Installation and

Operation Manual

240 VAC NATURAL GAS/LP GAS

MODELS Natural Propane

200HD (200 MJ/h)

300HD (300 MJ/h)

400HD (400 MJ/h)

270201

270301

270401

270202

270302

270402

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.

!

WARNING

FOR YOUR SAFETY - READ BEFORE OPERATING

• If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life.

• Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or death. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

• 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.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

www.waterco.com

Section 1. Heater Identification ............... 2

Information (HIN)

Heater Data Rating Plate ......................... 2

Section 2. Introduction ............................ 3

Important Notices ...................................... 3

Warranty Information ................................. 4

Code Requirements ................................... 4

Consumer Information and ........................ 5

Safety Information

General Specifications ............................... 8

Section 3. Installation .............................. 9

Heater Description ...................................... 9

Sequence of Operation .............................. 10

Putting the Heater into Service .................. 10

Specifications ............................................ 11

Plumbing Connections ............................... 12

Valves ......................................................... 12

Manual By-Pass ......................................... 12

Water Connections ..................................... 13

Below Pool Installation ............................... 13

Gas Connections ........................................ 14

Gas Pipe Sizing .......................................... 15

Sediment Trap/Drip Leg .............................. 15

Testing Gas Leaks and Gas Pressure ......... 15

Gas Pressure Requirements ....................... 16

Outdoor Installation / ................................. 16

Heater Clearances

Indoor Venting—General Requirements ..... 18

Heater Clearances / Outside Vent Removal

Combustion Air Supply / Corrosive ............ 20

Vapors and Possible Causes

Vent Installation (Indoor Installation or ........ 21

Outdoor Shelter) - Vertical Venting

Horizontal or Vertical Venting - Using ......... 24

Single-Wall Stainless Gas Vent

Connecting Single-Wall Stainless ............... 25

Steel Vent to the Heater

Horizontal or Vertical Venting Flexible ....... 28

Duct (Flex-Vent)

Corrosive Vapors and Possible Causes ...... 28

Control Panel Indexing ............................... 29

Final Installation Check .............................. 29

Electrical Connections ............................... 29

Fireman’s Switch Connection/ ................... 30

Remote Control Connections

Turbotemp Wiring Diagram / ...................... 32

Electrical Schematic Ladder Diagram

Section 4. Operation ................................ 34

Basic System Operation / HSI ................... 34

(Hot-Surface Ignition) Lighting/Operation

Operating Instructions ............................... 35

To Turn Off Gas to Appliance ..................... 36

Safety Controls (Air Flow Switch / .............. 37

Water Pressure Switch / Hight Limits /

Operation of Ignitiion Module)

Operating the Control Panel / .................... 38

Temperature Setting / Maximum

Temperature Set Point

Section 5. Troubleshooting ...................... 40

Initial Troubleshooting and ......................... 40

Troubleshooting Chart

Heater Will Not Fire Troubleshooting .......... 41

(A, B, C, D)

LED Diagnostics ......................................... 45

(AGS, AFS, HLS, PS Thermistor)

Burner / Heat Exchanger Troubleshooting .. 47

Section 6. Maintenance ............................ 48

Care and Maintenance ............................... 48

Pressure Relief Valve .................................. 49

After Start-Up ............................................. 49

Spring, Fall (Autumn) and ........................... 49

Winter Operation

Maintaining Pool Temperature / .................. 51

Energy Saving Tips

Chemical Balance ....................................... 51

Replacement Parts ..................................... 54

Section 1. Heater Identification Information

I pg 02

HEATER IDENTIFICATION INFORMATION (HIN)

To identify the heater, see the data rating plate on the inner front panel of the heater. There are two designators for each heater, one is the Model Number and the other is the Heater

Identification Number (HIN).

Heater Identification Number (HIN)

The following example simplifies the identification system:

1. MT : Turbotemp

2. Model Size : (200, 300 or 400) : Input rating (Mega Joule [MJ]/hr)

3. Construction : (HD = Heavy Duty Model)

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:

1 2

MT 300

3

HD

4

N

FUEL TYPE =

N = NATURAL GAS

LP = PROPANE GAS

HD = HEAVY DUTY MODEL

MODEL SIZE = MJ INPUT = Mega Joule [MJ] / HR

200 (200[MJ]/ HR), 300 (300[MJ]/ HR) or 400 (400[MJ] /HR)

MT = TURBOTEMP

HEATER DATA RATING PLATE

The heater data rating plate is located on the inner front panel of the heater. To access the data rating plate, unbolt and remove the side door access panel as shown below.

Heater Data Rating Plate Location

Top Panel

Door

Access

Panel

Door

Access Panel

INTRODUCTION

Turbotemp (Australia) Pool and Spa Heater

Congratulations on your purchase of a Turbotemp high performance heating system. Proper installation and service of your new heating system and correct chemical maintenance of the water will ensure years of enjoyment. The Turbotemp is a compact, lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe. The Turbotemp also comes equipped with the Pentair Water Pool and

Spa® multifunction temperature controller which shows, at a glance, the proper functioning of the heater. All Turbotemp heaters are designed with a direct ignition device, HSI (hot-surface ignition), which eliminates the need for a standing pilot. The Turbotemp requires an external power source (240 VAC 50 Hz) to operate.

SPECIAL INSTRUCTIONS TO OWNER: Retain this manual for future reference. This instruction manual provides operating instructions, installation and service information for the Turbotemp high performance heater. The information in this manual applies to all Turbotemp models.

READ

AND REVIEW THIS MANUAL COMPLETELY, it is very important that the owner/installer read and understand the section covering installation instructions, and recognize the local and state codes before installing the Turbotemp. Its use will reduce service calls and chance of injury and will lengthen product life. History and experience has shown that most heater damage is caused by improper installation practices.

IMPORTANT NOTICES

THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE

TECHNICIAN, QUALIFIED IN POOL HEATER INSTALLATION.

For the installer and operator of the Turbotemp pool and spa heater: The manufacturer’s warranty may be void if, for any reason, the heater is improperly installed and/or operated. Be sure to follow the instructions set forth in this manual. 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)

Tel : +61 2 9898 8686

QLD - Brisbane

Tel : +61 7 3299 9900

VIC/ TAS - Melbourne

Tel : +61 3 9764 1211

SA/ NT - Adelaide

Tel : +61 8 8244 6000

WA - Perth

Tel : +61 8 9273 1900

Waterco (NZ) Limited

Auckland, New Zealand

Tel : +64 9 525 7570

Section 2. Introduction

I pg 04

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.

These heaters are designed for the heating of chlorine, bromine or salt system swimming pools and spas or in non-stationary installations, and should never be employed for use as space heating boilers or general purpose water heaters. The manufacturer’s warranty may be void if, for any reason, the heater is improperly installed and/or operated. Be sure to follow the instructions set forth in this manual.

!

CAUTION

OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 20°C.

WILL CAUSE HARMFUL CONDENSATION AND WILL DAMAGE THE HEATER AND VOID

THE WARRANTY. Do not use the heater to protect pools or spas from freezing if the final maintenance temperature desired is below 20°C., as this will cause condensation related problems.

CODE REQUIREMENTS

Installation must be in accordance with the following:

• Manufacturer’s Installation Instructions

• AS/NZS 5601.1 for Gas Installations

• Local Gas Fitting Regulations,

• Municipal Building Codes,

• S.A.A. Wiring Code,

• Local Electrical Regulations

• Any other statutory regulations

!

DANGER

CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains toxic levels of carbon monoxide, a dangerous, poisonous gas you cannot see or smell.

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. Proper installation, operation and maintenance of fuel-burning appliances in the home is the most important factor in reducing carbon monoxide poisoning.

3. Be sure that fuel burning appliances such as heaters are installed by professionals according to manufacturer’s instructions and codes.

4. Always follow the manufacturer’s directions for safe operation.

5. Have the heating system (including vents) inspected and serviced annually by a trained service technician.

6. Examine vents regularly for improper connections, visible cracks, rust or stains.

7. Install battery-operated carbon monoxide alarms. The alarms should be certified to the requirements of the most recent UL, IAS, CSA and IAPMO standard for carbon monoxide alarms. Test carbon monoxide alarms regularly and replace dead batteries.

