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INSTALLATION AND SERVICE MANUAL
WARNING: Do not use
this pool heater if any part
has been under water. The
possible
damage
flooded pool heater can be
extensive
and
numerous safety hazards.
Any pool heater that has
been under water must be
replaced.
GAS HEATERS FOR COMMERCIAL
POOL APPLICATIONS
500,000 - 2,070,000 Btu/hr MODELS
Starting Serial #F0600187510
WARNING: Improper
installation,
alteration,
maintenance can cause
property damage, personal
injury, exposure to hazardous
materials or loss of life.
Refer
Installation
must be performed by a
to
a
qualified installer, service
agency or the gas supplier.
present
This pool heater contains
materials that have been
identified as carcinogenic,
or possibly carcinogenic,
to humans.
Save this manual for future reference.
adjustment,
service
or
to
this
manual.
and
service
CPE-I-S-10
WARNING:
If
information in this manual
is not followed exactly, a
fire or explosion may result
causing property damage,
personal injury or loss of
life.
– This appliance MUST
NOT be installed in any
location where gasoline or
flammable vapors are likely
to be present, unless the
installation
is
such
eliminate
the
probable
ignition of gasoline or
flammable vapors.
WHAT TO DO IF YOU SMELL
GAS
• Do not try to light any
appliance.
• Do not touch any electric
switch; do not use any
phone in your building.
• Immediately call your
gas supplier from a
neighbors phone. Follow
the
gas
supplier's
instructions.
• 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.
the
to
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Related Manuals for Lochinvar F0600187510
Summary of Contents for Lochinvar F0600187510
- Page 1 INSTALLATION AND SERVICE MANUAL GAS HEATERS FOR COMMERCIAL 500,000 - 2,070,000 Btu/hr MODELS Starting Serial #F0600187510 WARNING: Do not use this pool heater if any part has been under water. The possible damage flooded pool heater can be extensive present numerous safety hazards.
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Page 2: Table Of Contents
Commercial Pool Heaters Table of Contents General Product Information ......3 Special Instructions ........3 Unpacking . -
Page 3: General Product Information
Installation and Service Manual GENERAL PRODUCT INFORMATION Special Instructions This manual supplies information for the installation, operation and servicing of this pool heater. Read and understand this manual completely before installing the pool heater. Installation and service must be performed by a qualified service installer, service agency, or the gas supplier. - Page 4 Commercial Pool Heaters 5. If you smell gas, shut off the gas supply: • Do not try to light any appliance; • Do not touch any electrical switch; do not use any telephone in your building; • Immediately call your gas supplier from a neighbor’s telephone.
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Page 5: Product Identification
Installation and Service Manual PRODUCT IDENTIFICATION Figure 1A – Standard Horizontal Piping Loop Figure 1B – Optional Vertical Piping Loop... -
Page 6: Installation
Commercial Pool Heaters INSTALLATION This pool heater meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI Z21.10.3/CSA 4.3 standard for gas-fired water heaters. LOCATING POOL HEATER 1. Maintain all clearances from combustible construction when locating pool heater. -
Page 7: Freeze Protection
Installation and Service Manual TABLE - A COMBUSTIBLE FLOOR KITS Input Btu/hr 500,000 650,000 750,000 FREEZE PROTECTION Although this pool heater is CSA design certified for outdoor installations - such installations are not recommended in areas where the pool heater will be operated in the winter months and the danger of freezing exists. -
Page 8: Combustion Air Options
Commercial Pool Heaters INSTALLATION For convenience and flexibility, you can direct the combustion air inlet from either the back or right side of the pool heater. To arrange the combustion air inlet for side entry, follow the steps below. 1. Remove the metal panel from the pool heater’s side wall (see Figure 4). -
Page 9: Exhaust Fans
Installation and Service Manual 2. Outside Combustion Air, Using Ducts You can direct outside combustion air to this pool heater using two air ducts to deliver the air to the equipment room. Each of the two openings must have a minimum free area of one square inch per 2000 Btu input (11cm per kW). -
Page 10: Venting
Commercial Pool Heaters INSTALLATION VENTING General Information You must supply adequate combustion and ventilation air to this pool heater. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building... -
Page 11: Sidewall Vent Termination Clearances And Location
