Lochinvar GAS HEATER FOR COMMERICAL POOL manual

INST ALLA TION AND SER VICE MANU AL Sav e this manual f or futur e reference.  W W A A R R N N I I N N G G : If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or loss of life. – This appliance MUST NOT be inst alled in any location where gasoline or flammable vap[...]

Commer cial P ool Hea ter s 2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Codes [...]

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 Instr uctions 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 [...]

• 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 • if you cannot reach your gas supplier, call the fire department 6. This appliance is a high efficiency pool heater whic[...]

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 Installa tion and Ser vice Manual 5 Figure 1B - Optional V ertical Piping Loop Figure 1A - S tandard Horizontal Piping Loop[...]

INST ALLA TION 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. L OCA TING POOL HEA TER 1. Maintain all clearances from combustible construction when locating pool heater . See Clearances fr om Combustibl[...]

FREEZE PRO TECTION Although this pool heater is CSA design certified for outdoor installations - such installations are not recommended in areas where the pool heater will be operated in the winter months and the danger of freezing exists. Proper freeze protection must be provided for outdoor installations; pool heaters installed in unheated mechan[...]

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  CA UTION : 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 . T o arrange the combustion air inlet for side entry , follow the steps [...]

Figure 7 – Outside Combustion Air - T wo Openings 2. Outside Combustion Air , Using Ducts Y ou 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 (1 1cm 2 per kW). Figure 8 – Outside Comb[...]

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 V V E E N N T T I I N N G G General Infor mation Y ou must supply adequate combustion and ventilation air to this pool heater . Y ou must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in t[...]

Figure 12 – V ent T ermination from Flat Roof 10' or Less from Parapet W all Figure 13 – V ent T ermination from Flat Roof More Than 10' from Parapet W all Sidewall V ent T er mination Clearances and Location Locate the bottom of the vent terminal at least 12 inches (30cm) above grade and above normal snow levels. Locate the bottom of[...]

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 Combustion Air Inlet Piping  WARNING : Locate and inst all the combustion air inlet cap correctly . Failure to do so can allow the discharge of flue product s to be drawn into the combustion process. This can result in incomplete combustion and potentially hazardous levels of carbon monox[...]

Figure 14 – Sidewall Combustion Air Inlet Figure 15 – Air Inlet Cap for Sidewall T ermination T o 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 [...]

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 to the common air inlet. This exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 50 (15.2m) equivalent feet. Subtract 5 feet (1.5m) for each 90° elbow in the air inlet pipe. Y ou must deduct[...]

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. If the draft in a dedicated stack for a single pool heater installation[...]

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 problems. The temperature of the flue products from a high efficiency pool heater may not be able to suf ficiently heat the masonry structure of the chimney to generate proper draft. This will result in condensing of flue products, damage to the masonry flue/tile, insufficient draft and poss[...]

Figure 20 – V ertical DirectAir e Installation with Rooftop Combustion Air Inlet V ent Kits  WARNING : Only use a sidewall air inlet cap supplied by the appliance manufacturer or a roof top air inlet cap supplied by the vent manufacturer . Using any other air inlet cap for single-unit inst allations or using a common air inlet cap for multiple[...]

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 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 T ABLE–E for kit numbers. The vent[...]

Figure 22A – Direct V ent (Illustration with Sidewall V ent and Sidewall Combustion Air) Figure 22B – Sidewall V enting  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 st ack. Connect the flu[...]

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 Input Kit* Max. Vent Vent Max. Vent Btu/hr (w/Power Length Termination Only Length Fan Assy.) (500,000 - 750,000 Btu/hr) 500,000 SVK3006 100 ft. SVK3043 50 ft. 650,000 SVK3008 100 ft. SVK3044 50 ft. 750,000 SVK3008 100 ft. SVK3044 50 ft. 990,000 SVK3053 100 ft. N/A N/A 1,260,000 SVK3054 100 [...]