!

WARNING

The U.S. Consumer Product Safety Commission warns that elevated water temperature can be hazardous. See below for water temperature guidelines before setting temperature.

1. Spa or hot tub water temperatures should never exceed 40° C. A temperature of 37° C. is considered safe for a healthy adult. Special caution is suggested for young children.

Prolonged immersion in hot water can induce hyperthermia.

2. Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning.

3. Pregnant women beware! Soaking in water above 37° C. can cause fetal damage during the first three months of pregnancy (resulting in the birth of a brain-damaged or deformed child).

Pregnant women should stick to the 37° C. maximum rule.

4. Before entering the spa or hot tub, the user should check the water temperature with an accurate thermometer. Spa or hot tub thermostats may err in regulating water temperatures by as much as -15° C.

5. Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure problems should obtain their physician’s advice before using spas or hot tubs.

6. Persons taking medication which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants should not use spas or hot tubs.

!

WARNING

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater. Do not use this heater if any part has been under water.

Immediately call a qualified service technician to inspect the heater and to replace any part of control system and gas control which has been under water.

Section 2. Introduction

I pg 06

SAFETY INFORMATION

The Turbotemp pool heaters are designed and manufactured to provide many years of safe and reliable service when installed, operated and maintained according to the information in this manual. Throughout the manual, safety warnings and cautions are identified by the

“ “symbol. Be sure to read and comply with all of the warnings and cautions.

!

DANGER

CARBON MONOXIDE GAS IS DEADLY

• • READ OWNERS MANUAL COMPLETELY BEFORE OPERATING. • •

THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A

PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED IN POOL HEATER

INSTALLATION. Some jurisdictions require that installers be licensed. Check with your local building authority about contractor licensing requirements.

Improper installation and/or operation could create carbon monoxide gas and flue gases which could cause serious injury or death. Improper installation and/or operation will void the warranty.

Exhaust from this pool heater contains carbon monoxide, a dangerous, poisonous gas you cannot see or smell. Symptoms of carbon monoxide exposure or poisoning include dizziness, headache, nausea, weakness, sleepiness, muscular twitching, vomiting and inability to think clearly. IF YOU

EXPERIENCE ANY OF THE ABOVE SYMPTOMS, IMMEDIATELY TURN

OFF THE POOL HEATER, LEAVE THE VICINITY OF THE POOL OR SPA

AND GET INTO FRESH AIR IMMEDIATELY. THE POOL HEATER MUST BE

THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE RESUMING

OPERATION.

EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN

DAMAGE OR DEATH.

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. Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool heater. The carbon monoxide detectors must be periodically inspected for proper operation so as to insure continued safety. Broken or malfunctioning carbon monoxide detectors must be replaced immediately.

!

WARNING

This heater is equipped with an unconventional gas control valve that

is factory set with a manifold pressure of 11 ± 5 Pa. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation or service must be performed by a qualified installer, service agency or the gas supplier. If this control is replaced, it must be replaced with an identical control.

Do not attempt to adjust the gas flow by adjusting the regulator setting.

!

WARNING

Risk of fire or explosion from incorrect fuel use or faulty fuel conversion.

Do not try to run a heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should attempt to convert heater from one fuel to the other. Do not attempt to alter the rated input or type of gas by changing the orifice. If it is necessary to convert to a different type of gas, consult your Waterco dealer. Serious malfunction of the burner can occur which may result in loss of life. 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. It is not designed to operate with any other fuels. Refer to the nameplate for the type of gas the heater is equipped to use.

• Use heater only with the fuel for which it is designed.

• If a fuel conversion is necessary, refer this work to a qualified service technician or gas supplier before putting the heater into operation.

!

WARNING

Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, varnishes, paints, or other volatile flammable liquids near heater.

!

WARNING

Risk of explosion if unit is installed near propane gas storage. Propane

(LP) gas is heavier than air. Consult local codes and fire protection authorities about specific installation requirements and restrictions. Locate the heater away from propane gas storage and filling equipment as specified by the

Standard for the Storage and Handling of Liquefied Petroleum Gases (latest edition).

!

WARNING

Risk of fire. Do not place articles on, near or against the heater.

!

WARNING

Vent

Cover

Risk of burn hazard. To reduce the risk of injury, do not touch the side heater vent cover when the heater is operating. Side heater vent covers are HOT and can burn when touched causing personal injury. Do not allow children to play on or around heater or associated equipment.

!

WARNING

Risk of asphyxiation if exhaust is not correctly vented. Follow venting

instructions exactly when installing heater. Do not use a drafthood with this heater, as the exhaust is under pressure from the burner blower and a draft hood will allow exhaust fumes to blow into the room housing the heater. The heater is supplied with an integral venting system for outdoor installation.

Section 2. Introduction

I pg 08

!

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring 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.

• Verify proper operation after servicing.

• Do not allow children to play on or around heater or associated equipment.

• Never allow children to use the pool or spa without adult supervision.

• Read and follow other safety information contained in this manual prior to operating this pool heater.

GENERAL SPECIFICATIONS

NOTICE:

• Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty.

• The Combination Gas Control Valve on this heater differs from most appliance gas controls.

If it must be replaced, for safety reasons replace it only with an identical gas control.

• The access door panels must be in place to provide proper ventilation. Do not operate the heater for more than five (5) minutes with the access door panels removed.

• This heater is design certified by IAPMO as complying with the Standard for Gas Fired Pool

Heaters, and is intended for use in heating fresh water swimming pools or spas.

• The heater is designed for the heating of chlorine, bromine or salt system swimming pools and spas. It should NOT be used as a space heating boiler, or general purpose water heater.

The heater requires an external 240 VAC single-phase electric power source.

• The heater should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the heater. The pan must not restrict air flow.

• The heater may not be installed within 3.5M (11.5 ft.) of the inside surface of a pool or spa unless it is separated by a solid fence, wall or other permanent barrier.

INSTALLATION INSTRUCTIONS

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 handheld carbon monoxide meter and/or by consulting with a gas professional.

Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool heater. The carbon monoxide detectors must be periodically inspected for proper operation so as to insure continued safety. Broken or malfunctioning carbon monoxide detectors must be replaced immediately.

HEATER DESCRIPTION

Figure 1 is a diagram of the heater showing how it operates. Precisely matched orifice plates meter the air and gas into the mixer. The blower draws the air and gas through the mixer and forces it into the burner’s flame holder. A sealed heat exchanger surrounds the flame holder, discharging exhaust gases out the flue.

Five (5) cm PVC water piping connects directly to the manifold/ header on the heat exchanger using 5 cm PVC slip unions provided with the heater. The outer manifold remains cool; no heat sinks are required. A thermal regulator and an internal bypass regulate the water flow through the heat exchanger to maintain the correct outlet temperature. The heater operator control panel board assembly is located on top of the heater.

Inlet

(Cold

Water)

Air

Mixer

Blower

Outlet

(Mixed

Water)

Burner

Figure 1.

Heating Coils

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. The interlocks consist of: above 53° C (127° F), and

automatic gas shut-off (AGS) switch, which opens if the heat exchanger outlet temperature goes above 60° C (140° F).

• the reaches 249° C (480° F).

• the

goes above 55° C (131° F), and....

inlet temperature control switch, which opens if the inlet temperature goes above

45° C (110° F).

The air flow switch (AFS) senses the pressure drop across the air metering orifice. As soon as there is sufficient air flow, the AFS closes, closing the circuit to the

hot surface igniter (HSI), which ignites the fuel mixture. On a call for heat, the blower and HSI are energized. In about 20 seconds, the gas valve opens and ignition occurs. The HSI then switches to a sensing mode and monitors the flame.

The heater is equipped with a digital operating control that enables the user to pre-set the desired pool and spa water temperatures. The control enables the user to select between pool and spa heating, and features a digital display that indicates the water temperature.

PUTTING THE HEATER INTO SERVICE

If the heater is installed below the level of the pool, or more than 0.6 meters (2 feet) above pool level, the pressure switch setting should be adjusted. See “WATER PRESSURE SWITCH” in the “SAFETY CONTROLS Section” (page 32) and the “CAUTION” under “BELOW POOL

INSTALLATION Section” (page 12).

