250 000 HDK3024 300 000 HDK3025 399 999 HDK3025 The flue pipe from the flue outlet on the side of the pool heater to the sidewall vent cap is under a positive pressure and must use a totally sealed Category IV vent pipe E Rite Sidewall Vent Pipe Requirements The connection from the vent to the sidewall cap MUST be made with listed Category IV vent material and accessories There shall be no reduction in vent size from the pool heater s flue outlet to the inlet of the sidewall vent cap Vent pipe material may be purchased locally by the installer Flue Pipe Materials Select venting material from the following specified vent materials Protech Systems Inc Fas N Seal Vent with AL29 4C stainless steel Call 1 800 766 3473 for nearest distributor Z Flex Z Vent with AL29 4C stainless steel Call 1 800 654 5600 for nearest distributor Heat Fab Inc Saf T CI Vent with AL29 4C stai
33. 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 The Outdoor Vent System FIG 9 Outdoor Installation Illustration OUTDOOR INSTALLATION Units are self venting and can be used outdoors when installed with the factory supplied Outdoor Vent Cap The outdoor vent cap is mounted directly to the rear of the pool heater as shipped from the manufacturer and covers the flue outlet and combustion air inlet openings on the jacket No additional vent piping is required A WARNING The flue products discharged from the flue outlet on the outdoor vent cap may be very hot Avoid touching or other direct contact with the flue gases or the vent cap assembly These components are HOT and direct contact can result in burns A WARNING Outdoor models MUST be installed outdoors and MUST use the outdoor vent cap assembly supplied by the manufacturer Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors All covers doors and jacket panels must be properly installed to insure proper operation and prevent a hazardous condition A CAUTION Pool heaters which are shut down or will not operate may experience freezing due to convective air flow in the outdoor vent cap installed on the unit If operated in cold climates continuous pump operation is recommende
34. ap supplied in the Vertical DirectAire Vent Kit is used to supply combustion air to a single pool heater The rooftop vent cap for flue products should be a standard commercial cap purchased locally The use of a sidewall or rooftop air inlet cap other than the manufacturers recommended cap for single pool heater installations or use of a common air inlet cap for multiple pool heaters with insufficient free area and or protection from wind and weather may result in operational problems with the pool heater or potentially hazardous spillage of flue products which can cause personal injury death or property damage Venting of Flue Products For venting flue products vertically to the outdoors follow all requirements in the installation instructions for conventional venting Termination point for the flue products must follow the clearance requirements in the Vertical Vent Termination section of Conventional Venting A barometric damper is NOT required in the flue on Vertical DirectAire installations if the draft is within the 0 02 to 0 08 inches water negative required for proper operation If the draft exceeds this range a barometric damper MUST be installed 17 Pool heaters which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit If operated in cold climates continuous pump operation is recommended to help prevent freezing of pool water on DirectAir
35. ay the flue products and provide combustion air The flue outlet combustion air inlet cap of an outdoor pool heater must not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure Walls or enclosed fencing may cause eddy currents which can re circulate the flue products into the combustion air inlet Recirculation of flue products may cause operational problems bad combustion or non warrantable damage to controls Do not install the pool heater with outdoor venting under a deck Do not install an outdoor pool heater in a well stairwell alcove courtyard or other recessed area The outdoor cap must be located 4 feet 1 22m below and 4 feet 1 22m horizontally from any window door walkway or gravity air intake The combustion air inlet of the outdoor cap must be located at least one foot 0 30m above grade and above normal snow levels The pool heater must be at least 10 feet 3 05m away from any forced air inlet The pool heater must be 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 Do not install in locations where rain from building runoff drains will spill onto the pool heater Do not locate the pool heater so that water from sprinklers may spray directly on the unit Water may damage controls or other electrical
36. combustion air fan turns on Turn knob an additional 1 4 turn counter clockwise Oo Turn filter pump off and on several times The heater should shut down immediately when the pump stops N If the heater does not shut down immediately as the filter pump stops repeat steps 4 5 and 6 until proper operation is achieved oo Reset thermostat to desired temperature setting A WARNING Operation of the pool heater without proper flow will cause immediate non warrantable damage to the heat exchanger LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot Itis equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department C Use only your hand to push the gas control switch Never use too
37. control and the pool heater s internal controller FACTS ABOUT WATER CHEMISTRY Factors which affect pool and spa water and more importantly the efficiency of your new pool spa heater are 1 PROPER FILTRATION 2 PROPER CIRCULATION 3 DISINFECTION AND OXIDATION 4 pH CONTROL AND TOTAL ALKALINITY 5 ALGAE CONTROL The water chemistry of your pool or spa 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 If there is an imbalance in the pool water chemistry the minerals in the pool water will precipitate out and collect in the pool filter system and the pool heater 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 the most important factor in maintaining proper balance in your pool spa water pH is the measurement of the acidity or alkalinity of water The chart below shows the ideal pH range and what can happen when the pH increases or decreases from the ideal of 7 2 to 7 8 45 High PH FIG 58 pH Scale If the pH becomes too high it lowers the ability of chlorine to destroy bacteria and algae water can become cloudy filter elements may become blocked and scale formation will occur in the pool and heat exchanger If the pH becomes too low the water becomes
38. cur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material When an E Rite Sidewall vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturers instructions to insure that flue products will not be discharged into the equipment room or other occupied spaces in the building The air inlet pipe must also be resealed to insure that combustion air will be free of contaminants and supplied in proper volume The connection from the vent to the vent termination outside the building MUST be made with one of the specified vent materials and must be direct as possible with no reduction in diameter The vent accessories not otherwise provided such as firestop spacers thimbles caps etc MUST be from the same vent material manufacturer and installed in accordance with the manufacturers listing The vent connection through the sidewall must provide correct spacing to combustible surfaces The vent pipe connection to the sidewall vent cap MUST have a gas tight seal to prevent the leakage of flue products Installation of an E Rite Sidewall Vent System requires that each pool heater in a multiple unit installation have a dedicated flue pipe and sidewall vent cap The flue discharge or air inlet from multiple pool heaters installed with the E Rite Sidewall Vent System may NOT be combined to a single common vent A
39. d air inlet cap Proper sealing of the air inlet pipe insures that combustion air will be free of contaminants and supplied in proper volume Sealing of vent material for use with the E Rite Sidewall Vent System The vent materials Heat Fab Saf T CI Vent Z Flex Z Vent Protech Systems Fas N Seal Vent Flex L Star 34 Vent Metal Fab Corr Guard Vent or listed AL29 4C vent systesm suitable for positive pressure must be installed and sealed per the vent manufacturers installation instructions WIRE TIE 3 DIA CIRCULAR TRAP CS TO SUITABLE DRAIN FIG 31 Drain Tee Installation 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 the typical vent installation drawings Plastic drain tubing sized per the vent manufacturers 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 oc
40. d is the pool temperature setting Figure 42B NOTE Pressing the Select key takes you to the next parameter setting If for example you are not using the spa function simply press the Select key to move on to the next parameter O Pool Mode SELECT QO FIG 42B Pool Temperature Setting 5 Using the Up and Down arrow keys adjust the pool temperature When at the desired temperature press the Select key Figure 42B oN The pool differential is displayed N Using the Up and Down arrow keys adjust the pool differential When at the desired differential between 1 20 F press the Select key oo The spa temperature is displayed Figure 42C 5 Spa Mode 75 F SPA SELECT FIG 42C Spa Temperature Setting 9 Using the Up and Down arrow keys adjust the spa temperature Figure 42C When at the desired temperature press the Select key 10 The next parameter displayed is the spa differential 11 Press the Up and Down arrow keys until the desired differential is reached between 1 20 F for the spa When at the desired differential press the Select key 12 A choice of F or C is displayed Using the arrow keys select F or C Press the Select key 13 After a period of 10 seconds with no activity to adjust control settings the display will revert back to normal display of water temperature Figure 42A NOTE When power is ini