For proper operation, a barometric damper is provided for Horizontal DirectAire TM installations. The damper will help to ensure a draft between negative 0.04 to 0.08 inches w .c. Input Btu/hr Kit* 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 incl[...]

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 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 . T o use a masonry chimney , the chimney must use a sealed, corrosion-resistant [...]

In cold climates, use a T ype-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.  CA UTION : Pool heaters that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pip[...]

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 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. 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 [...]

V ertical Combustion Air Inlet Clearances Y ou 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 [...]

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 * These kits include an outdoor vent cap and gasket. Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building or pool heater surfaces can be expected. Adjacent brick [...]

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. T est all gas connections for gas leaks before placing the pool heater in operation. Gas Piping T o safely operate this pool heater , you must properly size the [...]

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 29 shows a typical pool heater gas train. Figure 29 – T ypical Pool Heater Gas T rain Drawing Combination Gas V alv es These pool heaters fire in a single stage of operation. Note : This pool heater incorporates a “soft start” feature which lights approximately half of the burne[...]

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. T urn on the gas supply at the manual valve, turn on L.P . gas at the tank if required. 15. Turn the power switch to the “ON” position. 16. Turn the gas valve knobs to the “ON” position. 17. S[...]

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 Gas Manifold Pressure Adjustment IMPORT ANT : 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 t ap located on the front inside portion of the jacket. Reference the drawings in this section for c[...]

* Net Manifold Pressure equals the measured manifold pressure minus the chamber pressure. See Figure 31 to measure the Net Manifold Pressure. POOL HEA TER PIPING INST ALLA TION Install piping from the filter system to the pool heater as shown in the pool heater piping diagrams. See Figures 34 - 38. Minimum pipe diameter to and from the installed po[...]

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 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. Install the end caps (JKD6653 and JKD6654) using the[...]

Installa tion and Ser vice Manual 33 Figure 34 - Heater is W ithin 15 Feet of Pool Piping Figure 35 - Heater is Beyond 15 Feet of Pool Piping[...]

Commer cial P ool Hea ter s 34 Figure 36 - Heaters ar e within 15 feet Perpendicular of Pool Piping Figure 37 - Heaters ar e Beyond 15 feet of Pool Piping 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[...]

Installa tion and Ser vice Manual 35 R elief V alv e This pool heater is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure V essel Code, Section IV . The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. Place no other valve between the relief valve and the pool heater . T o p[...]

Commer cial P ool Hea ter s 36 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 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[...]

Installa tion and Ser vice Manual 37 Figure 39 - Contr ol Panel Component Location Drawing TABLE–N T er minal Strip Connection Options The scenarios shown in Figures 40 A - C represent typical terminal strip connection requirements. The terminal strips are located on the left side of the pool heater under the electrical access panel. Other applic[...]

Commer cial P ool Hea ter s 38 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 40 (A-C) - T erminal S trip Connection OPERA TION FOR Y OUR SAFETY READ BEFORE OPERA TING  WARNING : If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury or loss of life. A. This poo[...]

39 Figure 42 – ON/OFF Switch 8. T urn the manual gas cock clockwise  to the “OFF” position. 9. W ait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow What T o Do If Y ou Smell Gas in the safety information. If you don’t smell gas, go on to the next step. 10. T urn the manual gas cock counterclockwise  to the “ON[...]

Commer cial P ool Hea ter s 40 OPERA TION Continued Figure 44 – V ertical Pool Heater Piping Figure 45 – Horizontal Pool Heater Piping OPERA TING TEMPERA TURE 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 o[...]

Installa tion and Ser vice Manual 41 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 T ar get is shown and the text T ARGET on the display . This is the pool temperature set point. By pressing the Select key again, the Boiler Inlet T emperatur[...]

Commer cial P ool Hea ter s 42 OPERA TION Continued HO T SURF ACE IGNITION SY STEM Hot Surface Igniter and Ignition Control Module This unit has one ignition module and one hot surface igniter . Figure 47 – Hot Surface Igniter Figure 48 – Hot Surface Ignition Contr ol Module Hot Surface Ignition Control Module Ignition Module Lock out Functions[...]