Before putting the heater into service for the first time, follow the instructions under “BEFORE

START-UP” (page 30) in the front of this manual. Check for proper operation of the heater by following the steps under “OPERATION INSTRUCTIONS.”

Damage to equipment caused by improper installation or repair will void the warranty.

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. See Figure 2 for Outdoor Installations.

DIMENSIONS IN CENTIMETERS & INCHES

58.5 cm

(23.02")

71.5 cm

(28.15")

82.8 cm

(32.61")

53.3 cm

(21.0")

40.6 cm

(16")

FRONT

ELECTRICAL

CONDUIT PORT

TOP

EXHAUST SIDE

40.6 cm

(16.0")

57.7 cm

(22.7")

71.6 cm

(28.2")

Figure 2.

PLUMBING SIDE

14.2 cm

(5.6")

25.7 cm

(10.13")

Section 3. Installation

I pg 12

PLUMBING CONNECTIONS

The Turbotemp heater has the unique capability of direct schedule 40

PVC plumbing connections. A set of bulkhead fittings is included with the

Turbotemp to insure conformity with

Waterco’s recommended PVC plumbing procedure. Other plumbing connections can be used. See Figure 3 for plumbing connections.

POOL

HEATER

MANUAL

BY-PASS

TO

POOL

GATE

VALVE

FILTER

PUMP

Figure 3.

FROM POOL

!

CAUTION

Before operating the heater on a new installation, turn on the circulation pump and bleed all the air from the filter using the air relief valve on top of the filter. Water should flow freely through the heater. Do not operate the heater unless water in the pool/spa is at the proper level. If a manual by-pass is installed, temporarily close it to insure that all air is purged from the heater.

VALVES

When any equipment is located below the surface of the pool or spa, valves should be placed in the circulation piping system to isolate the equipment from the pool or spa. Check valves are recommended to prevent back-siphoning. Backsiphoning is most likely to occur when the pump stops, creating a pressure-suction differential. Do NOT sanitize the pool by putting chlorine tablets or sticks into the skimmer(s). When the pump is off, this will cause a high concentration of chlorine to enter the heater, which could cause corrosion damage to the heat exchanger.

!

CAUTION

Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater, filters or pump. When chemical feeders are installed in the circulation of the piping system, make sure the feeder outlet line is down stream of the heater, and is equipped with a positive seal noncorrosive “Check Valve”, (P/N

R172288), between the feeder and heater.

MANUAL BY-PASS

( WATER FLOW RATE)

Where the water flow rate exceeds the maximum 454 LPM, a manual bypass should be installed and adjusted. After installing the valve, adjust the valve to bring the flow rate within the acceptable range.

Then remove the valve handle or lock it in place to avoid tampering.

See Figure 4.

Table 1.

Model Min. LPM (GPM) Max. LPM (GPM) *

200

300

76 (20)

114 (30)

454 (120)

454 (120)

400 152 (40) 454 (120)

*Do not exceed the maximum recommended flow rate for the connecting piping.

See page 32 for Pressure Relief Valve Installations.

Cool water

Warm water out

1. Set Manual

By-Pass Valve.

2. Remove Handle.

Outlet to pool

Figure 4.

Inlet to heater

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). See “WATER FLOW RATE” on page 11 - Table 1 for setting of the manual by-pass valve.

Make sure that the outlet plumbing from the heater contains no shut-off valves or other flow restrictions that could prevent flow through the heater (except for below pool as noted below,

Figure 5.

or winterizing valves where needed). To switch flow between the pool and spa, use a diverter valve. Do not use any valve that can shut off the flow. Do not use a shut-off valve to isolate the heater unless it is below the level of the pool or spa. Install the chemical feeder downstream of the heater. Install a chemical resistant one-way check valve between the heater and the chemical feeder to prevent back-siphoning through the heater when the pump is off.

NOTICE: If the heater is plumbed in backwards, it will cycle continuously. Make sure piping from filter is not reversed when installing heater.

Connect the heater directly to 5 cm PVC pipe, using the integral unions provided. Heat sinks are not required. The low thermal mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down unexpectedly.

Occasionally a two-speed pump will not develop enough pressure on the low speed to operate the heater. In this case, run the pump at high speed only to operate the heater. If this does not solve the problem, do not try to run the heater. Instead, correct the installation.

Do not operate the heater while an automatic pool cleaner is also operating. If the circulation pump suction is plugged (for example by leaves), there may not be adequate flow to the heater.

Do not rely on the pressure switch in this case.

Local codes may require the installation of a pressure relief valve (PRV), see page 50 for

“PRESSURE RELIEF INSTRUCTIONS”.

BELOW POOL INSTALLATION

If the heater is below water level, the pressure switch must be adjusted. This adjustment must be done by a qualified service technician.

See following CAUTION before installation.

!

CAUTION

BELOW OR ABOVE POOL INSTALLATION

The water pressure switch is set in the factory at 21 kPa (± 5 kPa). This setting is for a heater installed at pool level. If the heater is to be installed more than 0.3 m above or below, the water pressure switch must be adjusted by a qualified service technician.

See page 36, Figure 28.

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. Locate and install the flow switch externally on the outlet piping from the heater, as close as possible to the heater. Connect the flow switch wires in place of the water pressure switch wires.

GAS CONNECTIONS

GAS LINE INSTALLATIONS

The gas supply must be installed in accordance with the Gas Installation Code, AS/NZS 5601.1, as applicable and all applicable local codes.

Before installing the gas line, be sure to check which gas the heater has been designed to burn.

This is important because different types of gas require different gas pipe sizes. The rating plate on the heater will indicate which gas the heater is designed to burn. Table 2 below shows the recommended gas inlet pipe sizes required for the distance from the gas meter to the heater.

The table is for natural gas at a specific gravity of .65 and propane at a specific gravity of 1.55.

When sizing gas lines, calculate 0.9 additional meters of straight pipe for every elbow used.

When installing the gas line, avoid getting dirt, grease or other foreign material in the pipe as this may cause damage to the gas valve, which may result in heater failure.

The gas meter should be checked to make sure that it will supply enough gas to the heater and any other appliances that may be used on the same meter. Insufficient gas supply will cause the heater to operate below its designed performance or not at all. The gas line from the meter will usually be of a larger size than the gas valve supplied with the heater. Therefore a reduction of the connecting gas pipe will be necessary. Make this reduction as close to the heater as possible. Gas supply companies are increasingly supplying natural gas to new installations with 2.75 kPa; this means if the gas pressure is not adjusted to the correct working pressure, the heater will be over gassed and cause serious damage within minutes. This damage is not covered under the heater warranty.

Install a manual shut-off valve that conforms with Type 1 or Type 2 as per AG201 and/or AS4617 standards, and a sediment trap/drip leg and union located outside the heater panels, see Figure

6. Do not use a restrictive gas cock.

The heater and any other gas appliances must be disconnected from the gas supply piping system during any pressure testing on that system, (greater than 6.0 kPa). The heater and its gas connection must be leak tested before placing the heater in operation.

Do not use flame

to test the gas line. Use soapy water or another nonflammable method.

NOTE

A manual main shut-off valve must be installed externally to the heater.

!

WARNING

DO NOT INSTALL THE GAS LINE UNION INSIDE THE HEATER CABINET. THIS WILL

VOID YOUR WARRANTY.

GAS PIPE SIZING

Heater Size

200

300

400

0 to 15 m

Distance from the Meter

16 to 30 m 31 to 60 m

25 mm 32 mm 32 mm

32 mm

32 mm

32 mm

40 mm

40 mm

50 mm

Table 2.

SEDIMENT TRAP/DRIP LEG

Install a sediment trap/drip leg and union located outside the heater panels in accordance with National code requirements. Do not use a restrictive gas cock. The sediment trap/drip leg shall be either a tee fitting with a capped nipple in the bottom outlet which can be removed for cleaning, as illustrated in Figure 6, or an other device recognized as an effective sediment trap/drip leg. All gas piping should be tested after installation in accordance with local codes.

Figure 6.