Installation and Service Manual Figure 12 – Vent Termination from Flat Roof 10' or Less from Parapet Wall Figure 13 – Vent Termination from Flat Roof More Than 10' from Parapet Wall Sidewall Vent Termination Clearances and Location Locate the bottom of the vent terminal at least 12 inches (30cm) above grade and above normal snow levels. -
Page 12: Combustion Air Inlet Piping
Commercial Pool Heaters Combustion Air Inlet Piping WARNING: Locate and install the combustion air inlet cap correctly. Failure to do so can allow the discharge of flue products to be drawn into the combustion process. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. -
Page 13: Vertical Rooftop Air Inlet
Installation and Service Manual Figure 14 – Sidewall Combustion Air Inlet Figure 15 – Air Inlet Cap for Sidewall Termination To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance requirements in the latest edition of the National Fuel Gas Code and/or CAN/CGA-B149 Installation Code and instructions in the Installation and Service Manual. -
Page 14: Vent System Options
Commercial Pool Heaters INSTALLATION Vent System Options This pool heater has six venting options. 1. Conventional Negative Draft Venting This option uses a vertical rooftop flue termination. Combustion air is supplied from the equipment room. 2. Vertical DirectAire™ Venting This option uses a vertical conventional vent for flue products. Combustion air is supplied by a pipe from the sidewall or rooftop. - Page 15 Installation and Service Manual Connect the flue vent directly to the flue outlet opening on the top of the pool heater. No additional draft diverter or barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the specified range of 0.02 to 0.08 inches w.c.
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Page 16: 2. Vertical Directaire™ Venting
Commercial Pool Heaters INSTALLATION Masonry Chimney Installations A masonry chimney must be properly sized for the installation of a high efficiency gas-fired pool heater. Venting of a high efficiency pool heater into a cold or oversized masonry chimney can result in operational and safety problems. -
Page 17: Sidewall Venting
Installation and Service Manual Figure 20 – Vertical DirectAire Installation with Rooftop Combustion Air Inlet Vent Kits WARNING: Only use a sidewall air inlet cap supplied by the appliance manufacturer or a rooftop air inlet cap supplied by the vent manufacturer. Using any other air inlet cap for single-unit installations or using a common air inlet cap for multiple units with insufficient free area and/or... - Page 18 Commercial Pool Heaters INSTALLATION Sidewall Fan The sidewall fan can be mounted on the inside/outside (depending upon model) with a sidewall vent hood installed on the exterior wall. The sidewall fan and accessories are included in a venting kit provided by the appliance manufacturer. See TABLE–E for kit numbers.
- Page 19 Installation and Service Manual 4’ MIN. Figure 22 – Sidewall Venting WARNING: Do not combine the flue from this unit with the vent from any other appliance. Do not combine flues from multiple appliances into a common vent. The flue from this unit must be a dedicated stack.
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Page 20: Horizontal Directaire™ Venting
Commercial Pool Heaters INSTALLATION TABLE-E Sidewall Vent Kits Kit* Input Max. Vent Termination Only (w/Power Btu/hr Length (500,000 - 750,000 Fan Assy.) 500,000 SVK3006 100 ft. 650,000 SVK3008 100 ft. 750,000 SVK3008 100 ft. 990,000 SVK3053 100 ft. 1,260,000 SVK3054 100 ft. -
Page 21: Direct Venting
Installation and Service Manual TABLE-F Horizontal DirectAire™ Kits Input Kit* Btu/hr 500,000 HDK3031 650,000 HDK3032 750,000 HDK3032 990,000 HDK3037 1,260,000 HDK3038 1,440,000 HDK3038 1,800,000 HDK3039 2,070,000 HDK3039 *These kits include a sidewall venter assembly, vent termination, DV box adapter, sidewall air inlet cap, and a barometric damper. See note on page 12 concerning DV box adapter. - Page 22 Commercial Pool Heaters INSTALLATION Masonry Chimney Installation Do not use a standard masonry chimney to directly vent the combustion products from this pool heater. To use a masonry chimney, the chimney must use a sealed, corrosion-resistant liner system. Sealed, corrosion-resistant liner systems (singlewall, doublewall, flexible, or rigid) must be rated for use with a high efficiency, positive pressure vent system.
- Page 23 Installation and Service Manual In cold climates, use a Type-B doublewall vent pipe or an insulated single wall pipe for combustion air. This will help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe. CAUTION: Pool heaters that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe.