41. d to help prevent freezing of pool water in an outdoor installation Proper freeze protection must be provided A pool heater that is not in use in the winter season must be properly drained and winterized See Freeze Protection Combustion air supply must be free of contaminants See Combustion and Ventilation Air To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section Outdoor Vent Air Inlet Location The venting areas must never be obstructed Keep area clean and free of combustible and flammable materials Maintain a minimum clearance of 3 76 mm to combustible surfaces and a minimum of 3 76 mm 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 leaves debris snow ice etc A unit should not be located 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 The unit should be located at least 3 feet 0 19m from any wall or vertical surface to prevent adverse wind conditions from affecting performance The outdoor pool heater must not be installed in an area that is enclosed by walls or a fence that will block free wind movements around the unit Free movement of wind around the outdoor unit is required to carry aw
42. dition of CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment Vent connection is made directly to the flue outlet connection on the unit No additional draft diverter or barometric damper is required on single unit installations when a negative draft is maintained within the specified range The connection from the pool heater s vent to the stack must be made as direct as possible Barometric Damper Location The preferred location for the barometric damper if required is in a tee or collar installed in the vertical pipe rising from the unit s flue outlet The barometric damper MUST NOT be installed in a bull head tee installed on the unit s flue outlet The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to the unit s flue outlet This location ensures that any positive velocity pressure from the unit s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products Adjust the weights on the damper to ensure that draft is maintained w
43. e that increased draft in the winter months will not exceed the specified maximum Maximum draft can not exceed a negative 0 08 inches of water On a conventionally vented negative draft pool heater the connection from the vent to the stack or vent termination outside the building MUST be made with listed Type B double wall or equivalent vent connectors and must be direct as possible with no reduction in diameter Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks The Type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturers instructions The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes Any vent materials specified must be listed by a nationally recognized test agency for use as vent material Locate the pool heater as close as practicable to chimney or gas vent Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions Horizontal portions of the venting system shall be supported to prevent sagging Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm m from the appliance to the vent terminal Follow manufacturers instructions Do not use an existing chimney as a raceway for a flue pipe
44. e area around the burner viewport is hot and direct contact could result in burns YELLOW TIP Miu Ms VA i B NORMAL a ae miner Mra nion D YELLOW FLAME FLAME LIFT FIG 47 Flame Pattern Illustration a Normal Flame A normal flame is blue with slight yellow tips with a well defined inner cone and no flame lifting b Yellow Tip Yellow tip can be caused by blockage or partial obstruction of air flow to the burner s c Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner s or excessive gas input This condition MUST be corrected immediately d Lifting Flames Lifting flames can be caused by over firing the burner s excessive primary air or high draft If improper flame is observed examine the venting system insure proper gas supply and adequate supply of combustion and ventilation air 3 Flue Gas Passageways Cleaning Procedures Any sign of soot around the outer jacket at the burners or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted units seldom need flue cleaning All gaskets on disassembled components MUST be replaced with new gaskets on reassembly Gasket kits are available from your di
45. e combustion air opening is provided to bring combustion air in directly from the outdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7cm per kW This opening must be located within 12 30cm of the top of the enclosure TABLE B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Combustion Air Source Outside Air 2 Openings Outside Air 1 Opening Inside Air 2 Openings Boiler Input 37 5 in 242 cm 50 0 in2 323 cm 62 5 in 403 cm 75 0 in 484 cm 100 in 645 cm 50 0 in 323 cm 66 7 in 430 cm2 83 3 in2 537 cm 100 in 645 cm 133 in 858 cm 150 in 968 cm 200 in 1290 cm 250 in 1613 cm 300 in 1935 cm 400 in 2581 cm 150 000 199 999 250 000 300 000 399 999 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 pool heater only additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada CAN CGA B149 Insta
46. e systems Proper freeze protection must be provided A pool heater that is not in use in the winter season must be properly drained and winterized See Freeze Protection The Powered Sidewall Venting System POWERED SIDEWALL VENTING WITH COMBUSTION AIR FROM THE EQUIPMENT ROOM This venting system uses a powered vent assembly which pulls the flue products from the pool heater and exhausts out a sidewall The fan in the powered vent cap generates a negative draft at the unit Combustion air is drawn from the equipment room see Combustion and Ventilation Air Requirements The outdoor vent cap must be removed and the optional Sidewall Vent Kit must be installed See Installation of Optional Vent Kits FIG 24 Cap Sidewall Venting Installation with Powered Vent The sidewall fan is mounted in a vent cap which is installed on an exterior wall The sidewall fan and accessories are included in a venting kit which must be furnished by the manufacturer in accordance with CSA International requirements This venting kit includes a flue adapter an air inlet cover the sidewall fan cap barometric damper proving switch and all necessary relays to interlock with the pool heater s control system A barometric damper is required in the flue on Powered Sidewall Venting installations A barometric damper is supplied with each Powered Sidewall Vent Kit and MUST be installed in the flue of each unit The barometric damper must be adjusted to
47. e the heat exchanger is removed from the unit a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces NOTE Do not wet the pool heater s refractory u Ensure that all burner ports are cleaned to remove any soot See Burner Cleaning Procedure v Carefully reinstall the heat exchanger and V baffles if removed from the unit w Reinstallation is the reverse of the installation procedure Use new gasket material to insure a proper air seal x Reassemble all gas and water piping Test for gas leaks y Reassemble outer jacket panels z Cycle unit and check for proper operation Combustion Air Fan The combustion air fan should be checked every 6 months or each season of operation Clean fan as required when installed in a dust or dirt contaminated location Water Circulating Pump Ensure that the filter system pump is providing adequate flow to the pool heater Backwash and clean filter as required to maintain proper flow Keep the pool heater area clear and free from combustible materials gasoline and other flammable vapors and liquids Check frequently to be sure the flow of combustion and ventilation air to the pool heater is not obstructed This pool heater uses a transformer to supply a low voltage control circuit The voltage on the secondary side should be 24 to 28 VAC when measured with a voltmeter Hot Surface Igniter Replacement The
48. ed for outdoor installations pool heaters installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower If freeze protection is not provided for the system a low ambient temperature alarm is recommended for the mechanical room Damage to the pool heater by freezing is non warrantable 46 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 unit The constant flow of warm pool water can help prevent freezing Location Indoor pool heaters must be located in a room having a temperature safely above freezing 32 F 0 C Caution A mechanical room operating under a negative pressure may experience a downdraft in the flue of a pool heater which is not firing The cold outside air pulled down the flue may freeze a heat exchanger This condition must be corrected to provide adequate freeze protection 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 Shut down and Draining If for any reason the pool heater is to be shut off when temperatures may be below 35 F 2 C you must winterize the unit a Shut off gas supply
49. en the connections to the pool heater to allow a portion of the excess flow to be diverted to the pool The bypass allows the proper volume of water to be supplied to the pool heater to prevent sweating and condensate The bypassed water prevents needless pressure drop and reduction in flow rates TO HEATER 9 FROM HEATER C2 Cc FIG 40 Auxiliary Bypass Piping ADJUSTMENT OF AUXILIARY BYPASS 1 Backwash and clean pool filters 2 Start with bypass valve in half open position 3 Start the pool heater 4 Check the temperature of the outlet piping from the pool heater It should be slightly warm to the touch 5 If the pipe is hot close the bypass to increase flow to the pool heater If the pipe is cold open the valve to decrease flow to the pool heater and increase temperature rise 6 High water flow can cause condensate and operational problems which are non warrantable AUTOMATIC CHLORINATORS AND CHEMICAL FEEDERS All chemicals must be diluted into the pool or spa water before they are circulated through the pool heater Any concentration of chlorine in the pool heater can cause damage to the unit Do not place chlorine tablets or bromine sticks in the skimmer High chemical concentrations will result when the pump is not running Chlorinators must feed downstream of the pool heater and have an anti siphoning device to prevent chemical back up in the heater when the pump is shut off 32 IMPORTANT High chemica