TESTING GAS LEAKS AND GAS PRESSURE

Before operating the heater, the heater and its gas connections must be leak tested. Do NOT use an open flame to test for leaks. Test all gas connections for leaks with soapy water.

The gas valve must be completely disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 6.0 kPa (.87 psig).

TESTING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE

!

WARNING

Risk of fire and explosion. Alteration, service, or maintenance of the Combination Gas

Control Valve can lead to fire or explosion, causing loss of life, personal injury, and/or property damage. DO NOT ATTEMPT TO ADJUST THE GAS CONTROL VALVE.

These instructions are for the use of qualified service technicians only!

1. Shut off the gas supply to the heater.

2. Loosen the small screw inside the pressure tap as shown in Figure 7.

3. Connect the manometer hose.

4. Open the gas supply to the heater.

5. Turn on the heater.

6. Take the gas pressure reading.

7. Turn off the heater.

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.

Note: If the pressure reading is out of range,

(see Table 3), regulate the incoming gas pressure.

INLET GAS PRESSURE REQUIREMENTS

Gas Pressure

Natural Gas

Propane Gas

Minimum

1.0 kPa

2.5 kPa

Maximum

6.0 kPa

6.0 kPa

NOTE: The minimum value approved for input adjustment.

Do not exceed the maximum supply pressure.

All readings must be taken while heater is operating. Any adjustments or readings made while heater is off will result in performance problems.

Table 3.

Figure 7.

OUTDOOR INSTALLATION (Australia)

For heaters located outdoors, using the built-in stackless venting system.

!

DANGER

CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains carbon monoxide, a dangerous, poisonous gas you cannot see or smell. Symptoms of carbon monoxide exposure or poisoning include dizziness, headache, nausea, weakness, sleepiness, muscular twitching, vomiting and inability to think clearly. IF YOU EXPERIENCE

ANY OF THE ABOVE SYMPTOMS, IMMEDIATELY TURN OFF THE POOL HEATER, LEAVE

THE VICINITY OF THE POOL OR SPA AND GET INTO FRESH AIR IMMEDIATELY. THE

POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE

RESUMING OPERATION.

EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR

DEATH.

!

WARNING

Risk of explosion if a unit burning propane gas is installed in a pit or other low spot.

Propane is heavier than air. Do not install the heater using propane in pits or other locations where gas might collect. Consult your local building code officials to determine installation requirements and specific installation restrictions of the heater relative to propane storage tanks and filling equipment. Installation must meet the requirements for the Standard for the

Storage and Handling of Liquid Petroleum Gases. Consult local codes and fire protection authorities about specific installation restrictions.

OUTDOOR INSTALLATION (Australia)

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.

BASE FOR USE ON

COMBUSTIBLE FLOORS

Figure 8.

It is recommended that a non-combustible base be a platform under the heater constructed of hollow masonry blocks, not less than 100 millimeters (mm) thick (laid with ends unsealed and joints matched for air circulation). Cover blocks with 0.75 mm (min.) galvanized sheet metal, see Figure 8.

To avoid damage to the electronic components in the heater, take care to prevent prolonged exposure to driving sources of water (such as lawn sprinklers, heavy roof runoff, hoses, etc.).

Avoid operation in persistent, extreme, moist or salty environments.

In extreme weather, shut down the heater and disconnect the power to it until the weather has moderated. In areas subject to hurricanes or very high winds, purchase the Bolt Down

Bracket Kit, P/N 460738, see Figure 9.

SHEET

METAL

BLOCKS

152.4 mm Min.

152.4 mm Min.

Hollow masonry blocks, not less than 100 mm thick, (laid with ends unsealed and joints matched for air circulation). Cover blocks with

0.75 mm (min.) galvanized sheet metal.

Figure 9.

HEATER CLEARANCES – OUTDOOR

IMPORTANT!

• In an outdoor installation it is important to ensure water is diverted from overhanging eves with a proper gutter/ drainage system. The heater must be set on a level foundation for proper drainage.

• This unit shall not be operated outdoors at temperatures below -7˚C.

If the heater is located under a roof or deck overhang, there must be at least 1 meter (3 ft.) of clearance between the bottom of the overhang and the top of the heater exhaust vent, see

Figure 10. If the heater is under a roof or deck overhang, the space around the heater must be open on three sides.

For minimum exhaust vent clearances for building openings, see below Figure 11.

Orient the heater for convenient access to the water connections and the gas and electrical connections.

Check local building codes for setback (property line) requirements.

1 meter (3 ft.) or more

Figure 10.

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. Do not spray aerosols in the vicinity of the heater while it is in operation. Chemicals should not be stored near the heater installation. Combustion air can be contaminated by corrosive chemical fumes which can damage the heater and will void the warranty.

INDOOR VENTING — General Requirements

NOTE: REMOVE OR COVER “OUTDOOR ONLY” LABEL LOCATED ON HEATER OUTSIDE

PANEL WITH “INDOOR INSTALLATION” LABEL (P/N 474275) INCLUDED IN ACCESSORY

BAG (P/N 473607).

INDOOR INSTALLATION

(SEE INSTALLATION GUIDE FOR CORRECT PLACEMENT OF THIS LABEL)

P/N 474275

If you are considering connecting this heater to a pre-existing vent system, make sure that the vent system meets the appropriate venting requirements as given in this manual on pages 17-

28. If not, replace the vent system. DO NOT use a draft hood with this heater. The Turbotemp heaters are capable of a 270-degree discharge rotation and with a vent gas temperature less than 204° C (400° F). The total length of the horizontal run must not exceed the length that is listed in Table 7, Page 24.

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* ........ 15 cm (6 in.)

Note (*) For service access it is advisable to allow for sufficient clearance on at least one door panel. The heater is designed for installation on combustible flooring. For installation on carpeting, the heater must be mounted on a metal or wood panel that extends at least three inches (10cm) beyond the base of the heater. If the heater is installed in a closet or alcove, the entire floor shall be covered by the panel. On an outdoor shelter installation, the exhaust discharges into a vent pipe. Orient the heater so that the vent pipe does not interfere with adjustment of the operating controls. The control panel located on the top panel can be rotated to any of the three sides of the heater for easy access. However, the control panel must not be located on the side where the vent is located.

Chimney or Gas Vent

(*) For service access, it is advisable to allow for sufficient clearance on at least one door panel.

15 cm (6 in)

Vent Cap and

Riser Furnished by Installer

Outlet Air

Opening

15 cm* (6 in)

15 cm (6 in)

15 cm*

(6 in)

Side

Wall Vent

Heater

Inlet Air

Opening

15 cm (6 in)

Figure 12.

Figure 12a.

OUTSIDE VENT COVER REMOVAL

The heater is supplied from the factory with a built-in stackless outside vent for outdoor installation. Remove the outside vent cover for outdoor shelter installation.

Section 3. Installation

I pg 20

COMBUSTION AIR SUPPLY

For indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area

(in accordance with AS/NZS 5601.1).

The minimum requirements for the air supply specify that the room in which a heater is installed should be provided with two permanent air supply openings; one within 30 cm (12 in) of the ceiling, the other within 30 cm (12in) of the floor for combustion air, in accordance with the AS/

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

Model

200

300

400

Minimum Net Free Open Area for Each Opening*

(Square Inches/Centimeters)

All Air From Inside Building

Combustion Vent

200 sq. in.

1290 sq. cm.

200 sq. in.

1290 sq. cm.

All Air From Outside Building

Combustion Vent

50 sq. in.

323 sq. cm.

50 sq. in.

323 sq. cm.

325 sq. in.

2097 sq. cm.

325 sq. in.

2097 sq. cm.

80 sq. in.

516 sq. cm.

80 sq. in.

516 sq. cm.

400 sq. in.

2580 sq. cm.

400 sq. in.

2580 sq. cm.

100 sq. in.

645 sq. cm.

100 sq. in.

645 sq. cm.

* Area indicated is for one of two openings; one at floor level and one at the ceiling.

Table 4.