- Page 24 Commercial Pool Heaters INSTALLATION 3. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe. 4. Ensure that the air inlet pipes are properly supported. WARNING: Properly seal all joints and seams in the inlet vent piping system.
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Page 25: Outdoor Installation Venting
Installation and Service Manual Vertical Combustion Air Inlet Clearances You must locate the air inlet termination elbow at least 12" (30cm) above the roof or above normal snow levels. If the air inlet cap is within a 10 foot (3.05m) radius of the flue outlet, the point of termination for the combustion air inlet cap must be at least 3 feet (0.91m) below the point of flue gas termination (vent cap). -
Page 26: Connecting To Gas Supply
Commercial Pool Heaters INSTALLATION TABLE H Outdoor Vent Cap Kits Input Outdoor Vent Kit* Btu/hr 500,000 ODK3075 650,000 ODK3076 750,000 ODK3076 990,000 ODK3077 1,260,000 ODK3078 1,440,000 ODK3079 1,800,000 ODK3080 2,070,000 ODK3080 * These kits include an outdoor vent cap and gasket. Flue gas condensate can freeze on exterior walls or on the vent cap. -
Page 27: Gas Piping
Installation and Service Manual Gas Piping To safely operate this pool heater, you must properly size the gas supply piping. See Tables- J and K for piping and fitting requirements. Gas pipe size may be larger than pool heater connection. On models 500,000 - 750,000 Btu/hr the gas connection to the pool heaters are 1 1/4"... -
Page 28: Combination Gas Valves
Commercial Pool Heaters INSTALLATION Figure 29 shows a typical pool heater gas train. Figure 29 – Typical Pool Heater Gas Train Drawing TABLE-J Suggested Gas Pipe Size for Single Unit Installations Distance From Meter (in feet) Btu/hr Input 0-50 51-100 101-200 201-300 301-500 500,000 1 1/4"... - Page 29 Installation and Service Manual 13. Remove the manometer and related fitting from the “inlet” side of the gas valve, replace 1/8" hex plug in the gas valve and tighten. 14. Turn on the gas supply at the manual valve, turn on L.P. gas at the tank if required.
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Page 30: Gas Manifold Pressure Adjustment
Commercial Pool Heaters INSTALLATION Gas Manifold Pressure Adjustment IMPORTANT: The gas valves are referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the front inside portion of the jacket. -
Page 31: Pool Heater Piping Installation
Installation and Service Manual TABLE-L Net Manifold Pressure 500,000 – 750,000 Natural Gas LP Gas 990,000 – 2,070,000 Natural Gas LP Gas * Net Manifold Pressure equals the measured manifold pressure minus the chamber pressure. See Figure 31 to measure the Net Manifold Pressure. POOL HEATER PIPING INSTALLATION Install piping from the filter system to the pool heater as shown in... -
Page 32: Manual Operation Of The 3-Way Valve Actuator
Commercial Pool Heaters INSTALLATION Continued Note: If the wing nut underneath the valve actuator body is loose, retighten. 9. Reinstall the plastic actuator cover and secure with the screw loosened in Step 2. 10. Place the valve cover (JKD6653) over the 3-way automatic bypass valve. - Page 33 Installation and Service Manual MODEL NO. CP (N,L) 501 - 751 CP (N,L) 991 - 2071 20' MAXIMUM Figure 34 - Heater is Within 15 Feet of Pool Piping MODEL NO. BYPASS PIPE SIZE CP (N,L) 501 - 751 2” MINIMUM 2 1/2”...
- Page 34 Commercial Pool Heaters INSTALLATION MODEL NO. BYPASS PIPE SIZE CP (N,L) 501 - 751 CP (N,L) 991 - 2071 COPPER OR CPVC (SEE TABLE) Figure 36 - Heaters are within 15 feet Perpendicular of Pool Piping MODEL NO. CP (N,L) 501 - 751 CP (N,L) 991 - 2071 TO POOL Figure 37 - Heaters are Beyond 15 feet of Pool Piping...