50. er installation may require a 3 4 drain pipe Check with your local code authorities In these applications install a 3 4 threaded connection in the piping located immediately downstream of the inlet outlet connection on the front header for system drainage A metallic pipe heat sink is not required on pool heater installation PVC CPVC or other high temperature plastic piping may be used to pipe directly to the pool heater if permitted by local codes When the pool heater is used with a spa or therapy pool CPVC or metallic pipe is recommended A silicon type sealant with a high elasticity must be used at flanged connections to prevent leakage This helps to compensate for the large differences in expansion and contraction of the materials used in piping and the flanged connections The filtration pump must operate simultaneously when the heater is in service to ensure that there is no damage to PVC piping connected directly to the pool heater A check valve should be installed in the piping to the heater if there is the possibility of back siphoning when the pump stops AUXILIARY BYPASS When water flow rates to the pool heater exceed 100 GPM a portion of this high water flow MUST be diverted with an external bypass High performance pumps can provide flows in excess of 100 GPM An auxiliary bypass as shown in the attached drawing MUST be installed when the maximum flow is exceeded The bypass must have a valve installed betwe
51. er is equipped with two fixed settings auto reset high water temperature limit controls If water temperature exceeds the set point the limit will break the control circuit and shut down the unit The limit control will only be reset after the water temperature has cooled below the set point of the limit The high water temperature limit controls are mounted in the outlet side of the front header NOTE The limit control will not reset until the water temperature has dropped below the set point of the high limit WATER PRESSURE SWITCH The pressure switch is factory preset for normal installations at deck level The switch will stop operation of the pool heater on low water flow The water pressure switch is factory pre set at 5 PSI Do not adjust the pressure switch unless the pool heater is located more than four feet above or below the deck level PRESSURE SWITCH ADJUSTMENT The pressure switch is located in the front header behind the upper side jacket panel above the water connections When required the pressure switch can be reset with the following procedure 1 Clean filter and skimmer 2 Start filter pump 36 3 Set digital thermostat to highest setting 4 Turn the adjustment knob on the pressure switch clockwise until the combustion air fan in the front control panel turns off Fan will not turn off if system pressure exceeds 5 PSI Nn Slowly turn the adjustment knob counter clockwise until the
52. esulting high water hardness and high alkalinity that results in a lime scale build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty See Facts About Water Chemistry N 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 manufacturer s warranty See Water Connections Maximum Flow Rates for flow requirements SPECIAL INSTRUCTIONS TO OWNER NOTE Retain this manual for future reference This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation A WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or additional information consult a qualified installer service agency or the gas supplier CHECKING EQUIPMENT 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 packing slip with those actually received In case there is damage or a shortage immediately notify the carrier Do not use this pool heater if any part has been under water The poss
53. et If tubing is used obtain a tube to pipe coupling in order to connect the tubing to the pool heater s gas inlet Install a sediment trap in the supply line to the pool heater s gas inlet see Figure 33 Apply a moderate amount of good quality pipe compound DO NOT use Teflon tape to pipe only leaving two end threads bare Remove seal over gas inlet to pool heater FIG 34 Wrench to Support Gas Valve for Piping Connection 8 Connect gas pipe to inlet of unit Use a wrench to support the gas manifold on the unit 9 For LP gas consult your LP gas supplier for expert installation 10 Ensure that all air is properly 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 GAS MANIFOLD PRESSURE ADJUSTMENT PROCEDURE IMPORTANT The gas valve is 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 location and connection points for pressure measurement The referenced chamber pressure must be subtracted from the manifold pressure to obtain actual net manifold pressure for normal operation A manometer or magnahelic gauge legible in 0 1 increments up to 10 water column is
54. ferential Air Chart on page 44 if the air shutter is properly adjusted The differential pressure varies based on air density at elevation Air Shutter Adjustment MANOMETER FIG 55 Air Shutter Pressure Measurement DIFFERENTIAL AIR CHART Differential Air Elevation 1 55 1 75 W C 0 4000 1 4 1 6 W C 4000 8000 1 2 1 4 W C 8000 12 000 GAS TRAIN AND CONTROLS FIG 56 Gas Train Drawing NOTE The gas train and controls assembly provided on this unit 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 TERMINAL STRIP FOR REMOTE THERMOSTAT OR CONTROLS CONNECTION A remote thermostat or other remote safety control may be connected to the pool heater Follow the manufacturers instructions supplied with the remote control or thermostat for proper installation and adjustment The pool heater is equipped with a terminal strip to allow easy connection of a remote switching devices or additional field installed safety controls The terminal strip is located inside the jacket Connection of a set of dry switching contacts or a remote thermostat to cycle the unit ON and OFF from a remote source should be made to the R and W terminals The X and B terminals may also be used to connect any field installed safety control such as a flow switch that will not routinel
55. fetal damage during the first three months of pregnancy resulting in birth of brain damaged or a deformed child Pregnant women should observe the 100 F 38 C maximum rule A Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperatures by as much as 4 Fahrenheit 2 C Nn Persons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain their physician s advice before using spas or hot tubs 6 Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs A WARNING To minimize the possibility of serious personal injury fire or damage to your pool heater never violate the following safety rules 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 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 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 i
56. ff gas supply at the tank Supply Pressure Measurement INLET PRESSURE FIG 37 Gas Supply Pressure Measurement at Combination Gas Valve 3 Remove the 1 8 hex plug located on inlet side of the gas valve An inlet pressure tapping is located on the top side of the valve body A tapping on the field installed main manual gas cock may also be used 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 4 Turn on gas supply at the manual gas cock turn on LP gas at tank if required 5 Turn the power switch to the ON position 6 Ensure that the ON OFF switch on the smart valve is in the ON position 7 Set the electronic temperature control to call for heat 8 Observe the gas supply pressure as all burners are firing Ensure that inlet pressure is within the specified range Minimum and Maximum gas supply pressures are specified in the Gas Supply Section 9 If gas pressure is out of range contact gas utility gas 30 supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control 10 If gas supply pressure is within normal range proceed to remove gas manometer and replace pressure tap fittings in the gas control 11 Turn the power switch to the OFF position 12 Shut off gas supply at the manual gas cock in the gas pipi
57. fold pressure observed at the end of trial for ignition and when the burners are firing The gross manifold pressure will typically be within the range of 3 1 w c to 3 5 w c for Natural Gas and LP Gas The difference in the gross manifold pressure and the front chamber pressure is the net manifold pressure setting of the gas valve s regulator Compare the net setting to the setting specified for the type of gas used Adjust the regulator as required Set the electronic temperature control or thermostat to a setting lower than the unit s water temperature to turn the burners off Allow unit to run through the post purge sequence Turn the power switch to the OFF position Net Manifold Pressure Regulator Pressure Less Front Chamber Pressure Type of Gas Net Manifold Pressure Setting Natural Gas or LP Gas 1 8 w c NOTE The front chamber pressure must be subtracted from the gross regulator pressure to obtain actual net manifold pressure for normal operation The front chamber pressure may vary based on elevation vent length and model For information on chamber pressure see Combustion Air Adjustment Do not increase net manifold pressure beyond the specified pressure setting If adjustment is necessary remove the regulator cover screw on the gas valve r Turn regulator adjustment screw clockwise to raise regulator gas pressure counter clockwise to lower the regulator gas pressure Turn regulator adjustment
