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INSTALLATION AND SERVICE MANUAL
W W A A R R N N I I N N G G : 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
W W A A R R N N I I N N G G : Improper
installation,
alteration,
maintenance can cause
property damage, personal
injury,
hazardous
loss of life. Refer to this
manual. Installation and
service must be performed
to
a
by a qualified installer,
service agency or the gas
present
supplier. This pool heater
contains
have been identified as
carcinogenic, or possibly
carcinogenic, to humans.
Save this manual for future reference.
adjustment,
service
or
exposure
to
materials
or
materials
that
CPE-i&s-05
W W A A R R N N I I N N G G :
information in this manual
is not followed exactly, a
fire
or
explosion
result causing property
damage, personal injury or
loss of life.
– This appliance MUST
NOT be installed in any
location where gasoline or
flammable
vapors
likely to be present, unless
the installation is such to
eliminate
the
probable
ignition of gasoline or
flammable vapors.
WHAT TO DO IF YOU SMELL
GAS
• Do not try to light any
appliance.
• Do
not
touch
electric switch; do not
use any phone in your
building.
• Immediately call your
gas supplier from a
neighbors
Follow
the
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.
If
the
may
are
any
phone.
gas
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Summary of Contents for Lochinvar GAS HEATER FOR COMMERICAL POOL
- Page 1 INSTALLATION AND SERVICE MANUAL GAS HEATERS FOR COMMERCIAL 500,000 - 2,070,000 Btu/hr MODELS Starting Serial #F0600187510 W W A A R R N N I I N N G G : Do not use this pool heater if any part has been under water.
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Page 2: Table Of Contents
Commercial Pool Heaters T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s General Product Information ......3 Special Instructions . -
Page 3: General Product Information
Installation and Service Manual G G E E N N E E R R A A L L P P R R O O D D U U C C T T I I N N F F O O R R M M A A T T I I O O N N Special Instructions This manual supplies information for the installation, operation and servicing of this pool heater. - Page 4 Commercial Pool Heaters • 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. Follow the gas supplier’s instructions •...
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Page 5: Product Identification
Installation and Service Manual P P R R O O D D U U C C T T I I D D E E N N T T I I F F I I C C A A T T I I O O N N 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 I I N N S S T T A A L L L L A A T T I I O O N N CAUTION: Some pleated filters are too restrictive and could cause air flow problems. For convenience and flexibility, you can direct the combustion air inlet from either the back or right side of the pool heater. -
Page 9: Exhaust Fans
Installation and Service Manual Figure 7 – Outside Combustion Air - Two Openings 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 mechanical room. Each of the two openings must have a minimum free area of one square inch per 2000 Btu input (11cm Figure 8 –... -
Page 10: Venting
Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N V V E E N N T T I I N N G G General Information You must supply adequate combustion and ventilation air to this pool heater. -
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 I I N N S S T T A A L L L L A A T T I I O O N N Combustion Air Inlet Piping WARNING: Locate combustion air inlet cap correctly. Failure to do so can allow the discharge of flue products to be drawn into the combustion process. -
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 I I N N S S T T A A L L L L A A T T I I O O N N to the common air inlet. This exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 50 (15.2m) equivalent feet. - 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 I I N N S S T T A A L L L L A A T T I I O O N N problems. The temperature of the flue products from a high efficiency pool heater may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft. -
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. - Page 18 Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N 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.
- Page 19 Installation and Service Manual Figure 22A – Direct Vent (Illustration with Sidewall Vent and Sidewall Combustion Air) Figure 22B – 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.
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Page 20: 4. Horizontal Directaire™ Venting
Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N TABLE-E Sidewall Vent Kits Input Kit* Max. Vent Btu/hr (w/Power Length Termination Only Length Fan Assy.) (500,000 - 750,000 Btu/hr) 500,000... -
Page 21: Direct Venting
Installation and Service Manual For proper operation, a barometric damper is provided for Horizontal DirectAire installations. The damper will help to ensure a draft between negative 0.04 to 0.08 inches w.c. TABLE-F Horizontal DirectAire™ Kits Input Btu/hr Kit* 500,000 HDK3031 650,000 HDK3032 750,000... - Page 22 Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N 90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for each 45° elbow. Masonry Chimney Installation Do not use a standard masonry chimney to directly vent the combustion products from this pool heater.
- 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 I I N N S S T T A A L L L L A A T T I I O O N N 2. On horizontal runs, do not install vent pipe with seams pointing down. Position vent pipe so that the seams are on the top side of the vent pipe.
