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Installation and
Operation Manual
240 VAC NATURAL GAS/LP GAS
MODELS
200HD (200 MJ/h)
300HD (300 MJ/h)
400HD (400 MJ/h)
FOR YOUR SAFETY – This product must be installed and serviced
by authorized personnel, qualified in pool/spa heater installation.
Improper installation and/or operation can create carbon monoxide
gas and flue gases which can cause serious injury, property damage,
or death. As an additional measure of safety, Pentair Water Pool and
Spa, Inc. strongly recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this heater. Improper installation
and/or operation will void the warranty.
FOR YOUR SAFETY - READ BEFORE OPERATING
!
WARNING
• If you do not follow these instructions exactly, a fire or explosion may result, causing
• Improper installation, adjustment, alteration, service or maintenance can cause
• Do not place articles or against this appliance.
• Do not use or store flammable materials near this appliance.
• Do not spray aerosols in the vicinity of this appliance while it is in operation.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone.
• If you cannot reach your gas supplier, call the fire department.
Natural
Propane
270201
270202
270301
270302
270401
270402
property damage, personal injury or loss of life.
property damage, personal injury or death. Installation and service must be performed
by a qualified installer, service agency or the gas supplier.
Follow the gas supplier's instructions.
www.waterco.com
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Table of Contents
Troubleshooting
Related Manuals for Waterco Turbotemp 200HD
Summary of Contents for Waterco Turbotemp 200HD
- Page 1 • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. www.waterco.com...
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Page 2: Table Of Contents
Section 1. Heater Identification ....2 Corrosive Vapors and Possible Causes ..28 Information (HIN) Control Panel Indexing ....... 29 Heater Data Rating Plate ......2 Final Installation Check ......29 Electrical Connections ....... 29 Section 2. Introduction ......3 Fireman’s Switch Connection/ .... -
Page 3: Section 1. Heater Identification
4. Fuel Type : (LP = Propane gas or N = Natural gas) H. I. N. HEATER IDENTIFICATION NUMBER ID DESIGNATOR FOR WATERCO WATER POOL & SPA TURBOTEMP HEATERS Example: = NATURAL GAS FUEL TYPE = LP = PROPANE GAS... -
Page 4: Section 2. Introduction
If you need more information or if you have any questions regarding to this pool heater, please contact. Waterco Limited - Offices Australia NSW - Sydney (HEAD OFFICE) VIC/ TAS - Melbourne... -
Page 5: Warranty Information
The Turbotemp pool heater is sold with a limited factory warranty. Specific details are described in the Waterco Warranty Terms and Conditions booklet included with the product. Waterco pool and spa’s high standards of excellence include a policy of continuous product improvement resulting in your state-of-the-art heater. We reserve the right to make improvements which change the specifications of the heater without incurring an obligation to update the current heater equipment. -
Page 6: Consumer Information And
CONSUMER INFORMATION AND SAFETY WARNING The U.S. Consumer Product Safety Commission warns that carbon monoxide is an “invisible killer”. Carbon monoxide is a colorless and odorless gas. 1. Carbon monoxide is produced by burning fuel, including natural gas and propane. 2. -
Page 7: Safety Information
Install this pool heater far from open windows, doors, vents and other openings, see page 16 for minimum distances. Waterco strongly recommends that all vents, pipes and exhaust systems be initially and periodically tested for proper operation. This testing can be accomplished by using a hand-held carbon monoxide meter and/or by consulting with a gas professional. -
Page 8: Section 3. Installation
Any additions, changes, or conversions required in order for the appliance to satisfactorily meet the application needs must be made by a Waterco dealer or other qualified agency using factory specified and approved parts. The heater is available for use with natural gas or LP (propane) gas only. - Page 9 Section 2. Introduction I pg 08 Label all wires prior to disconnection when servicing controls. Wiring CAUTION errors can cause improper and dangerous operation. Wiring errors can also destroy the control board. • Connect heater to 240 Volt, 50 Hz., Single Phase power only. •...