58. hot surface igniter can be replaced with an OEM igniter available from your dealer FIG 51 Access to Hot Surface Igniter and Wiring Grommet a Turn off main power to unit b Turn off main manual gas shutoff to unit c chamber d SmartValve ignition module e out of the combustion chamber f support bracket as shown in the illustration J r l l l l l l l oN ron ROTATE FIG 52 Access and Positioning of Wiring Grommet 42 Remove the front outer jacket panels to access the front Disconnect the 1x4 Molex connector from the Remove the igniter retaining screw and slide the igniter Remove the two screws that secure the gas manifold g Push the strain relief bushing through the panel and slip the igniter and flame sensor wires down and around the manifold grommet h wm Install the new igniter and route the wires through the bushing Locate the bracket as shown in the illustration and rotate 90 to position i j Ensure that the manifold support bracket and vinyl grommet are properly positioned to seal the pressurized front chamber Incorrect installation of the grommet may result in reduced combustion air supply and operational problems k Reassemble in reverse order a Combustion Air Shutter Adjustment This unit uses a fan assisted combustion process The fan air shutter is factory pre set and should not need adjustment in mos
59. ible 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 A OWNER WARNING 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 MNL 7012 CONTENTS Warranty Safety Warnings Spa and Hot Tub Safety Location Combustible Floor Kits Clearances Combustion Ventilation Air Vent System Options Outdoor Installation Installation of Vent Kits Conventional Venting Vent Terminations Vent Clearances Vertical DirectAire Powered Sidewall Venting Horizontal DirectAire E Rite Sidewall Venting Gas Supply Gas Supply Pressures Net Manifold Pressure Gas Pipe Sizing LP Gas Installations Gas Line Connection Manifold Pressure Adjustment Supply Pressure Measurement Water Connections Minimum Flows Auxiliary Bypass Automatic Chlorinators Chemical Feeders Relief Valve Gas Valve Electrical Requirements Digital Temperature Control Adjusting Setpoints Temperature Adjustment Procedure Error Messages Temperature Limit Control Water Pressure Switch Lighting Instructions Ignition System Operation amp Diagnostic Lights Ignition amp Control Timings Energy Saving Recommendations Maintenance Flame Patterns Burner Cleaning Heat Exchanger Removal and Cleaning HSI Replacement Combustion Air Adjustment Gas
60. ing is properly filled with water Serious damage may result 6 Provide the pool heater with proper overload protection TABLE R AMP DRAW DATA Approximate Total Input Btu hr Controls Amps 120 VAC 150 000 0 5 1 7 199 999 i 0 5 1 9 250 000 0 5 2 0 300 000 0 5 2 1 399 999 0 5 23 GAS VALVE FIG 41 Component Location Drawing ELECTRONIC OPERATING TEMPERATURE CONTROL The pool heater is equipped with a microprocessor based adjustable digital electronic temperature control to provide ON OFF operation Operation is based on temperature input from an immersion sensor The immersion temperature sensor senses inlet water temperature to the pool heater and is located in the inlet side of the front header The digital electronic control allows two temperature set points to be programmed into the control one for pool operation and one for spa operation The sensor is a negative coefficient platinum thermistor A liquid crystal display is provided to indicate sensed temperature and operating parameters 85 F ACO o SELECT UP DOWN o eee FIG 42 Electronic Temperature Control Display and Programming Keys SPECIFICATIONS Set Point Adjustment Range 55 F up to 105 F 13 C up to 41 C Differential Adjustment Range 1 F up to 20 F 1 C 11 C Temperature Accuracy 1 F Display Resolution 1 F via Liquid Crystal Display LCD
61. isions of the local building codes The equipment room MUST be provided with properly sized Openings to assure adequate combustion air and proper ventilation when the unit is installed with conventional venting or sidewall venting and drawing combustion air from the room FIG 5 Combustion Air Direct from Outside 1 Ifair is taken directly from outside the building with no duct provide two permanent openings to the equipment room a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the bottom of the enclosure b Ventilation air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5cm per kW This opening must be located within 12 30cm of the top of the enclosure FIG 6 Combustion Air Through Ducts 2 If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11cm per kW FIG 7 Combustion Air from Interior Space 3 If air is taken from another interior space each of the two openings specified above should have a net free area of one square inch for each 1000 Btu hr 22cm per kW of input but not less than 100 square inches 645cm FIG 8 Combustion Air from Outside Single Opening 4 If a singl
62. ithin the specified range IMPORTANT Examine the venting system at least once a year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration Immediately correct any problems observed in the venting system VENT SYSTEM OPTIONS This pool heater has six venting options They are 1 Conventional Negative Draft Venting with vertical rooftop flue termination and combustion air supplied from the equipment room 2 Vertical DirectAire Venting with a vertical conventional vent for flue products and a combustion air pipe from either the sidewall or roof top 3 Powered Sidewall Venting to exhaust flue products out a sidewall with a powered vent assembly and combustion air supplied from the equipment room 4 Horizontal DirectAire Venting with a powered vent assembly to exhaust the flue products out a sidewall and a combustion air pipe from the sidewall 5 E Rite Sidewall Venting which uses the internal combustion air fan to exhaust the flue products out a sidewall vent termination with a limited vent length Combustion air for an E Rite Sidewall vent must be supplied with a combustion air pipe from the sidewall 6 Outdoor Venting using the factory supplied air inlet vent cap installed on the unit All pool heaters are shipped from the factory equipped for Outdoor Installation All other optional vent systems require the removal of the outdoor vent cap and installation of specific vent kits
63. l concentrations from improperly adjusted feeders and chlorinators can cause rapid corrosion to the heat exchanger This damage is non warrantable RELIEF VALVE An optional temperature and pressure relief valve may be field installed in the front header if required by local codes Open the upper side jacket panel above the water connections to access the mounting point Remove the 3 4 NPT plug in the outlet side of the front header to install the relief valve The relief valve should be properly sized based on local code requirements In the absence of local code requirements the relief valve should be sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve is installed in the vertical position and mounted in the front header on the hot water outlet of the pool heater Remove the plug from the rear jacket panel to route the discharge pipe to the outside of the jacket Water damage to the controls may occur if discharge piping is not properly installed to route relief valve discharge water to the exterior of the jacket No valve is to be placed between the relief valve and the unit To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves
64. le burners again to insure proper ignition and flame characteristics WATER CONNECTIONS This pool heater is equipped with an automatic built in bypass located in the front header This bypass is flow actuated to maintain proper flow through the pool heater at flow rates of less than 100 GPM If the water flow rate to the pool heater exceeds 100 GPM an auxiliary bypass MUST be installed in the piping to the pool heater See auxiliary bypass section for piping and adjustment TABLE Q MINIMUM WATER FLOW REQUIREMENTS Minimum water flow rates to insure proper operation are as follows Input Btu hr Minimum Flow 150 000 15 GPM 199 999 20 GPM 250 000 25 GPM 300 000 30 GPM 399 999 40 GPM FIG 38 Typical Piping for Water Connections Inlet and Outlet Connections Connection to the pool heater can be made with either 2 threaded pipe or a slip connection with 1 1 2 or 2 pipe Two inch threaded pipe may be directly screwed into the flanged header connections for both inlet and outlet piping Each pool heater is supplied with two sets of gaskets to allow a flanged compression attachment of either 2 or 1 1 2 copper pipe directly to the front header Ensure that the correct gasket is used to match the pipe diameter used Minimum pipe size for installation of the pool heater is 1 1 2 diameter 31 2 THREADED 2 SLIP 1 1 2 SLIP FIG 39 Alternate Piping Connections NOTE The pool heat
65. ler may increase diameter one pipe size for ease of installation if needed The sidewall air inlet cap supplied in the Power Horizontal DirectAire Vent Kit is used to supply combustion air to a single pool heater Combustion air supply pipes from multiple units can NOT be combined into a single air inlet pipe and inlet point The use of a sidewall air inlet cap other than the manufacturers recommended cap may result in operational problems with the boiler or potentially hazardous spillage of flue products which can cause personal injury death or property damage Venting of Flue Products For venting flue products horizontally to the outdoors follow all requirements in the installation instructions for sidewall venting Termination point for the flue products must follow the clearance requirements in the Sidewall Vent Termination section of Sidewall Venting A barometric damper is required in the flue on Power Horizontal DirectAire installations The barometric damper must be adjusted to maintain the draft within the 0 02 to 0 05 inches water negative required for proper operation The barometric damper provides dilution air to the vent system to prevent condensate formation A CAUTION Pool heaters which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit If operated in cold climates continuous pump operation is recommended to help prevent freezing of po
