Lochinvar GAS HEATER FOR COMMERICAL POOL Installation And Service Manual

[Page 1] Lochinvar GAS HEATER FOR COMMERICAL POOL

INSTALLATION AND SERVICE MANUAL Save this manual for future reference.  WWAARRNNIINNGG : 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 a...

[Page 2] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 2 TTaabbllee ooff CCoonntteennttss General Product Information . . . . . . . . . . . . . . . . . . . . . . . . .3 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Unpacking . . . . . ....

[Page 3] Lochinvar GAS HEATER FOR COMMERICAL POOL

GGEENNEERRAALL PPRROODDUUCCTT IINNFFOORRMMAATTIIOONN 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 heate...

[Page 4] Lochinvar GAS HEATER FOR COMMERICAL POOL

• 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 ...

[Page 5] Lochinvar GAS HEATER FOR COMMERICAL POOL

PPRROODDUUCCTT IIDDEENNTTIIFFIICCAATTIIOONN Installation and Service Manual 5 Figure 1B - Optional Vertical Piping Loop Figure 1A - Standard Horizontal Piping Loop ...

[Page 6] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 clear...

[Page 7] Lochinvar GAS HEATER FOR COMMERICAL POOL

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. Proper fre...

[Page 8] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued  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 heat...

[Page 9] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 m...

[Page 10] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued VVEENNTTIINNGG 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,...

[Page 11] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 termin...

[Page 12] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued 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 resu...

[Page 13] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 la...

[Page 14] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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. Sub...

[Page 15] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 o...

[Page 16] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued 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. This will result in condensing ...

[Page 17] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 o...

[Page 18] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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 pr...

[Page 19] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 ap...

[Page 20] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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. ...

[Page 21] Lochinvar GAS HEATER FOR COMMERICAL POOL

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...

[Page 22] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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. To...

[Page 23] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 shu...

[Page 24] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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 ...

[Page 25] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 te...

[Page 26] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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 discoloratio...

[Page 27] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 p...

[Page 28] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued Figure 29 shows a typical pool heater gas train. Figure 29 – Typical Pool Heater Gas Train Drawing Combination Gas Valves These pool heaters fire in a single stage of operation. Note: This pool heater incorpora...

[Page 29] Lochinvar GAS HEATER FOR COMMERICAL POOL

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. 15. Turn the p...

[Page 30] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN Continued 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 fron...

[Page 31] Lochinvar GAS HEATER FOR COMMERICAL POOL

* 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 the po...

[Page 32] Lochinvar GAS HEATER FOR COMMERICAL POOL

IINNSSTTAALLLLAATTIIOONN 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-w...

[Page 33] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 33 Figure 34 - Heater is Within 15 Feet of Pool Piping Figure 35 - Heater is Beyond 15 Feet of Pool Piping ...

[Page 34] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 34 Figure 36 - Heaters are within 15 feet Perpendicular of Pool Piping Figure 37 - Heaters are Beyond 15 feet of Pool Piping IINNSSTTAALLLLAATTIIOONN Continued ...

[Page 35] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 35 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 th...

[Page 36] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 36 IINNSSTTAALLLLAATTIIOONN 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 requirement...

[Page 37] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 37 Figure 39 - Control Panel Component Location Drawing TABLE–N Terminal Strip Connection Options The scenarios shown in Figures 40 A - C represent typical terminal strip connection requirements. The terminal strips...

[Page 38] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 38 IINNSSTTAALLLLAATTIIOONN Continued 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 c...

[Page 39] Lochinvar GAS HEATER FOR COMMERICAL POOL

39 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. If you don’t...

[Page 40] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 40 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 ...

[Page 41] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service 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 Target is shown and the text TARGET on the display. This is...

[Page 42] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 42 OPERATION Continued HOT SURFACE IGNITION SYSTEM 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 Igni...

[Page 43] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 43 Access to Internal 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 ...

[Page 44] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 44 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...

[Page 45] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service 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. Total alkalinity is the measurement of the total amount...

[Page 46] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 46 OPERATION Continued Pipe Size Requirements 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 s...

[Page 47] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 47 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 outlet head in the heat exchanger. This temperature l...

[Page 48] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 48 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...

[Page 49] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service 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...

[Page 50] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 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) duri...

[Page 51] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 51 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...

[Page 52] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 52 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 pro...

[Page 53] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 53 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 fue...

[Page 54] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 54 WIRING BOX CONNECTIONS ...

[Page 55] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 55 WIRING BOX CONNECTIONS ...

[Page 56] Lochinvar GAS HEATER FOR COMMERICAL POOL

Commercial Pool Heaters 56 LADDER DIAGRAM ...

[Page 57] Lochinvar GAS HEATER FOR COMMERICAL POOL

Installation and Service Manual 57 CONTROL BOX CONNECTIONS ...

[Page 58] Lochinvar GAS HEATER FOR COMMERICAL POOL

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/CG...

[Page 59] Lochinvar GAS HEATER FOR COMMERICAL POOL

Advanced settings: By pressing the Select key in the View mode while viewing the Boiler ΔT 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 th...

[Page 60] Lochinvar GAS HEATER FOR COMMERICAL POOL

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 ...