Combustion 3 in. PVC Pipe

Inlet Air Intake Duct Requirements*

Combustion Air Intake 3 in. Pipe

(Vertical or Horizontal)

No. of 90° Elbows

0

Maximum Length in Feet (M)

70 ft. (21.3 M)

1

2

58 ft. (17.7 M)

46 ft. (14.0 M)

3

4

34 ft. (10.4 M)

22 ft. ( 6.7 M)

!

WARNING

DO NOT USE PVC PIPE FOR FLUE EXHAUST VENT. FLUE EXHAUST VENT

TEMPERATURES CAN BE IN EXCESS OF 400° F. FLUE EXHAUST VENT

MUST BE

CATEGORY I or CATEGORY III METAL VENT.

Note (*) Combustion Air Intake Duct Connection Kit (Part Number 6844326) for all Turbotemp heater models can be purchased separately. See page 52 for parts list.

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.

Corrosive Vapors and Possible Causes

Area

Chlorinated swimming pools and spas

New construction and remodeling areas

Beauty parlors

Refrigeration plants or various industrial finishing and processing plants

Dry cleaning and laundry areas

Likely Contaminants

Pool or spa cleaning chemicals. Acids, such as hydrochloric or muriatic acid.

Glues and cements, construction adhesives, paints, varnishes, and paint and varnish strippers. Waxes and cleaners containing calcium or sodium chloride.

Permanent wave solutions, bleaches, aerosol cans containing chlorocarbons or fluorocarbons.

Refrigerants, acids, glues and cements, construction adhesives.

Bleaches, detergents, or laundry soaps containing chlorine.

Waxes and cleaners containing chlorine, calcium or sodium chloride.

Table 5.

!

CAUTION

Chemicals should not be stored near the heater installation. Combustion air can be contaminated by corrosive chemical fumes which can void the warranty.

VENT INSTALLATION –

INDOOR INSTALLATION OR OUTDOOR SHELTER

Flueing must be in accordance with AS/NZS 5601.1

Always vent the heater to the outdoors, see Note*.

• Vent it vertically using double wall vent

connector pipe.

NOTE *: Vent must be at least 2.4 m (8 ft) away from nearest vertical surface. Vents extending 1.5 m (5 ft) or more above the roof must be braced or guyed. Consult your local code officials for detailed information.

Locate the heater so as to minimize the length of horizontal venting and the number of vent elbows required. Horizontal vent runs must slope to allow exhaust condensate to drain and it is recommended to have a condensate drain as described in the venting installation instructions.

VERTICAL VENTING

(See Figures 12 and 14)

Vent the heater vertically in a system in accordance with AS/NZS 5601.1 and local codes. Double-wall vent connector is recommended; however single-wall pipe is allowed in some circumstances. Consult your local code official for detailed information. Do not use a draft hood with this heater.

To connect a double wall metal gas vent to the heater, order the appropriate Metal Flue Collar from the chart below:

1. See Table 6 to determine allowable vent sizes for your heater.

Metal Flue Collar

100 mm x 150 mm (4” x 6”)

100 mm x 200 mm (4” x 8”)

Table 6.

Part No.

684431106

684431108

Figure 13.

NOTICE: Table 6 is for installations in which the total lateral vent length (that is, the horizontal distance from the flue collar to the main vertical portion of the vent) is less than half the total vent height (the vertical distance from the flue collar to the vent termination) and which have three or less elbows in the system. For vent lenghts greater than 16 m (52.5 ft), only one elbow is allowed. See Table 6a below for details.

Read “VERTICAL VENTING” before using this table.

Section 3. Installation

I pg 24

Table 6.

– Permitted Minimum and Maximum Vent Heights By Size and Heater Model

Vent Size

Double-Wall Vent with Double-Wall Connector in Meters (Feet)

Model 200

Height min./max.

Model 300

Height min./max.

Model 400

Height min./max.

150 mm (6 in.) 1.8 m (6 ft.) / 22 m (72 ft.) 9 m (30 ft.) / 22 m (72 ft.) Not Suitable

200 mm (8 in.) 1.8 m (6 ft.) / 22 m (72 ft.) 1.8 m (6 ft.) / 22 m (72 ft.) 2.4 m (8 ft.) / 22 m (72 ft.)

Double-Wall Vent with Single-Wall Connector in Meters (Feet)

Vent Size

150 mm (6 in.)

Model 200

Height min./max.

1.8 m (6 ft.) / 4.6 m (15 ft.)

Model 300

Height min./max.

Not Suitable

Model 400

Height min./max.

Not Suitable

200 mm (8 in.) Not Suitable 1.8 m (6 ft.) / 6 m (20 ft.) 2.4 m (8 ft.) / 6 m (20 ft.)

Table 6a.

– Maximum Number of Elbows per Vent Lengths

Maximum

Elbows

Allowed

3

2

1

Maximum Number of Elbows per Vent Lengths

[C]

Total Vent Length

(C=A+B)

[A]

Horizontal Maximum

Vent Length

[B]

Vertical Vent Length

2m (6.6 ft.)

3m (9.8 ft.)

4m (13.1 ft.)

5m (16.4 ft.)

6m (19.7 ft.)

7m (23 ft.)

8m (26.2 ft.)

9m (29.5 ft.)

10m (32.8 ft.)

11m (36.1 ft.)

12m (39.4 ft.)

13m (42.6 ft.)

14m (45.9 ft.)

15m (49.2 ft.)

16m (52.5 ft.)

17m (55.8 ft.)

18m (59 ft.)

19m (62.3 ft.)

20m (65.6 ft.)

21m (68.9 ft.)

22m (72.2 ft.)

0.67m (2.2 ft.)

1m (3.3 ft.)

1.33m (4.4 ft.)

1.67m (5.5 ft.)

2m (6.6 ft.)

2.33m (7.6 ft.)

2.67m (8.8 ft)

3m (9.8 ft.)

3.33m (10.9 ft.)

3.67m (12 ft.)

4m (13.1 ft.)

4.33m (14.2 ft.)

4.67m (15.3 ft ft.)

5m (16.4 ft.)

5.33m (17.5 ft.)

5.67m (18.6 ft.)

6m (19.7 ft)

6.33m (20.8 ft.)

6.67m (21.9 ft.)

7m (23 ft.)

7.33m (24 ft.)

1.33m (4.4 ft.)

2m (6.6 ft.)

2.67m (8.8 ft.)

3.33m (10.9 ft.)

4m (13.1 ft.)

4.67m (15.3 ft.)

5.33m (17.5 ft.)

6m (19.7 ft.)

6.67m (21.9 ft.)

7.33m (24 ft.)

8m (26.2 ft.)

8.67m (28.4 ft.)

9.33m (30.6 ft.)

10m (32.8 ft.)

10.67m (35 ft.)

11.33m (37.2 ft.)

12m (39.4 ft.)

12.67m (41.6 ft.)

13.33m (43.7 ft.)

14m (45.9 ft.)

14.67m (48.1 ft.)

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. Before connecting the metal

Flue Collar to the Vent Body, wet a clean cloth or paper towel with isopropyl alcohol

(rubbing alcohol) and vigorously wipe the socket of the Vent Body. Immediately wipe the cleaned surfaces dry with a clean cloth or paper towel. Repeat for the exterior of the 100 mm (4”) end of the metal Flue

Collar. Attach the metal Flue Collar to the

Vent Body using the RTV supplied with the kit, following the vent manufacturer’s instructions (included with kit).

3. Attach the vent pipe to the metal Flue Collar with sheet-metal screws.

!

WARNING

Risk of fire or asphyxiation if vent is not assembled according to manufacturer’s instructions or if vent parts from different

manufacturers are mixed. Vent parts from different manufacturers ARE NOT interchangeable. Mixing parts from more than one manufacturer may cause leaks or damage to vent. When assembling a vent, pick one manufacturer and be sure that all vent parts come from that manufacturer and are specified by the manufacturer for your system. Follow manufacturer’s instructions, local code requirements and

AS/NZS 5601.1 standards carefully during assembly and installation.

Figure 14. – Typical Metal Vent Pipe

Installation (Vertical Venting)

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 the 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. Slope horizontal pipe down to condensate trap at least 2 cm per meter (1/4 in per foot). Install approved condensate drains at low points where condensate might collect. Plumb condensate drains to a drain through hard piping or high temperature tubing such as silicone rubber or EPDM rubber – do not use vinyl or other low temperature tubing. Follow drain manufacturer’s installation instructions.