66. let 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 Use care to insure that the air inlet cap assembly is properly installed on the air inlet pipe The combustion air inlet cap and the powered vent cap MUST be installed on the same wall and in the same pressure zone The combustion air inlet cap must not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure Incorrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the pool heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the pool heater and possible spillage of flue products which can cause personal injury death or property damage Air Inlet Pipe Materials The Power Horizontal DirectAire system requires installation of a separate pipe to supply combustion air from outdoors directly to the pool heater See the air inlet pipe materials specified in the DirectAire venting section for material requirements and sealing recommendations for the air inlet pipe in a Horizontal DirectAire system A WARNING Using other vent or air intake materials failure to properly seal all seams and joints or failure to follow vent pipe manufactu
67. llation Code for Gas Burning Appliances and Equipment Check all local code requirements for combustion air All dimensions are based on net free area in square inches Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the mechanical room Each opening must have net free area as specified in Table B Single openings shall be installed within 12 30 cm of the ceiling A CAUTION Under no circumstances should the mechanical room ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit 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 chemcial 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 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 failu
68. ls If the switch will not move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this pool heater if any part has been under water Immediately call a qualified service technician to inspect the appliance The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced LIGHTING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the digital thermostat to the lowest setting 3 Turn Off all electrical power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burners DO NOT try to light the burners by hand PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW alla CONNECTOR MOLEX CONNECTOR LINE VOLTAGE CONNECTOR MOLEX INLET Bary 3 TAP CONNECTOR 1 8 NPT GAS VALVE DISABLE SWITCH 24V CONTROL CONNECTOR MOLEX CONNECTOR FIG 44 SmartValve Combination Gas Valve OUTLET PRESSURE TAP 1 8 NPT 5 Remove the control access panel 6 Push the gas control switch to the OFF position 7 Wait five 5 minutes to clear out any gas If you smell gas STOP Follow B in the safety information If you don t smell gas go on to the next step 8 Turn the gas control switch to the ON position 9 Replace the control access panel 10 Turn on all electric power
69. must not exceed a maximum of 20 equivalent feet 6 1m in length Subtract 5 feet 1 52m for each elbow in the flue pipe or the air intake system The transition adapter mounted to the flue outlet on the pool heater does not count as one of the elbows in the venting system Do not exceed limits for the combustion air inlet and flue outlet piping lengths Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet pipe on a Rite Sidewall Vent System a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c 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 23 d Ensure that the air inlet pipes are properly supported The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used The PVC CPVC ABS or Dryer Vent air inlet pipe should use a silicone sealant to insure a proper seal at the pool heater connection and the air inlet cap connection Dryer vent should use a screw type clamp to seal the vent to the boiler an
70. nal data and equipment to make this measurement if a problem exists HEAT EXCHANGER INSPECTION Tubes This pool heater is especially designed to operate without accumulation of scale in the heat exchanger even in very hard water Periodic inspections of the tubes should be made to be sure that no scale is accumulating Water piping should be disconnected at the flanges The front header can be removed to inspect the tubes A scale deposit of paper thickness is normal Heavier deposits should be cleaned out If scale is found in the tubes THE CAUSE SHOULD BE FOUND AND CORRECTED Removal and cleaning of the heat exchanger must be performed by a qualified serviceman or installer The probable cause is improper water chemistry Check the following possible causes 1 High pH 2 Improper adjustment of an external bypass 3 Inadequate pump flow Always be sure that the filter pump is in good operating condition and runs continuously when the pool heater is in operation PREVENTION OF FREEZING Heat exchangers and headers damaged by freezing are not covered by warranty If equipment is subject to freezing temperature the following precautions must be observed FREEZE PROTECTION Although this pool heater is CSA design certified for outdoor installations such installations are not recommended in areas where pool heater will be operated in the winter months and the danger of freezing exists Proper freeze protection must be provid
71. nance for your heater each new swimming season Check heat exchanger controls burners and operation of the unit 8 For pools used only on weekends the thermostat may be set lower than 78 F 25 C during the week Lower setting to a range that can be easily achieved in one day s operation of the pool heater MAINTENANCE Listed in this section are items that must be checked to insure safe reliable operations Verify proper operation after servicing 39 1 Examine the venting system at least once a year Check more often in first year to determine inspection interval A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Outdoor Installations Check vent cap for proper mounting corrosion or any obstruction of the flue outlet or combustion air inlet Indoor Installations Check all joints and pipe connections for tightness corrosion or deterioration Flush condensate drain hose with water to clean when required 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 2 Visually check main burner flames at each start up after long shutdown periods or at least every six months A burner viewport is located on the left side of the unit below the water connections on the front header Remove cap to view flame A WARNING Th
72. ng See the following data 1 Gas pipe size may be larger than heater connection TABLE M FITTINGS TO EQUIVALENT STRAIGHT 2 Installation of a union is highly recommended for ease of service Install union as close as possible to gas valve inlet PIPE 3 Install a manual main gas shutoff valve outside of the appliance Diameter gas connection and before the gas valve when local codes require Pipe inches 3 4 1 1 1 4 1 1 2 2 1 3 1 4 5 4 A trap drip leg MUST be provided in the inlet of the gas Equivalent connection to the unit length of Straight Pipe 5 The combination gas valve has an integral vent limiting device feet xx 3 4 5 iolls iiao and does not require venting to atmosphere outside the building 6 Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes LP GAS INSTALLATIONS TABLE L A WARNING LOW PRESSURE NATURAL GAS LP propane gas is heavier than air and will remain at SINGLE UNIT INSTALLATIONS floor level if there is a leak Basements crawl spaces SUGGESTED GAS PIPE SIZE alcoves and areas below ground level will serve as pockets for accumulation of leaking gas Before lighting sniff at floor level IF YOU SMELL GAS follow instructions on PAGE ONE of INSTALLATION amp SERVICE MANUAL Shut off gas at LP tank outside of building DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED Input Btu
73. ng to the appliance If fuel supply is LP gas shut off gas supply at the tank 13 Remove the manometer and related fittings from inlet side of the gas valve replace 1 8 hex plug in gas valve and tighten 14 Turn on gas supply at the manual valve turn on LP gas at tank if required 15 Turn the power switch to the ON position 16 Ensure that the ON OFF switch on the smart valve is in the ON position 17 Set the electronic temperature control or thermostat to call for heat If proper ignition and burner operation is not achieved after checking gas supply pressure and setting the correct net manifold pressure see the Maintenance section for Combustion Air Adjustment Follow the procedure to adjust the combustion air fan IMPORTANT Upon completion of any testing on the gas system leak test all gas connections with a soap and water solution while main burners are operating Do not spray soap and water solution on the SmartValve housing The use of an excessive amount of soap and water solution can damage the control Immediately repair any leak found in the gas train or related components Do Not operate an appliance 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 Maintenance Normal Flame Pattern Turn system off and allow burners to cool then cyc
74. nless steel Call 1 800 772 0739 for nearest distributor Flex L International Inc StaR 34 Vent with AL29 4C stainless steel Call 1 800 561 1980 for nearest distributor Metal Fab Inc Corr Guard Vent with AL29 4C stainless steel Call 1 800 835 2830 for nearest distributor Or other listed Category IV vent systems suitable for a positive pressure gas fired appliance Air Inlet Pipe Materials The E Rite Sidewall Vent system requires installation of a separate pipe to supply combustion air from outdoors directly to the pool heater See the air inlet pipe materials specified in the DirectAire venting section for material requirements and sealing recommendations for the air inlet pipe on an E Rite Sidewall Vent system NOTE The use of double wall vent material for the combustion air inlet pipe is recommended when the pool heater is operated in cold climates to prevent the condensation of airborne moisture in the incoming combustion air A WARNING Using other vent or air intake materials failure to properly seal all seams and joints or failure to follow vent pipe installation instructions can result in injury death or property damage personal Improper sealing of venting materials will void the warranty and certification of the pool heater Length of Flue Pipe and Air Inlet Pipe for an E Rite Sidewall Vent System The maximum total equivalent length of the sidewall flue or the sidewall combustion air inlet pipe