Installa tion and Ser vice Manual 43 Access to Inter nal Control Panel The control panel is accessed by turning the knurled knob located at the bottom center of the exterior control panel. Pull the panel out at the bottom. The door will tilt into unit until it comes free from the outer top. The outer control panel has an overlay attached to the ext[...]

Commer cial P ool Hea ter s 44 OPERA TION Continued OPERA TION AND DIA GNOSTIC INDICA T ORS 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 T emperature Control that give status information as well. Figure 49 – Exte[...]

Installa tion and Ser vice Manual 45 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. T otal alkalinity is the measurement of the total amount of alkaline chemicals in the water . Alkalinity controls pH. Sodium bicarbonate is used to raise[...]

Commer cial P ool Hea ter s 46 OPERA TION Continued Pipe Size R equirements The pipe sizing chart provides the minimum pipe size for common manifold piping to ensure adequate flow . 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 po[...]

Installa tion and Ser vice Manual 47 High Wa ter T emper ature Limit Control This pool heater is equipped with a fixed setting, auto reset high water temperature limit control that is screwed into the outlet head in the heat exchanger . This temperature limit control has a maximum limit setting of 200°F (93°C). It is also equipped with an adjusta[...]

Commer cial P ool Hea ter s 48 CLEANING AND MAINTENANCE Continued Bur ner Remo val and Cleaning 1. T urn “OFF” the main power to the pool heater . 2. T urn “OFF” the main manual gas shutoff to the pool heater . 3. Remove the front outer jacket panels. 4. Disconnect the manifold from the gas train using the union(s) just below each gas valve[...]

Installa tion and Ser vice Manual 49 Combustion Air Fans Both the 500,000 - 750,000 Btu/hr models and the 990,000 - 2,070,000 Btu/hr models use a fan-assisted combustion process. The 500,000 - 750,000 Btu/hr models have one fan and the 990,000 - 2,070,000 Btu/hr models use two fans to supply combustion air to the burners. Fan Cleaning Check each co[...]

Commer cial P ool Hea ter s 50 CLEANING AND MAINTENANCE Continued If the air pressure switch does not make within 60 seconds from the time the fans turn ON, the ignition module will go into a soft lockout period (approximately 5 minutes in duration) during which time the fans are turned off and the module shows the Low Air flash code. If necessary [...]

Installa tion and Ser vice Manual 51 ENERGY SA VING RECOMMEND A TIONS 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. Use an accurate pool thermometer to monitor water temperature. 4. Use a tim[...]

Commer cial P ool Hea ter s 52 GL OSSAR Y POWER SUPPL Y 120V AC/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 SWIT CH The black line voltage wire runs[...]

Installa tion and Ser vice Manual 53 PREPURGE (Ignition Module Function) Once the ignition module sees a 24V AC 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 PRO VING (Ignition Module Function) Once the ignition module h[...]

Commer cial P ool Hea ter s 54 WIRING BO X CONNECTIONS[...]

Installa tion and Ser vice Manual 55 WIRING BO X CONNECTIONS[...]

Commer cial P ool Hea ter s 56 LADDER DIA GRAM[...]

Installa tion and Ser vice Manual 57 CONTR OL BO X CONNECTIONS[...]

Unit Star t 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. Measure the supply gas pr essure. For natural gas models, the supply g[...]

Advanced settings: By pressing the Select key in the Vi e w mode while viewing the Boiler Δ T reading (or the Supply Sensor temperature if the Pool Supply sensor is connected), the Boiler On hours will be displayed, indicated by the text BOIL ON in the display . This is the total number of hours the pool heater has been heating the pool. By pressi[...]

6/06-Printed in U.S.A. Lochinvar Corporation • 300 Maddox Simpson Pkwy • Lebanon, TN 37090 • 615-889-8900 / Fax 615-547-1000 www .Lochinvar .com[...]