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Page 10: Heater Description
THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED IN POOL HEATER INSTALLATION. Waterco strongly recommends that all vents, pipes and exhaust systems be initially and periodically tested for proper operation. This testing can be accomplished by using a hand- held carbon monoxide meter and/or by consulting with a gas professional. -
Page 11: Sequence Of Operation
Section 3. Installation I pg 10 SEQUENCE OF OPERATION An electronic temperature sensing thermistor in the manifold adapter inlet controls the heater operation. When the inlet water temperature drops below the temperature set on the operating control, the burner controller supplies power to the combustion air blower through a series of safety interlocks. -
Page 12: Specifications
SPECIFICATIONS These installation instructions are designed for use by qualified personnel only, trained especially for installation of this type of heating equipment and related components. Some states require installation and repair by licensed personnel. If this applies in your state, be sure your contractor bears the appropriate license. -
Page 13: Plumbing Connections
The Turbotemp heater has the unique capability direct schedule PVC plumbing connections. A set of bulkhead fittings is included with the Turbotemp to insure conformity with Waterco’s recommended PVC plumbing PUMP POOL procedure. Other plumbing connections POOL HEATER FILTER MANUAL can be used. -
Page 14: Water Connections
WATER CONNECTIONS The heater requires proper water flow and pressure for its operation. See Figure 5 for the recommended installation. The filter pump discharges to the filter, the filter discharges to the heater, and the heater discharges directly to the pool or spa. A manual bypass valve should be installed across the heater when the pump flow exceeds 454 LPM (120 GPM). -
Page 15: Gas Connections
Section 3. Installation I pg 14 FLOW SWITCH If the heater is installed more than 1.5 m above the pool or more than 1.2 m below the pool level, you will be beyond the limits of the pressure switch and a flow switch must be installed. -
Page 16: Gas Pipe Sizing
GAS PIPE SIZING Table 2. Distance from the Meter Heater Size 0 to 15 m 16 to 30 m 31 to 60 m 25 mm 32 mm 32 mm 32 mm 32 mm 40 mm 32 mm 40 mm 50 mm SEDIMENT TRAP/DRIP LEG Install a sediment trap/drip leg and union located outside the heater panels... -
Page 17: Gas Pressure Requirements
Section 3. Installation I pg 16 8. Shut off the gas supply to the heater. 9. Disconnect the manometer hose. 10. Tighten the small screw inside the pressure tap. 11. Open the gas supply to the heater. 12. Verify that the seal connection in the pressure tap is closed by testing for leaks with soapy water. -
Page 18: Heater Clearances
OUTDOOR INSTALLATION (Australia) BASE FOR USE ON COMBUSTIBLE FLOORS Figure 8. Locate the heater in an open, unroofed area and on a level surface that is protected from drainage or run-off. Install the heater in an area where leaves or other debris will not collect on or around the heater. -
Page 19: Indoor Venting-General Requirements
Section 3. Installation I pg 18 CAUTION If installing the heater next to or near an air conditioning unit or a heat pump, allow a minimum of 91.4 cm (36 in.) between the air conditioning unit and the heater. Figure 11. WARNING Risk of fire and explosion. - Page 20 HEATER CLEARANCES — General Requirements INDOOR INSTALLATION AND OUTDOOR SHELTER The following clearances must be maintained from the nearest walls: (See Figure 12 and Figure 12a) TOP ......15 cm. (6 in) EXHAUST SIDE ..15 cm (6 in.) HEADER SIDE ... 15 cm (6 in.) DOOR PANELS* ..
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Page 21: Combustion Air Supply / Corrosive
NZS 5601.1 as applicable, and any local codes that may apply. These openings shall directly, or through duct, connect to outdoor air. Waterco Limited does not recommend indoor installations that do not provide combustion air from outside the building. Air Supply Requirement Guide for Turbotemp Heaters... - Page 22 Combustion 3 in. PVC Pipe Inlet Air Intake Duct Requirements* Combustion Air Intake 3 in. Pipe (Vertical or Horizontal) No. of 90° Elbows Maximum Length in Feet (M) 70 ft. (21.3 M) 58 ft. (17.7 M) 46 ft. (14.0 M) 34 ft.
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Page 23: Corrosive Vapors And Possible Causes
Section 3. Installation I pg 22 NOTE Each 90-degree elbow reduces the maximum horizontal PVC air intake duct run by 3.6 metres and each 45-degree elbow in the PVC air intake duct run reduces the maximum run by 1.8 metres. See the Table 5 above for the maximum lengths using 90-degree elbows. -
Page 24: Vent Installation
VENT INSTALLATION – INDOOR INSTALLATION OR OUTDOOR SHELTER NOTE *: Vent must be at least 2.4 Flueing must be in accordance with AS/NZS 5601.1 m (8 ft) away from nearest vertical surface. Vents extending 1.5 m (5 ft) or Always vent the heater to the outdoors, see Note*. more above the roof must be braced or guyed. - Page 25 Section 3. Installation I pg 24 Table 6. – Permitted Minimum and Maximum Vent Heights By Size and Heater Model Double-Wall Vent with Double-Wall Connector in Meters (Feet) Model 200 Model 300 Model 400 Vent Size Height min./max. Height min./max. Height min./max.