75. nlet cover when combustion air is drawn from the equipment room Remove the screws surrounding the outdoor vent cap and the two screws in the divider between the flue outlet and air inlet chambers on the vent cap Use the screws removed from the outdoor vent cap to secure the components in the vent kit Mount the flue adapter on the back of the pool heater over the flue outlet Mount the air inlet collar or air inlet cover over the combustion air inlet opening on the rear of the jacket Seal the flue adapter and air inlet collar with the gaskets provided in the kit The flue adapter transitions the rectangular flue outlet to a round flue pipe connection and turns the flue outlet vertical for ease of installation Vent pipe connection is made directly to the outlet of the flue adapter The air inlet collar allows connection of a round pipe to the pool heater to supply combustion air The inlet air cover provides a grill to limit the entrance of foreign matter into the pool heater s air inlet FIG 15 Conventional Negative Draft Vertical Venting with Combustion Air Louvers Conventional Venting A CONVENTIONAL NEGATIVE DRAFT VENTING SYSTEM The outdoor vent cap assembly MUST be removed before any connection to a conventional negative draft vent system can be made A conventional vent adapter kit MUST be installed on the pool heater s flue outlet The conventional vent kit includes the flue adapter and an air inlet cover Mount the air inle
76. ntake system or any location from which fumes could reach the pool heater or vent air intake system 070 D The pool heater 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 As an option all pool heaters may be ordered with heat exchanger construction that conforms to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Part HLW See Note on page 31 for additional information INSTALLATION PROCEDURE FIG 1 Front View 150 000 399 999 Btu hr Models FIG 2 Rear View 150 000 399 999 Btu hr Models LOCATION OF UNIT Locate the pool heater so that if water connections should leak water damage will not result in damage to the area adjacent to the pool heater or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the pool heater The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this pool heater or any of i
77. oint for the Pool temperature setting or the Spa temperature setting may be adjusted at any time by pushing the Up or Down arrow keys Ten seconds after any activity to adjust the set point has stopped the display will revert to showing the current inlet water temperature Set Point The value selected to be maintained by your temperature controller Differential The difference between levels for Turn On and Turn Off operation in your control system For Example If your pool temperature is set at 85 F and you were to set your differential at 5 F the pool heater would shut down when it reached 85 F and would fire back up when the temperature drops to 80 F due to the 5 F differential Your differential is adjustable between 1 20 F NOTE Be careful not to set your differential too low this could lead to short cycling which in turn could cause non warrantable conditions Control values and operation selection will remain in the device memory even after power is removed TEMPERATURE ADJUSTMENT PROCEDURE Follow the steps below to program your electronic temperature control ra If the temperature control is in the Off Mode press the Select key This will take it out of Off Mode and into Operation Mode N Press and hold the Select and the Up and Down arrow keys simultaneously for approximately three seconds 05 You are now in Programming Mode P The first parameter displaye
78. ol heater is placed in service A WARNING The combustion chamber lining in this appliance contains ceramic fiber materials Ceramic fibers can transform into cristobalite crystalline silica when exposed to temperatures above 2192 F 1200 C dependent upon the length of exposure time The International Agency for Research on Cancer I A R C has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Testing has confirmed that the ceramic fibers in this application do not reach 2192 F 1200 C Reference Dyson D Butler M Hughes R Fisher R and Hicks G The Devitrification of Alumino silicate Ceramic Fiber Materials The Kinetics of the Formation of Different Crystalline Phases Ann Occup Hyg Vol 41 No 55 1997 Reference I A R C Monograph 68 June 1997 Note The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guides REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS e Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 http www cdc gov niosh hompage html e Lightly mist with water only those areas being handled the combustion chamber lining or base insulation to prevent airborne fibers e Remove combustion chamber lining or base insulation from
79. ol water on DirectAire systems Proper freeze protection must be provided A pool heater that is not in use in the winter season must be properly drained and winterized See Freeze Protection E RITE SIDEWALL VENTING SYSTEM FIG 28 E Rite Sidewall Vent Installation This venting system uses the internal combustion air fan to force the flue products out of a sealed vent pipe to a sidewall vent cap assembly The fan generates a positive pressure in the flue to the vent cap and requires the use of a Category IV stainless steel vent pipe with joints and seams fully sealed Combustion air must be drawn from the outside with a separate combustion air pipe connected to the pool heater The outdoor vent cap must be removed and the optional E Rite Sidewall Vent Kit must be installed See Installation of Optional Vent Kits The air shutter on the combustion air fan MUST be adjusted when the E Rite Sidewall Vent Kit is installed Use a rule to measure the distance from the base of the fan to the end of the air shutter Follow the steps below to adjust the fan air shutter Compare this distance to the specified A dimension for the unit 1 Turn the power switch to the OFF position 2 Turn the gas valve switch to the OFF position 3 Remove upper front access door 4 Use a ruler or the spacer supplied in the vent kit to measure the distance from the base of the fan to the end of the air shutter Compare this distance to the specified
80. oper sequence System lockout flame signal not present After 1 hour lockout reset delay control will reset and initiate a new ignition 6 Flashes sequence if the call for heat is still present IGNITION AND CONTROL TIMINGS F 9 Hot Surface Ignition System with SmartValve Prepurge 15 Seconds Hot Surface Igniter Heat up Time 7 seconds first try 10 seconds subsequent tries Trial for Ignition 7 Seconds Flame Recognition Period 1 Second Automatic Restart Delay Minimum 60 Minutes Ignition Retries 3 Retries after initial trial 4 total ignition cycles Failure Response Time 2 Seconds at less than 0 5 pA flame current ENERGY SAVING RECOMMENDATIONS 1 Keep the pool spa covered when not in use This will cut heating cost reduce water evaporation conserve chemicals and reduce load on the filtering system 2 Reduce pool thermostat to 78 F 25 C or lower reduce spa temperature to 100 F 38 C 3 Use an accurate pool spa thermometer to monitor water temperature 4 Record the proper temperature settings for your pool and spa set points and discourage further adjustments of the digital control 5 Use a time clock to start filter pump no earlier than 6 a m during pool spa season This is the time when nightly heat loss stabilizes 6 Turn the pool spa heater off and drain during long periods when the pool will not be used winter vacations etc 7 Follow a regular program of preventative mainte
81. rating The Power Horizontal DirectAire combustion air supply system has specific vent material and installation requirements The air inlet pipe uses an adapter to connect directly to the pool heater to supply combustion air The combustion air inlet pipe will be a dedicated system with one air inlet pipe per pool heater The air inlet pipe must be connected to a combustion air inlet cap as specified in this section Combustion air supply pipes for multiple pool heater installations can NOT be combined into a single pipe and inlet termination point Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation Air FIG 27 Air Inlet Cap for Sidewall Termination Sidewall Air Inlet The sidewall air inlet cap is supplied in the Power Horizontal DirectAire Vent Kit which must be ordered from the manufacturer This sidewall cap will supply combustion air for a single unit only Locate units as close as possible to sidewall where the combustion air supply system will be installed 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 instructions in this manual The combustion air inlet cap must be installed at least one foot 0 30m above ground level and above normal snow levels The point of termination for the combustion air in
82. re 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 DirectAire Vertical DirectAire Horizontal and E Rite Venting systems have specific requirements for combustion air ducts from the outside which are directly connected to the pool heater See the requirements for this combustion air duct in the venting section for each specialized vent system VENTING General Vent installations for connection to gas vents or chimneys must be in accordance with Part 7 Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Conventional negative draft venting and sidewall venting applications where outside air is used must have adequate combustion and ventilation air supplied to the equipment room in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest e