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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 I I N N S S T T A A L L L L A A T T I I O O N N TABLE-H Outdoor Vent Cap Kits Input Outdoor Vent Kit* Btu/hr 500,000 ODK3075 650,000 ODK3076 750,000 ODK3076... -
Page 27: Gas Piping
Installation and Service Manual 2. Isolate the pool heater from the gas supply piping system by closing a manual shutoff valve during any piping system pressure testing that is equal to or less than 1/2 PSIG (3.5kPa). 3. Test all gas connections for gas leaks before placing the pool heater in operation. -
Page 28: Combination Gas Valves
Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N 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 Btu/hr... - 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 I I N N S S T T A A L L L L A A T T I I O O N N 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 Nat. Gas 1.8" w.c. LP Gas 4.6" w.c. 990,000 - 2,070,000 Nat. Gas 1.2" w.c. LP Gas 4.6" w.c. * Net Manifold Pressure equals the measured manifold pressure minus the chamber pressure. -
Page 32: Manual Operation Of The 3-Way Valve Actuator
Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N Note: If the wing nut underneath the valve actuator body is loose, retighten. 9. - Page 33 Installation and Service Manual Figure 34 - Heater is Within 15 Feet of Pool Piping Figure 35 - Heater is Beyond 15 Feet of Pool Piping...
- Page 34 Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N Continued Figure 36 - Heaters are within 15 feet Perpendicular of Pool Piping Figure 37 - Heaters are Beyond 15 feet of Pool Piping...
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Page 35: Relief Valve
Installation and Service Manual Relief Valve Figure 38 - Multi-Stack Frame - Heaters are Beyond 15 feet from Pool Piping 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 I I N N S S T T A A L L L L A A T T I I O O N N Ensure that the pump installed on the pool heater will supply adequate flow to make the flow switch contacts and operate the pool heater. -
Page 37: Terminal Strip Connection Options
Installation and Service Manual Figure 39 - Control Panel Component Location Drawing TABLE-M Remote Wire Connection Wire Maximum Gauge Allowable Length 12 GA 100 ft 14 GA 75 ft 16 GA 50 ft 18 GA 30 ft TABLE–N Terminal Strip Connection Options The scenarios shown in Figures 40 A - C represent typical terminal strip connection requirements. -
Page 38: Operation
Commercial Pool Heaters I I N N S S T T A A L L L L A A T T I I O O N N 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... -
Page 39: To Turn Off Gas To Pool Heater
Commercial Pool Heaters Figure 42 – ON/OFF Switch 8. Turn the manual gas cock clockwise 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: Temperature Controller Error Messages
Installation and Service Manual pool return sensor has been installed and connected, this will be the temperature of the water coming from the pool. By pressing the Select key, the Pool Target is shown and the text TARGET on the display. This is the pool temperature set point. -
Page 42: Hot Surface Ignition System
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. Figure 47 – Hot Surface Igniter Figure 48 –... -
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. Possible control fault, check power; Constant OFF replace control if all operational sequences function TroubleShooting Guide. One Flash Low Air, check air pressure switch and hoses to pressure sensing points, fan, venting and sealing of pressurized 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. Figure –... - Page 45 Installation and Service Manual TABLE-P Recommended Water Chemistry 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.
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Page 46: Pipe Size Requirements
Commercial Pool Heaters OPERATION Continued Pipe Size Requirements The pipe sizing chart provides the minimum pipe size for common manifold piping to ensure adequate flow. TABLE-R Pipe Sizing Chart Number of Units 500,000 - 750,000 Btu/hr Models Number of Units 990,000 - 2,070,000 Btu/hr Models Circulating Pump 1. -
Page 47: High Water Temperature Limit Control
Installation and Service Manual WARNING: Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the pool heater. High Water Temperature Limit Control This pool heater is equipped with a fixed setting, auto reset high water temperature limit control that is screwed into the... -
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... - Page 53 Installation and Service Manual PREPURGE (Ignition Module Function) Once the ignition module sees a 24VAC input from its pressure switch, it runs the blowers for approximately 15 seconds in order to purge the combustion chamber of any unburned fuel/air mixture. IGNITER WARM-UP AND PROVING (Ignition Module Function) Once the ignition module has completed its prepurge period, it...
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Page 54: Wiring Box Connections
Commercial Pool Heaters WIRING BOX CONNECTIONS... - Page 55 Installation and Service Manual WIRING BOX CONNECTIONS...
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Page 56: Ladder Diagram
Commercial Pool Heaters LADDER DIAGRAM... -
Page 57: Control Box Connections
Installation and Service Manual CONTROL BOX CONNECTIONS... -
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. -
Page 59: Advanced Settings
SPEED on the overlay. This setting is used to control the responsiveness of the 3-way automatic bypass valve, and should only be adjusted under the direction of Lochinvar’s Technical Services personnel. seconds. - Page 60 Lochinvar Corporation • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax 615-547-1000 www.Lochinvar.com 6/06-Printed in U.S.A.
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