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Page 35: Relief Valve
Installation and Service Manual 110° LIMIT TO POOL Figure 38 - Multi-Stack Frame - Heaters are Beyond 15 feet from Pool Piping Relief Valve This pool heater is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV. The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. -
Page 36: Pump Purge Delay Option
Commercial Pool Heaters INSTALLATION Ensure that the pump installed on the pool heater will supply adequate flow to make the flow switch contacts and operate the pool heater. A water flow switch meets most code requirements for a low-water cut off device on appliances requiring forced circulation for operation. -
Page 37: Terminal Strip Connection Options
Installation and Service Manual Figure 39 - Control Panel Component Location Drawing TABLE-M Remote Wire Connection Wire Gauge Allowable Length 12 GA 14 GA 16 GA 18 GA Terminal Strip Connection Options The scenarios shown in Figures 40 A - C represent typical terminal strip connection requirements. -
Page 38: Operation
Commercial Pool Heaters INSTALLATION Figure 40 (A-C) - Terminal Strip Connection OPERATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. -
Page 39: To Turn Off Gas To Pool Heater
Installation and Service Manual Figure 42 – ON/OFF Switch 8. Turn the manual gas cock clockwise ; to the “OFF” position. 9. Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow What To Do If You Smell Gas in the safety information. -
Page 40: Operating Temperature Control
Commercial Pool Heaters OPERATION Continued Figure 44 – Vertical Pool Heater Piping Figure 45 – Horizontal Pool Heater Piping OPERATING TEMPERATURE CONTROL The pool heater is equipped with a microprocessor based adjustable digital temperature control to provide ON/OFF operation. The temperature control is located behind the overlay on the front of the control panel. -
Page 41: Programming Mode
Installation and Service Manual By pressing the Select key, the Pool Target is shown and the text TARGET on the display. This is the pool temperature set point. By pressing the Select key again, the Boiler Inlet Temperature is shown, indicated by the text Boil In. This is the temperature of the water going into the pool heater. -
Page 42: Hot Surface Ignition System
This unit has one ignition module and one hot surface igniter. CAUTION: The igniter is extremely fragile, be very careful when removing. A faulty or damaged hot surface igniter MUST BE replaced with a Lochinvar PLT3400 igniter. DO NOT use general purpose field replacement igniters. -
Page 43: Operation And Diagnostic Lights
Installation and Service Manual TABLE-N Ignition Control Diagnostic Codes Code Sequence Condition Constant ON System OK, no faults present. Constant OFF Possible control fault, check power; replace control sequences function TroubleShooting Guide. One Flash Low Air, check air pressure switch and hoses to pressure sensing points, fan, venting chamber. -
Page 44: Water Chemistry
Commercial Pool Heaters OPERATION Continued OPERATION AND DIAGNOSTIC INDICATORS The control panel has up to six indicating and diagnostic lights to show all major steps of operation and control sensed malfunctions. There are display indicators on the Operating Temperature Control that give status information as well. -
Page 45: Pipe Size Requirements
Installation and Service Manual Refer to Circulating Pump on page 46 for information relating to pump wiring. TABLE-P AMP Draw Data Btu/Hr Controls Fans Pump Input 500,000 650,000 750,000 990,000 1,260,000 1,440,000 1,800,000 2,070,000 Pipe Size Requirements The pipe sizing chart provides the minimum pipe size for common manifold piping to ensure adequate flow. -
Page 46: Circulating Pump
Commercial Pool Heaters OPERATION Continued Circulating Pump 1. This pool heater is factory supplied with a properly sized pump that circulates water between the pool heater and system. 2. The pump is sized to pool heater input and water hardness. See Water Chemistry on page 44. -
Page 47: Cleaning And Maintenance
Installation and Service Manual CLEANING AND MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing. CAUTION: Label disconnection when servicing controls. Wiring errors cause improper operation. Appliance Area Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids. -
Page 48: Burner Removal And Cleaning