- Page 26 2. Install the metal Flue Collar in the Vent Body of the heater (located under the outside vent cover). Fasten the metal Flue Collar to the Vent Body with two #10 sheet metal screws. Use high temperature silicone RTV to seal the Flue Collar to the Vent Body.
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Page 27: Horizontal Or Vertical Venting - Using
Section 3. Installation I pg 26 5. Use approved fire stop for floor and ceiling penetrations. Use approved thimble for wall penetrations. Use a approved roof flashing, roof jack, or roof thimble for all roof penetrations. Do not fill the space around the vent (that is, the clear air space in the thimble or fire stop) with insulation. -
Page 28: Connecting Single-Wall Stainless
After installation, installer must check for correct and safe operation of the heater. CONNECTING SINGLE-WALL STAINLESS STEEL VENT TO THE HEATER Metallic: 1. Order an optional appliance adapter kit, (Waterco offers optional appliance adapter kits, call our Customer Service dept.): - Part No. 6844320 150mm Flexible Duct Exhaust Double Wall Metal 2. - Page 29 Section 3. Installation I pg 28 4. Install vent pipe so that it can expand and contract freely as the temperature changes. Support the vent pipe according to applicable codes and vent manufacturer’s instructions. Pipe support must allow the vent pipe free movement out and back, from side to side, or up and down as necessary, without putting a strain on the heater or vent body.
- Page 30 8. Vent Termination – Horizontal The terminal must be located (See Figure 17): • at least 76 mm (3 in) and at most 304 mm (12 in) out from the wall (see Figure 18), following the vent manufacturer’s instructions • at least 304 mm (12 in) above finished grade or the normally expected snow accumulation level, whichever is higher •...
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Page 31: Horizontal Or Vertical Venting Flexible
Section 3. Installation I pg 30 HORIZONTAL OR VERTICAL VENTING FLEXIBLE DUCT (FLEX-VENT) (See Figures 15, 16, 17 & 19) Table 8. NOTE: THE ALLOWABLE VENT RUNS 150 mm (6 in.) Flex-Vent FOR EACH VENT PIPE DIAMETER (Vertical or Horizontal)* ARE DIFFERENT AND CAN NOT BE No. -
Page 32: Control Panel Indexing
CONTROL PANEL INDEXING On an outdoor shelter installation, the exhaust discharges into Top Panel a vent pipe. Orient the heater so that the vent pipe does not Door Access interfere with adjustment of the operating controls. The control Panel panel located on the top panel can be rotated to any of the three sides of the heater for easy access, see Figure 20. - Page 33 Section 3. Installation I pg 32 Please read the boxes headed “IMPORTANT! READ ME FIRST!” on pages 40 and 44 before proceeding. 1. All wiring must be in accordance with all applicable codes and must be wired by a licensed electrician to AS3000 Wiring rules.
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Page 34: Remote Control Connections
REMOTE CONTROL CONNECTIONS 1. Switch off power to heater at main circuit breaker panel. 2. Unbolt and remove the access door panels. 3. Open control box cover (see Figure 23). 4a. To connect a 2-Wire Control (such as the Pentair Water Pool and Spa IntelliTouch™ or EasyTouch™) or a timer: - Remove the factory installed jumper from the Fireman’s Switch terminals. -
Page 35: Turbotemp Wiring Diagram
Section 3. Installation I pg 34 TURBOTEMP WIRING DIAGRAM (3-WIRE SYSTEM) CONNECTION DIAGRAM Inlet Temperature Control Switch and AGS Switch Air Flow Switch Stack Flue Sensor Extra Switch 1 Gas Valve Y/BL Hi-Limit Switch Pressure Switch NA/LP Models Only Y/BL OPERATING CONTROL MEMBRANE PAD CONNECTION... -
Page 36: Ladder Diagram
TURBOTEMP ELECTRICAL SCHEMATIC LADDER DIAGRAM LADDER DIAGRAM IGNITER BLOWER CLASS II TRANSFORMER 24 VAC OPERATING CONTROL 24 VAC 24 VAC FLOW LOGIC SWITCH WATER LIMIT PRESSURE SWITCH SWITCH COM NO INLET TEMPERATURE SWITCH CONTROL SWITCH GAS VALVE STACK FLUE THERMISTOR SENSOR SENSOR NOTES:... -
Page 37: Section 4. Operation
Section 4. Operation I pg 36 OPERATION INSTRUCTIONS BASIC SYSTEM OPERATION Start pump, make sure the pump is running and is primed, to close the water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. Follow the Lighting/Operating instructions below. -