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. The roof opening must be located so that the vent is vertical.

6.

Do not run the heater vent into a common vent with any other appliance.

!

WARNING

Fire Hazard. Do not vent the heater directly into a masonry chimney. Installation into a masonry chimney must use a chimney liner which must meet AS/NZS 5601.1 standards and all local code requirements.

!

WARNING

Risk of fire, carbon monoxide poisoning, or asphyxiation. It is recommended to use a

CO Monitor and Fire Alarm in rooms that contain gas fired appliances.

NOTE

After installation, installer must check for correct and safe operation of the heater.

HORIZONTAL OR VERTICAL VENTING - USING SINGLE-WALL STAINLESS GAS VENT

(See Figures 15, 16 & 17)

Vent the heater either horizontally or vertically using an optional vent adapter of the 150 mm (6 in) special gas approved stainless steel vent pipes. Installation must be in accordance with all local codes and ordinances/or the latest edition of the AS/NZS 5601.1 standards and/or local codes. The heater, when installed, must be electrically grounded and bonded in accordance with local codes. Do not use a draft hood with this heater. Install the vent according to the vent manufacturer’s detailed instructions. Note: Keep a 150 cm (6 in) minimum clearance between the vent pipe and combustible surfaces. Follow the vent manufacturer’s instructions and code requirements. Do not place any insulating materials around the vent or inside the required clear air space surrounding the vent. See Table 7 for maximum permissible vent lengths.

NOTE

The allowable vent runs for each vent pipe diameter are different and can not be exceeded.

150 mm (6 in.) Special Gas Vent

(Vertical or Horizontal)*

No. of 90° Elbows Maximum Length in Feet (M)

0 11.6 m (38 ft.)

Each 90-degree elbow reduces the maximum horizontal vent run by 3.6 m

(12 feet) and each 45-degree elbow in the vent run reduces the maximum vent run by 1.8 m (6 feet). See the Table 7 for the maximum vent lengths using 90° elbows.

1 8 m (26 ft.)

*Minimum vent length is 0.34M (1 ft.) or in accordance with vent manufacturer’s instruction, and local and national codes. Horizontal vents 1 m (3 in) or less in length do not require a condensate tee, but must slope down toward the outlet at 2 cm to the meter (1/4 in / ft.) to allow condensate to drain.

Table 7.

NOTE

It is recommended that vent runs over 5.4 m (18 feet) may need to be insulated to reduce condensation related problems and/or the use of a condensate trap in the vent run close to the heater may be necessary in certain installations such as cold climates. Horizontal vents 1 m (3 feet) or less in length do not require a condensate tee. The Turbotemp heater is suitable for throughthe-wall venting.

Flue gases may escape into the dwelling with any cracks or loose joints in the vent pipe, or

improper vent installation. The vent pipe must be of a sealed-seam construction and for operating temperatures less than 204° C (400°F). Vent pipe construction will be of AS/NZS

5601.1 approved non-corrosive material, such as stainless steel. A condensate trap may be needed. The use of “Approved” thimbles, roof jacks and/or side vent terminals are required; and the proper clearances to combustible materials must be maintained in accordance with type of vent pipe employed—in the absence of a clearance recommendation by the vent pipe manufacturer, the requirements of the Uniform Mechanical Code should be met. The ventilation

air requirements for the Turbotemp heater can be found on page 20. It is recommended that vent runs over 5.4 M (18 ft) may need to be insulated to reduce condensation related problems and/or the use of a condensate trap in the vent run close to the heater may be necessary in certain installations such as cold climates. Horizontal vents 1 M (3 ft) or less in length do not require a condensate tee. The Turbotemp heater is suitable for through-the-wall venting.

NOTE

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. Remove the outside vent cover.

3. Install the Appliance Adapter in the Vent Body of the heater (located under the outside Vent

Cover). Before connecting the Appliance Adapter to the Vent Body, wet a clean cloth or paper towel with isopropyl alcohol (rubbing alcohol) and vigorously wipe the socket of the

Vent Body. Immediately wipe the cleaned surfaces dry with a clean cloth or paper towel.

Repeat for the exterior of the heater end of the Appliance Adapter. Attach the appliance adapter to the vent body using the adhesive specified by the vent manufacturer, following the vent manufacturer’s instructions.

!

WARNING

Risk of carbon monoxide poisoning if adapter is improperly attached. Mechanical connections (such as screws) can cause cracking and leaks in the adapter. Do NOT drill holes or use screws to connect the appliance adapter to the heater vent body. Attach with manufacturer’s specified adhesive.

!

WARNING

Risk of fire or asphyxiation if vent is not assembled according to manufacturer’s

instructions or if vent parts from different manufacturers are mixed. Vent parts from different manufacturers ARE NOT interchangeable. Mixing parts from more than one manufacturer may cause leaks or damage to vent. When installing a vent, pick one manufacturer and be sure that all vent parts come from that manufacturer and are specified by the manufacturer for your system. Follow manufacturer’s instructions and local and AS/

NZS 5601.1 requirements carefully during assembly and installation.

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. It is recommended to slope the horizontal pipe down to condensate trap at least 2cm/M (1/4 in per foot). Install “Approved” condensate drains at low points where condensate might collect. Plumb condensate drains to a drain through hard piping or high-temperature tubing such as silicone rubber or EPDM rubber – do not use vinyl or other low temperature tubing.

Follow drain manufacturer’s installation instructions.

5. Use an “Approved” firestop for floor and ceiling penetrations. Use an “Approved” thimble for wall penetrations. Use an “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 firestop) with insulation. The roof opening must be located so that the vent is vertical.

6. Vent Termination – Vertical (See Figures 14, 15 and 16), for height of vent termination above the roof. Use an “Approved” vent terminal specified by local and national codes and your manufacturer’s instructions. A roof termination must be vertical.

7. Make sure entire installation is sealed according to approved standard.

Chimney or Gas Vent Chimney or Gas Vent

Vent Cap and

Riser Furnished by Installer

Vent Cap and

Riser Furnished by Installer

Outlet Air

Opening

Outlet Air Opening

Side

Wall Vent

Figure 15.

Heater

Inlet Air

Opening

Side

Wall Vent

Vent

Termination

0.3 M (1 in) Minimum above sn ow or finished grade

(whichever is higher)

Forced Air

Inlet

Figure 17.

1.2 M (4 in) Min.

1.2 M (4 in) Min.

1.2 M (4 in) Min.

Vent

Termination

0.3 M (1 in) Min.

1.2 M

(4 in)

Min.

Gas Meter r hor izontal distance to exhaust opening is less than 3.3 M (10 ft).

Heater

Inlet Air Opening

Figure 16.

Max. 304 mm (12 in)

Min. 76 mm (3 in)

Vent

Termination

At least 2.1 M (7 in) above grade adjacent to public walkways

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

• at least 1.2 M (4 ft) below or horizontally from, or 0.3 M (1 ft) above, any doors or windows or gravity air inlet to a building

• at least 0.9 M (3 ft) above any forced air inlet located within 3 M (10 ft)

• at least 1.2 M (4 ft) horizontally from electric meters, gas meters, regulators and relief equipment

• at least 2.1M (7 ft) above grade adjacent to walkways or similar traffic areas.

The terminal must be located (See Figure 17):

• at least 3.3M (10 ft) from any opening into a building

• at least 0.3 M (12 in) above finished grade or the normally expected snow accumulation level, whichever is higher

• at least 1.2 M (4 ft) horizontally from electric meters, gas meters, regulators and relief equipment

• at least 2.1 M (7 ft) above grade adjacent to walkways or similar traffic areas

Allow at least 1 M (3 ft) vertical clearance over vent termination when terminating under an overhang or deck.

Avoid corners or alcoves where snow or wind could have an effect. Exhaust may affect shrubbery and some building materials. Keep shrubbery away from termination. To prevent staining or deterioration, sealing or shielding exposed surfaces may be required.

Metal

Vent

Body

Metal Special

Gas Vent requires

Appliance

Adapter

Support weight of pipe

Condensate

Tee

Condensate drain w/Trap

(Optional)

Figure 18.