83. rer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the pool heater 20 NOTE The use of double wall vent material for the combustion air inlet pipe is recommended when the pool heater is operated in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Length of Air Inlet Pipe The total equivalent length of the Power Horizontal DirectAire combustion air inlet pipe must not exceed a maximum of 75 22 9m equivalent feet in length Subtract 5 feet 1 52m for each elbow in the air intake system Do not exceed limits for the combustion air inlet piping lengths Vent Kits The Power Horizontal DirectAire Vent Kit for sidewall installation MUST be ordered from the pool heater manufacturer The part number for each kit is listed by unit size Each kit has a flue adapter inlet air collar sidewall powered vent cap barometric damper proving switch controls and combustion air inlet cap to supply air to a single pool heater and instructions for proper installation The flue pipe and air inlet pipes are purchased locally TABLE G POWERED HORIZONTAL DIRECTAIRE VENT KITS Input Btu hr DirectAire Inlet Pipe Power Horizontal DirectAire Kit 150 000 4 SVK3034 199 999 SVK3034 250 000 SVK3035 300 000 SVK3036 399 999 SVK3036 Minimum diameter instal
84. screw 4 turn in the desired rotation and cycle the burners on in the sequence listed below and record the observed chamber and regulator settings Subtract to determine the net manifold pressure setting Repeat as necessary to achieve the specified net manifold pressure setting s Replace cover screw on the regulator and turn the power switch to the ON position Set the electronic temperature control or thermostat to call for heat Observe gas regulator pressure again at the burner ON stages Repeat this sequence until the proper regulator setting has been obtained t Turn the power switch to the OFF position u Turn manual gas cock knob to the OFF position v Remove the gas pressure fitting from the gas valve and replace with the 1 8 hex plug that was previously removed and tighten w Ensure that the chamber pressure reference hose is properly connected to the gas valve x Turn the manual gas cock to the ON position y Turn the power switch to the ON position and replace the jacket panels The appliance is now ready to operate If manifold pressure can not be properly maintained check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control 29 CHECKING GAS SUPPLY PRESSURE 1 Turn the main power switch to the OFF position 2 Shut off gas supply at the field installed manual gas cock in the gas piping to the appliance If fuel supply is LP gas shut o
85. should be manually operated at least once a year A CAUTION Avoid contact with hot discharge water SmartValve COMBINATION GAS VALVE The SmartValve combination gas valve will regulate gas pressure cycle the gas supply on and off to the burners in addition to containing the electronics for burner ignition and operation of the combustion air fan Each combination SmartValve consists of two valve seats to meet the requirements for redundant gas valves The SmartValve has an ON OFF switch that must remain in the ON position at all times when the unit 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 adjustment screw located under the cover screw The manifold pressure is preset at the factory and adjustment is not usually required If the manifold pressure is to be adjusted follow the Gas Manifold Pressure Adjustment Procedure for proper adjustment Venting of the Combination Gas Valve The combination gas valve regulator used on all models is equipped with an integral vent limiting orifice per ANSI Z21 78 This vent limiter insures that the volume of gas emitted from the valve is minimal should a rupture of the diaphragm occur Combination gas valve regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors A barbed connection is provided at the vent termination
86. should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators nd relief equipment 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 surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate Combustion Air Inlet Combustion air supply pipes can NOT be combined into a single pipe for multiple unit installations Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation Air To prevent recirculation of flue products into the combustion air inlet follow all instructions in this section To help prevent recirculation of flue products The combustion air inlet cap MUST NOT be installed above the flue outlet cap The combustion air inlet cap must be installed horizontally or below the flue outlet and MUST maintain a minimum 3 foot 0 91m radius clearance from the flue outlet cap The combustion air inlet cap and vent cap for flue outlet MUST be located on the same sidewall and in the same pressure zone The combustion air inlet cap must not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure The combustion air inlet cap must be
87. stributor BURNER REMOVAL AND CLEANING FIG 48 Gas Train and Burners a Turn off main power to unit b Turn off main manual gas shutoff to unit c Remove the front outer jacket panels d Disconnect the gas supply from the gas valve manifold assembly with a field supplied union before the gas valve FIG 49 Gas Train Rotated Up for Burner Removal e Remove mounting screws from manifold mounting brackets Rotate the manifold orifice assembly up and away from burners Figure 50 f Remove the mounting screws from each burner and slide the burner out toward front of unit Use caution to prevent damage to burners burner gaskets refractory hot surface igniter or wiring g Remove soot from burners with a stiff bristle brush Dirt may be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installing Damaged burners must be replaced A pool heater installed in a dust or dirt contaminated atmosphere will require cleaning of the burners on a 3 to 6 month schedule or more often 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 Use extreme care when operating a unit during new construction The burners will probably require a thorough cleaning before the po
88. strip connections are provided on the unit for easy connection of the factory supplied vent kit and control package for the sidewall vent fan See the installation instructions provided with the vent kit 18 Sidewall Vent Pipe Requirements The connection from the vent to the powered sidewall fan cap MUST be made with listed type B double wall or equivalent vent and accessories There shall be no reduction in vent size from the units flue outlet to the inlet of the sidewall vent fan Vent pipe material must be supplied by the installer Follow all requirements in the General Venting and Sidewall Vent Termination sections for venting flue products to the outdoors See the Combustion and Ventilation Air Requirements section to insure that adequate combustion and ventilation air is supplied to the mechanical room All other general installation requirements must be followed Venting of Flue Products The sidewall vent cap shall terminate at least 3 feet 0 91m above any forced air inlet within 10 feet 3 05m The sidewall vent shall terminate at least 4 feet 1 22m below 4 feet 1 22m horizontally from or 1 foot 0 30m above any door window or gravity air inlet to the building Do not terminate the sidewall vent in a window well stairwell alcove courtyard or other recessed area The sidewall vent cannot terminate below grade The sidewall vent system shall terminate at least 1 foot 0 30m above grade above normal snow le
89. sually indicates a gas air mixture problem that must be corrected Flame current can be measured using a DC microamp meter that can be installed in series with the pink wire from the flame rod to the ignition module on the SmartValve 38 Top View FIG 46 Top View of SmartValve and LED Indicator The SmartValve has a single LED located in the top center of the control Illumination of the LED indicates operation and troubleshooting assistance TABLE S LED INDICATOR ASSISTANCE LED Status Indicates off No power to system controls Normal operation shows whenever the system is powered on a call for heat unless an abnormal event has occurred Airflow proving switch remains closed more than 30 seconds after a call for heat sequence begins Combustion air blower is not energized until airflow proving switch opens Airflow proving switch remains open longer than 30 seconds after combustion air blower is energized System goes into a 5 minute delay period with combustion air blower off At the end of the 5 minute delay another ignition cycle will begin Bright Dim 2 Flashes 3 Flashes Temperature limit controls open Low or no water pressure Combustion air blower is 4 Flashes energized 5 Flashes Flame signal sensed out of pr
90. t cases If adjustment is required the fan air shutter may be manually adjusted to a dimension specified for each model Follow the steps below to adjust the fan air shutter if the unit does not function properly or a continuous low air condition is observed a Check for proper installation and draft in venting system Correct as required b Turn the power switch to the OFF position c Turn the gas valve switch to the OFF position d Remove upper front access door e Use a ruler to measure the distance from the base of the fan to the end of the air shutter Compare this distance to the specified A dimension for the unit aN TRANSFORMER RYE COMBUSTION AIR FAN AIR PRESSURE SWITCH TEMPERATURE CONTROL GAS VALVE FIG 53 Combustion Air Fan Location 43 TABLE T AIR SHUTTER ADJUSTMENT OPENING Chamber Pressure A Dimension Opening Input Btu hr 150 000 199 999 250 000 300 000 399 999 FIG 54 Dimension Combustion Air Fan with Air Shutter A Differential Air Pressure Measurement The position of the air shutter on the combustion air fan can be checked with a slack tube manometer Figure 55 Disconnect the two tubes from the air pressure switch and connect one to each side of a manometer Turn on the pool heater and allow the combustion air fan to operate The observed pressure reading on the manometer should correspond to the range shown in the Dif