Page 38: Operating Instructions
F. Before operating the appliance for the first time or after it has been off for an extended time, perform the following checklist: 1. Remove debris or other articles from inside the heater and the area around the heater and its exhaust vent. -
Page 39: To Turn Off Gas To Appliance
Section 4. Operation I pg 38 14. If the appliance will not operate, follow the instructions below “TO TURN OFF GAS TO THE APPLIANCE”, and call your service technician or gas supplier. 15. If the electrical power is lost while the heater is running, the heater will retain all program settings and the unit will come back to it’s original mode and settings once the power is restored. -
Page 40: Operation Of Ignitiion Module)
Turn star wheel clockwise to raise pressure set point if pressure switch is more than 1.2M (4 ft.) below water level Star Wheel A reference scale is on the back of pressure switch Turn star wheel counterclockwise to lower pressure set point if pressure switch is more Figure 30. -
Page 41: Operating The Control Panel
Section 4. Operation I pg 40 OPERATING THE CONTROL PANEL The five operating switches are: POOL ON Press this button to govern heater operation by the pool temperature setting. SPA ON Press this button to govern heater operation by the spa temperature setting. -
Page 42: Temperature Setting / Maximum
TEMPERATURE SETTING The heater comes factory set at 25.6° C (78° F). for the pool mode and 37.8° C (100° F). for the spa mode. Using the up and down arrows, you can set the pool/spa thermostats to a minimum temperature of 18.3°... - Page 43 Section 5. Troubleshooting I pg 42 TROUBLESHOOTING INSTRUCTION Initial Troubleshooting Only qualified, trained service technicians with appropriate test equipment should service the heater. Remember that all parts of the system affect heater operation. Before starting this troubleshooting procedure, make sure that the pump is running correctly, that there are no blockages in the system, that the valves are correctly set and that the time clock is correctly set and is running.
- Page 44 Heater Will Not Fire - A Start Depress “POOL” or “SPA” ON Heater should fire on demand Is green “SPA” or button on Membrane Pad. for heat. “POOL” LED “on” Does “POOL” or “SPA” LED come on? Check that the 12-pin Check for line voltage to Restore power to heater.
- Page 45 Section 5. Troubleshooting I pg 44 Heater Will Not Fire - B Start Increase POOL/SPA Is red “SERVICE Is red “SERVICE SYSTEM” temperature setting on HEATER” LED “on” LED on? Membrane Pad above actual water temperature. Heater should fire on demand for heat. Verify that pump is on, filter is If not, and no other red LED’s not blocked, and the water...
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Page 46: Section 5. Troubleshooting
Heater Will Not Fire - C Start Is “SERVICE HEATER” LED Go to “INITIAL “on”? TROUBLESHOOTING” Turn off power to Continue to observe heater for heater for 5 seconds, several minutes. Cycle heater and turn back on. on and off several times. Make sure temperature Observe for delayed or rough setting is above... - Page 47 Section 5. Troubleshooting I pg 46 Heater Will Not Fire - D IMPORTANT! READ ME FIRST! IMPORTANT! READ ME FIRST!! If your heater is correctly connected to 240 Volts AC, the Ignition Control Module (ICM) will convert the 240VAC to an intermittent pulse to the ignitor. Digital meters don’t read this type of signal well. (An analog meter will give a better reading than a digital meter).
- Page 48 Diagnostic LED’s: AGS, AFS, HLS, PS, THERMISTOR Verify that water flow rate is Service pump and filter to AGS or HLS "on" above minimum required for restore proper flow. After ser- heater. vicing, verify proper operation Replace High Limit of Pressure Switch (PS). Switch (HLS) or Automatic Gas Verify that inlet water temper-...
- Page 49 Section 5. Troubleshooting I pg 48 Diagnostic LED’s: SFS SFS "on" Check Heat Exchanger Coil for leaks, liming, soot, or low flow. Heater starts and runs OK, but temperature of exhaust Check Thermal climbs to 204°–260°C in Regulator: Open at 3-5 minutes.