Commercial Pool Heaters CLEANING AND MAINTENANCE Continued Burner Removal and Cleaning 1. Turn “OFF” the main power to the pool heater. 2. Turn “OFF” the main manual gas shutoff to the pool heater. 3. Remove the front outer jacket panels. 4. -
Page 49: Adjusting Differential Air Pressure
Installation and Service Manual Combustion Air Fans Both the 500,000 - 750,000 Btu/hr models and the 990,000 - 2,070,000 Btu/hr models use a fan-assisted combustion process. The 500,000 - 750,000 Btu/hr models have one fan and the 990,000 - 2,070,000 Btu/hr models use two fans to supply combustion air to the burners. -
Page 50: Adjustment Procedure
Commercial Pool Heaters CLEANING AND MAINTENANCE Continued If the air pressure switch does not make within 60 seconds from the time the fans turn ON, the ignition module will go into a soft lockout period (approximately 5 minutes in duration) during which time the fans are turned off and the module shows the Low Air flash code. -
Page 51: Energy Saving Recommendations
Installation and Service Manual ENERGY SAVING RECOMMENDATIONS 1. Keep the pool covered when not in use. This will cut heating cost, reduce water evaporation, conserve chemicals and reduce load on the filtering system. 2. Reduce pool thermostat to 78°F or lower. 3. -
Page 52: Glossary
Commercial Pool Heaters GLOSSARY POWER SUPPLY 120VAC/60Hz/1PH power connects to black (line) and white (neutral) wires located within an electrical wiring box located on the left side of the pool heater. A green chassis grounding wire is also provided for connection to earth ground. ON/OFF ROCKER SWITCH The black line voltage wire runs directly to a single pole, single throw On/Off rocker switch located behind the front cover accessible by a... - Page 53 Installation and Service Manual IGNITER WARM-UP AND PROVING (Ignition Module Function) Once the ignition module has completed its prepurge period, it turns on the hot surface igniter. Once the hot surface igniter’s current draw reaches a proper level, the ignition module begins an additional period of approximately 25 seconds for the igniter to ensure the ignition temperature is attained to ignite the fuel/air mixture.
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Page 54: Wiring Box Connections
Commercial Pool Heaters WIRING BOX CONNECTIONS SENSOR CONNECTOR AC POWER BR/W CONNECTOR BR/W 1 2 3 4 BR/W Outlet Inlet Sensor Sensor BL/BK BL/BK 25' X 2 18AWG BL BL ~~~~ ~~~~ 110°F REMOTE POOL HI-LIMIT FIELD INSTALLED POOL SUPPLY RETURN SENSOR FIELD INSTALLED... - Page 55 Installation and Service Manual WIRING BOX CONNECTIONS MAIN UNIT CONNECTOR IGNITER CONNECTOR O/BK STAGE #1 O/BK LOW GAS 501-2071 MAIN UNIT CONNECTIONS LWCO BK or R BK R W G O/BK BLOWER 501 -2071 STAGE #1 AIR SW BURNER GROUND 651 -2071 501 -2071 CHASSIS...
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Page 56: Ladder Diagram
Commercial Pool Heaters LADDER DIAGRAM OPTIONAL ALARM INPUT 4 MAN. RESET AUX. HI-LIMIT ADJ. HI-LIMIT PROBE TEST SWITCH O.C. RESET PR PR HIGH OPTIONAL HIGH-LOW GAS PRESSURE SWITCHES FIELD CONNECTION FOR REMOTE OPERATOR BR/W O/BK 1C 1NO FLOW SWITCH O/BK FIELD INSTALLED SAFETY DEVICES CONTINUOUS INTERMITTENT... -
Page 57: Control Box Connections
Installation and Service Manual CONTROL BOX CONNECTIONS O/BK R/BK SERVICE- OPTIONAL BR/W BR/W MAINT... -
Page 58: Appendix A_Unit Start Up Checklist
Commercial Pool Heaters Appendix A Unit Start Up Checklist Ensure that the location and installation of the equipment is in accordance with the installation manual, all local installation requirements, and with the latest edition of the National Fuel Gas Code, ANSI 223.1 and/or CAN/CGA-B149 Installation Code. 1. -
Page 59: Advanced Settings
This setting is used to control the responsiveness of the 3-way automatic bypass valve, and should only be adjusted under the direction of Lochinvar’s Technical Services personnel. The default setting is 20 seconds. By pressing the Select key again, the pump Delay setting is displayed, indicated by the DLY on the display. -
Page 60: Revision Notes
Lochinvar Corporation • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax 615-547-1000 www.Lochinvar.com Revision Notes: Revision 6 (CPE-i&s-06) reflects changes made to LBL2296. Revision 7 (CPE-i&s-07) reflects changes made to the pressure switch, page 50. Revision 8 (CPE-i&s-08) reflects deletion of Table P and changes to associated paragraph on pages 44 &...
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