91. t cover over the combustion air inlet opening on the rear of the jacket 11 No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft within the specified range of a negative 0 02 to 0 08 inches water If the draft in a dedicated stack for a single unit installation exceeds the maximum specified draft a barometric damper must be installed to control draft Multiple unit installations with combined venting or common venting of this pool heater with other Category I negative draft appliances requires that each pool heater must have a barometric damper installed to regulate draft within the proper range a yA 0 e D CONVENTIONAL VENT DATA Conventional Vent Flue Size Conventional Vent Kit Number Input Btu hr 150 000 CVK3000 199 999 CVK3000 250 000 CVK3000 300 000 CVK3001 399 000 CVK3002 The negative draft in a conventional vent installation must be within the range of a negative 0 02 to 0 08 inches water to insure proper operation All draft readings are made while unit is in stable operation approximately 2 to 5 minutes Remember that the draft in a conventional negative draft vent may vary seasonally A pool heater with a high draft when operating in the winter months may have a much lower draft in the summer Initial set up of a vent system with a draft of not more than a negative 0 05 inches water will generally insur
92. the boiler and place it in a plastic bag for disposal e Wash potentially contaminated clothes separately from other clothing Rinse clothes thoroughly e NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air 41 HEAT EXCHANGER CLEANING FIG 50 Exploded View of Heater h While burners are removed check the heat exchanger surface for sooting If soot is present heat exchanger must be cleaned and problem corrected Proceed as follows i Remove the top jacket panel j Disconnect the two pin connector to the combustion fan k Remove the four nuts that hold the fan to the inner cabinet 1 Remove two screws from the front and lift off the inner top heat shield m Remove the fiberglass insulation on top of the combustion chamber n Remove the screws that hold down the combustion chamber top 0 Remove the six screws that hold the heat exchanger front head in place p Remove the front and rear heat exchanger retaining brackets q Remove the V baffles and frame end runners and clean as necessary r Remove soot from heat exchanger with a stiff bristle brush Use a vacuum to remove loose soot from surfaces and inner chamber s Remove the one screw on both sides of the rear header of the heat exchanger and bend the bracket out a little bit t The heat exchanger can be removed by disconnecting all water piping and sliding the heat exchanger towards the front of the unit Onc
93. the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems before installation If there is any doubt about the sizing or condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system 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 An unlined masonry chimney must not be used to vent flue products from this high efficiency appliance An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall 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 The Vertical DirectAire Vent System A CONVENTIONAL VERTICAL NEGATIVE DRAFT VENTING SYSTEM WITH A COMBUSTION AIR PIPE FROM A SIDEWALL OR ROOFTOP INLET CAP Follow all requirements in the General Venting section and Conventional Negative Draft Venting
94. tially applied to a new pool heater the control points will be pre programmed The factory final quality test sets the unit for test firing The preset values are as follows Selection Set Point Differential Pool 80 F 4 F Spa 100 F 5 F NOTE The control values programmed into memory will not be lost because of a power failure ERROR MESSAGES DISPLAYED BY THE ELECTRONIC TEMPERATURE CONTROL There are three error messages that can be displayed in response to software or hardware problems with the pool heater s internal electronic temperature control The error codes that may be seen on the display are ERR The internal EEPROM of the microprocessor in the electronic temperature control has a read error at power up This error cannot be field repaired Replace the pool heater s electronic temperature control if error persist 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 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 HIGH WATER TEMPERATURE LIMIT CONTROLS WATER PRESSURE SWITCH TEMPERATURE HIGH LIMITS FIG 43 Front Header with Limits Pressure Switch and Temperature Sensor High Water Temperature Limit Control The pool heat
95. ts components 2 The indoor pool heaters must be installed so that the ignition system components are protected from water dripping spraying rain etc during appliance operation and service fan adjustment control replacement etc 3 Pool heaters located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46cm above the floor The pool heater must be located or protected so that it is not subject to physical damage by a moving vehicle 4 DO NOT install this pool heater in any location where gasoline or flammable vapors are likely to be present 5 The pool heater must be installed on a level non combustible floor Concrete over wood is not considered a non combustible floor Maintain required clearances from combustible surfaces 6 The pool heater must not be installed on carpet or other combustible material 7 For installation on a combustible floor only when installed on a special base Pool heaters installed over a combustible floor MUST use the Special Combustible Floor Base The heater must be centered on the base as shown in Figure 3 The correct part number for the required base is noted on the rating plate of each unit and listed in Table A Combustible Floor Base FIG 3 Special Combustible Floor Base TABLE A COMBUS
96. vels and at least 7 feet 2 13m above grade when located adjacent to public walkways The sidewall vent shall not terminate directly above a public walkway The sidewall vent terminal shall not be installed closer than 10 feet 3 05m from an inside corner of an L shaped structure The sidewall vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment 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 surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate Powered Sidewall Vent Kits The Powered Sidewall Vent Kit MUST be ordered from the pool heater manufacturer The part number for each kit is listed by unit size Each kit includes a flue adapter an air inlet cover a powered sidewall fan cap assembly barometric damper control relay proving switch and instructions for proper installation The outdoor vent kit installed on the pool heater as shipped from the factory must be removed to install the Powered Sidewall Vent Kit TABLE F POWERED SIDEWALL VENT KITS Input Powered Sidewall Btu hr Kit 150 000 SVK3031 199 999 SVK3031 250 000 SVK3032 3
97. y cycle Remove the jumper between the selected terminals before making a connection to these terminals A control connected to the R and W terminals will interrupt the 24 VAC control circuit to shut off the pool heater Additional safety controls are added to the boiler s 24 VAC control circuit by connecting them to terminals X and B on the boiler terminal strip Remove the jumper between the X and B terminals before making a connection to these terminals A control with contacts that routinely cycle on normal operation should not be connected to these terminals A control connected to the X and B terminals will interrupt the 24 VAC control circuit to shut off the pool heater MPMMOQOO FIG 57 Terminal Strip Remove the brass jumper between the terminals to be used Refer to the chart in this section to determine maximum allowable wire length and gauge recommended to connect the switching contacts of the remote thermostat or control to the appropriate terminals on the terminal strip TABLE U WIRE GAUGE FOR REMOTE CONNECTION Wire Gauge Maximum Allowable Length 12 GA 100 ft 14 GA 16 GA 75 ft 50 ft 18 GA 30 ft When connecting a remote temperature controller to R and W on the terminal strip to cycle pool heater operation the pool heater s internal electronic temperature control should be set as an additional high limit control This will prevent problems between the set point of the remote temperature
98. y 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 Multiple air inlets for DirectAire systems may be combined if the guidelines in Combined Air Inlet Points are followed The air inlet pipe will be connected to a combustion air inlet cap as specified in this section Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation Air FIG 20 Vertical Horizontal Installation Illustration Sidewall Air Inlet The Sidewall Air Inlet Cap Kit is supplied as one of the DirectAire Vent Kits which must be ordered from the manufacturer This sidewall cap will supply combustion air for a single pool heater only FIG 21 Air Inlet Cap for Sidewall Termination Locate units as close as possible to sidewall where the combustion air supply system will be installed 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 instructions in this manual The combustion air inlet cap must be installed at least one foot 0 30m above ground level and above normal snow levels FIG 22 Vertical DirectAire Installation with Rooftop Combustion Air Vertical Rooftop Air Inlet The air inlet cap for the vertical roof top air inlet is supplied in the Vertical

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