Slope at least

(2 cm per Meter)

1/4" per foot down towards condensate drain

Approved

Termina l

12" (30.5 cm) Max.

3" (7.6 cm) Min.,

Clearance

!

WARNING

Fire Hazard. Do not run the heater vent into a common vent with any other appliance. Do not run the Special Gas Vent into, through, or within any active vent such as a factory built or masonry chimney.

NOTE: After installation, installer must check for correct and safe operation of the heater

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

FOR EACH VENT PIPE DIAMETER

ARE DIFFERENT AND CAN NOT BE

EXCEEDED.

It is recommended that vent runs over

No. of 90° Bends Maximum Length in Feet (M)

0

1

150 mm (6 in.) Flex-Vent

(Vertical or Horizontal)*

11.6 m (38 ft.)

8 m (26 ft.)

5.4 m (18 ft) may need to be insulated to reduce condensation related problems and/or the use of a condensate trap in

*Minimum vent length is 0.34M (1 ft.) or in accordance with vent manufacturer’s instruction, and local and national codes. Horizontal vents 1 m (3 in) or less in length do not the vent run close to the heater may be necessary in certain installations such as cold climates. Horizontal vents 1 m

(3 feet) or less in length do not require a condensate tee. The Turbotemp heater is suitable for through-the-wall venting.

See Table 8 for maximum permissible

Flexible Vent lengths.

require a condensate tee, but must slope down toward the outlet at 2 cm to the meter (1/4 in / ft.) to allow condensate to drain.

** Radius minimum to be 110 mm (4.33 in) as shown in

Figure 19.

Flexible Vent

Section

Figure 19.

!

CAUTION

Do NOT combine exhaust vent pipes to a common exhaust vent in multiple unit installations. Run separate vent pipes.

110 mm (4.33 in)

Radius Minimum

MINIMUM FLEX BEND RADIUS

NOTE: KEEP A 150 CM (6 IN) MINIMUM CLEARANCE BETWEEN THE VENT PIPE AND

COMBUSTIBLE SURFACES. FOLLOW THE VENT MANUFACTURER’S INSTRUCTIONS

AND CODE REQUIREMENTS.

Each 90° bend reduces the maximum horizontal vent run by 3.6 m (12 feet) and each 45° bend in the vent run reduces the maximum vent run by 1.8 m (6 feet). See Table 8 for the maximum vent length using one 90° bend.

NOTE

After installation, installer must check for correct and safe operation of the heater.

Corrosive Vapors and Possible Causes

Area

Chlorinated swimming pools and spas

Table 5.

Likely Contaminants

Pool or spa cleaning chemicals. Acids, such as hydrochloric or muriatic acid.

New construction and remodeling areas

Beauty parlors

Glues and cements, construction adhesives, paints, varnishes, and paint and varnish strippers. Waxes and cleaners containing calcium or sodium chloride.

Permanent wave solutions, bleaches, aerosol cans containing chlorocarbons or fluorocarbons.

Refrigeration plants or various industrial finishing and processing plants

Refrigerants, acids, glues and cements, construction adhesives.

Dry cleaning and laundry areas Bleaches, detergents, or laundry soaps containing chlorine.

Waxes and cleaners containing chlorine, calcium or sodium chloride.

CONTROL PANEL INDEXING

On an outdoor shelter installation, the exhaust discharges into a vent pipe. Orient the heater so that the vent pipe does not interfere with adjustment of the operating controls. The control panel located on the top panel can be rotated to any of the three sides of the heater for easy access, see Figure 20.

1. Remove the bolts from the door panels. Remove both door access panels.

2. Remove the four corner screws that secure the top panel.

Lift the top panel upward to remove the top panel.

3. Rotate the top panel to the desired position located at 90° angles. Note that the control panel must NOT be located on the side where the vent is located.

4. Replace the top panel down onto the side panels. Be sure that there are no wires caught under the panel.

5. Secure the top panel using the four corner screws.

6. Reattach the door access panels.

Top Panel

Door

Access Panel

Door

Access

Panel

Figure 20.

FINAL INSTALLATION CHECK

After installation, the installer MUST test and check that the heater is operating and functioning properly.

Some building codes require that the heater be anchored to the equipment pad or platform to withstand high wind pressures created during hurricanes. A Bolt Down Bracket Kit, P/N 460738, is available with anchor clamps designed to hold the unit to the equipment pad in high wind conditions, see Figure 21. Installation of the anchor clamps are recommended in all installations.

Figure 21.

ELECTRICAL CONNECTIONS

Electrical Rating 50 Hz 240 Volts AC, single phase

The heater is supplied with a 240V VAC, 10 AMP, 50 Hz power cord (AS/NZS 3112) approved for outdoor use. The power cord wire is 3 x 16 AWG (3 x 10 mm2).

!

CAUTION

This heater is designed to operate at 240 VAC. It is not recommended to be connected to OR operate on 208 VAC.

NOTE

• If any of the original wiring supplied with this heater must be replaced, installer must supply (No.

18 AWG, 600V, 105° C. U.L. approved AWM low energy stranded) copper wire or it’s equivalent.

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.

2. The heater, when installed, must be electrically grounded and bonded in accordance with local codes or, in the absence of local codes, with the National

Electrical Standards. A bonding lug is provided on the outside of the panel under the vent for this purpose.

3. Electrical power circuits to the pool heater must follow local codes and National

Electrical Standards.

4. All wiring between the heater and devices not attached to it, or between separate devices which are installed in the field, must be “Type T” wire rated for 35°C rise.

5.

The filter pump should run continuously when the heater is on, and for at least 15

minutes after the heater turns off. Any switches in the pump circuit (including circuit breakers) that can disconnect the pump must also disconnect the heater.

AC Plug

240 Volt

Figure 22.

including protective devices, into a grounded line. The heater is not sensitive to polarity.

Use the provided waterproof wire nuts when connecting the power supply.

A time clock controlling the filter pump should have a low-voltage Fireman’s Switch that switches off the heater at least 15 minutes before shutting off the pump.

CONNECTION OF FIREMAN’S SWITCH OR REMOTE CONTACT

!

CAUTION

This heater is designed to operate at 240 VAC. It is not recommended to be connected to OR operate on a 208 VAC.

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.

- Connect wires between the Fireman’s Switch terminals on the heater and the relay.

Connect wires from the controller or timer to the Fireman’s Switch. Controller, timer or relay should be sized to handle 24VAC at 0.5 Amp (because it will be completing the 24VAC control board circuit on the heater as shown in Figure 24). DO NOT apply line voltage to the Fireman’s

Switch terminals. Use 18 gauge wire with a minimum 1.2 mm

(3/64 in.) thick insulation rated for a temperature rise of at least

105° C.

- Knock-outs are provided to route the wires through the bottom of the control box and past the junction box.

4b. To connect a 3-Wire Control:

- Connect wires between the control board terminals on the heater and the external relays, as shown in Figure

25 on page 32. Use at least 2 relays per heater, to allow for an “OFF setting” on each heater mode. Select relays that can handle logic level switching. DO NOT apply line voltage to control board terminals.

- Move jumper (as shown in Figure 25 on page 28) to enable external control and to disable the heater membrane pad’s “Pool

ON” and “Spa ON” buttons (the “OFF” key on the membrane pad remains functional).

- Knock-outs are provided to route the wires through the bottom and the top of the control box and past the junction box.

5. Close control box cover.

6. Re-install the access door panels.

To control heaters that are operated in parallel, connect wiring at same locations on heater as

2-Wire or 3-Wire Control. It is imperative that each control circuit is isolated from the other control circuits, to avoid that current will flow from one heater to another through the control circuits.

NOTICE: The fuse for the Fireman’s Switch is a

1.25 Amp 31.75 mm x 6.35 mm fast blow fuse, which is commonly available.

Figure 23.

Figure 24.