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Page 50: (Ags, Afs, Hls, Ps Thermistor) Burner / Heat Exchanger Troubleshooting
Burner Troubleshooting SYMPTOM CAUSE REMEDY Loud, high-pitched Flame is too rich. Verify pressure tap between gas valve and whine blower inlet. Verify that the gas regulator setting is 11 ± 5 Pa. Contact a qualified technician or service agency to replace the gas orifice. Flame is “fluttery .”... -
Page 51: Section 6. Maintenance
Section 6. Maintenance I pg 50 MAINTENANCE INSTRUCTIONS CARE AND MAINTENANCE WARNING Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, varnishes, paints, or other volatile flammable liquids near heater or in the same room with heater. -
Page 52: Pressure Relief Valve
PRESSURE RELIEF VALVE Local codes may require installation of a pressure relief valve (PRV). Purchase separately and install a 19 mm pressure relief valve complying with the local Plumbing Codes, having a capacity equal to the Mega Joule (MJ/hr) rating of the heater. The relief pressure of the valve MUST NOT EXCEED 344 kPa. -
Page 53: Winter Operation
Section 6. Maintenance I pg 52 WINTER OPERATION CAUTION Operating this heater continuously at water temperatures below 20° C (68° F.) will cause harmful condensation and will damage the heater and void the warranty. • If the heater has been drained for freezing condition, do NOT turn “ON” until the system is circulating water. -
Page 54: Maintaining Pool Temperature
CHEMICAL BALANCE POOL AND SPA WATER Your Waterco pool heater was designed specifically for your spa or pool and will give you many years of trouble-free service, provided you keep your water chemistry in proper condition. Water chemistry should follow good swimming pool water chemistry practices. When using a chlorinator, install it down stream from the heater and at a lower level than the heater outlet. - Page 55 Section 6. Maintenance I pg 54 WHAT A DISINFECTANT DOES Two pool guests you do not want are algae and bacteria. To get rid of them and make pool water sanitary for swimming - as well as to improve the water’s taste, odor and clarity - some sort of disinfectant must be used.
- Page 56 ALKALINITY High or Low: “Total alkalinity” is a measurement of the total amount of alkaline chemicals in the water, and control pH to a great degree. (It is not the same as pH which refers merely to the relative alkalinity/acidity balance.) Your pool water’s total alkalinity should be 100 - 140 ppm to permit easier pH control.
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Page 57: Replacement Parts
(Key Nos. 8 through 9), see Page 43. Repair Parts are available from your Pentair dealer. Repair Parts are available from your Waterco Limited. If your dealer cannot supply you, call Customer Support If your dealer cannot supply you. Call Customer Support. - Page 58 TURBOTEMP REPLACEMENT PARTS CLAMP LID TUB DESIGN Lid Nut/Washer (9x) Combustion Chamber Gasket For heaters manufactured between 1/12/2009 and 10/31/2013 (clamp lid tub design) Note: Kits also include Clamp Assembly, O-Ring and Silicon Tube (see page 49)
- Page 59 Section 6. Maintenance I pg 58 TURBOTEMP REPLACEMENT PARTS REPAIR PARTS – BURNER SYSTEM Model Part 200NA 300NA 400NA Qty. Description 200LP 300LP 400LP Gas Valve Assembly [Australia] 474133Z 474133Z 474133Z 19 mm Union 38404-4097S 38404-4097S 38404-4097S Gas Orifice Gas Orifice O-Ring •...
- Page 60 TURBOTEMP REPLACEMENT PARTS REPAIR PARTS – WATER SYSTEM Model Part 200NA 300NA 400NA Description Qty. 200LP 300LP 400LP Tube Sheet Coil Assembly Kit (HD Series) (Includes Key No.3) 474062 474064 474065 Manifold Kit (Includes Key Nos. 3-14, 21, and Key Nos. 5-7, 17 in “Electrical System”, Page 51 474391 474392 474392...
- Page 61 Section 6. Maintenance I pg 60 TURBOTEMP REPLACEMENT PARTS REPAIR PARTS – ELECTRICAL SYSTEM Model Part 200NA 300NA 400NA Description QTY. 200LP 300LP 400LP Heater Display Cover 42002-0035 42002-0035 42002-0035 Igniter Bracket 42001-0030S 42001-0030S 42001-0030S Igniter/Igniter Gasket Kit Incl. Key Nos. 3 and 4) 77707-0054 77707-0054 77707-0054...
- Page 62 Tel : +65 6344 2378 Tel : +33 (0)4 72 79 33 30 ACT Distributor Waterco (NZ) Limited Tel : +61 2 6280 6476 Auckland, New Zealand Tel : +64 9 525 7570 Waterco Limited ABN 62 002 070 733 ZZM1439_02/2014...