Section 3. Installation

I pg 34

TURBOTEMP WIRING DIAGRAM

(3-WIRE SYSTEM)

CONNECTION DIAGRAM

Inlet Temperature Control Switch and AGS Switch

Stack Flue Sensor

Gas Valve

Y/W

Y

W

W

R

R

BL

BL

O

O

O

O

PR

PR

Air Flow Switch

Extra Switch 1

Hi-Limit Switch

Pressure Switch

PS

HLS

ES1

AFS

TH IND GND

OPERATING CONTROL

MEMBRANE PAD

CONNECTION

AGS

SFS

GAS

JMP3

1

External Control Interface Circuit Disabled,

Heater Membrane Pad Enabled

JMP

Spa Line

Common Line

External Control Interface

W

1

BK

Pool Line

J6

Y

Y/R

Y

BR

BR

Y

Y

Y

Y/BL

Y/O

Y/W

Y

NA/LP

Models Only

JMP

F1 F2

24

VAC

DIAGNOSTIC INDICATOR

IGNITION CONTROL

MODULE

1

External Control Interface Circuit

Enabled, "Pool On" and "Spa On"

Keys Disabled. "OFF" Key on

Membrane Pad Remains Functional.

S1

240

S1/

120 L1

L2 S2 TH IND VALGND

GY GY BK GY

Y/W

Y/O

Y/BL

Y/R

120 VAC

IGNITER

Y/W

GND

Plug –12 pin

240V – Red

BK

GY

O

BK

BK

BK

1

GY

W

R

GY

12 Position

Receptacle

Y

BK

W W

BK

Y

R

Line 1

JUNCTION BOX

BR

Line 2

Ground

BL

G/Y

GND

BL

NOTICE: Touching any 24VAC wire, including the Fireman's Switch wire, to the 240V terminal while the heater is connected to line power will immediately destroy the control board and void the warranty.

G

GND

BL

R

L1

F1

BLOWER

Y

Y/W

Y/O

Y/BL

Y/R

Y Y Y Y

Y

24 VAC

SEC

Y

Y

FL

BK

W

O

W

TRAN S

L2

BM

R R W

TURBOTEMP ELECTRICAL SCHEMATIC LADDER DIAGRAM

L1

LADDER DIAGRAM

240

VAC

L2

L1 S1

IGNITER

S2 L2

F1

24 VAC

F2

240

VAC

BLOWER

GND

CLASS II

TRANSFORMER

24 VAC

OPERATING

CONTROL

24 VAC

GND

24V

COM NO

LOGIC

WATER

PRESSURE

SWITCH

HI

LIMIT

SWITCH

AIR

FLOW

SWITCH

TH

IND

VAL

AGS

SWITCH

INLET TEMPERATURE

CONTROL SWITCH

GAS VALVE

THERMISTOR

SENSOR

STACK FLUE

SENSOR

NOTES:

1.)

L1 L2 F1 F2 S1 24 VAC

2. )

3. )

S2 GND IND VAL AND TH

ARE CONNECTED ON THE IGNITION MODULE.

PIN AND SOCKET CONNECTOR.

IF ANY OF THE ORIGINAL WIRES AS SUPPLIED

WITH THE APPLIANCE MUST BE REPLACED,

THEY MUST BE REPLACED WITH TYPE 105° C

OR ITS EQUIVALENT.

Figure 26.

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.

TURBOTEMP HSI ELECTRONIC IGNITION LIGHTING/OPERATION

FOR YOUR SAFETY: READ BEFORE LIGHTING

!

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not attempt to light the heater if you suspect a gas leak. Lighting the heater can result in a fire or explosion which can cause personal injury, death, and property damage.

START-UP AND OPERATION

START-UP AND SHUTDOWN INSTRUCTIONS ARE ON THE LABEL ATTACHED TO THE

COVER OF THE APPLIANCE CONTROL BOX.

BEFORE START-UP

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

B.

BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

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.

Follow the gas supplier’s instructions.

– If you cannot reach your gas supplier, call the Fire Department.

C. Use only your hand to turn the gas control on or off. Never use tools. If you cannot change the ON/OFF setting by hand, don’t try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion.

D. Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water.

E. Do not operate the pool heater unless the pool or spa is properly filled with water.

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. Make sure the ventilation openings are clear of debris or obstruction. For installations in an enclosed space, make sure openings for combustion and ventilation air are unobstructed.

2. Keep heater area clear and free from combustibles, flammable liquids and chemicals.

3. Check that all water connections are tight.

4. Water must be flowing through the heater during operation. Make sure that pool/spa is filled with water and have pump operating. Check that water flow is unobstructed from the appliance. When operating for the first time or after an extended shut-down, run filter pump for several minutes to clear all air from the system.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information on (page 34).

External Manual

Shut-off Valve

2. Set both pool and spa thermostats to the lowest settings.

3. Turn off all electric power to the appliance.

4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Turn off the outside external manual shut-off gas valve, see Figure 27.

Figure 27.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the

“Before Start-up” instructions (page 34). If you don’t smell gas, go to the next step.

7. Turn on the outside external manual shut-off gas valve, see Figure 27.

8. Set 3-way valves on inlet and outlet to pool or spa, as appropriate.

9. Turn on all electric power to the appliance.

10. Press either the POOL ON or SPA ON button switch on the operating control.

11. Set the thermostat to desired setting (NOTICE: Setpoint must be above actual water temperature or burner will not fire). See “OPERATING the CONTROL PANEL”.

12. The blower should come on immediately, and after about 20 seconds, the burner should fire. When operating for the first time, the burner may not fire on the first try because of air in the gas line. If it does not fire at first, push the OFF switch, wait five minutes, and again push the POOL or SPA ON switch. The burner should fire after about 20 seconds. You may have to repeat this until all of the air has cleared the gas line.

13. The burner should fire until the pool/spa temperature reaches the desired temperature set on the thermostat. The blower will continue to run for about 45 seconds after the burner shuts off. If any of the safety interlocks should open during burner operation, the burner shuts off immediately, but the blower continues to run for about 45 seconds. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the 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.

TO TURN OFF GAS TO APPLIANCE

1. Press the OFF button on operating control.

2. Switch off all electric power to the unit.

3. Turn off the outside external manual shut-off gas valve, see Figure 27.

SAFETY CONTROLS

AIR FLOW SWITCH (AFS)

The air flow switch, (see Figure 28), is a safety device used to insure that the combustion air blower (fan) is operating and has been designed to monitor the vacuum (negative) pressure within the blower housing. The air flow switch is factory set and is connected upstream of the ignition module. The ignition module does not operate unless the air pressure switch and all safety switches are closed.

Air Flow Switch

Figure 28.

WATER PRESSURE SWITCH

!

WARNING

Hazardous pressure. Do not bypass the Water Pressure

Switch or render it inoperable.

Water

Pressure

Switch

The water pressure switch, (see Figure 29). If the water flow is restricted, the water pressure switch may prevent the burner from firing and cause the “Service System” light to go on. If the light remains on after the filter has been serviced, have a qualified service technician check the system.

For deck-level heater installations, the Water Pressure Switch is factory set at 20.6 kPa (3.00 psi).

NOTE: See, Below Pool Level

Installation instructions on page 13. If the pressure switch is .3M

(1 ft.) below or above the pool water level, reset the switch so that

Figure 29.

it is open when the pump is off and closed when the pump is running. Turn the star-wheel on the switch clockwise ( ) to raise setting (heater below the pool) and counterclockwise ( ) to lower the setting (heater above the pool – see Figure 30. Test the switch after resetting.

NOTICE: When the heater is mounted more than 1.5M (5 ft.) above or 1.2M (4 ft.) below the deck level, a Pressure Switch is no longer adequate. A Flow Switch must be installed instead.

NOTICE: Heater operation with incorrect Pressure Switch setting may cause operation with no water flow. Operation of the heater without sufficient water flow may severely damage it and

will void the warranty.

Turn star wheel clockwise to raise pressure set point if pressure switch is more than 1.2M (4 ft.) below water level

A reference scale is on the back of pressure switch

Star Wheel

Turn star wheel counterclockwise to lower pressure set point if pressure switch is more than 1.5M (5 ft.) above water level

Figure 30.

HIGH LIMITS

A “High Limit”, is a safety device that opens the electrical circuit and shuts off the heater based on a water temperature set point within the “High Limit Device”. The Turbotemp series of heaters contains two (2) high limit devices which are located on the main inlet /outlet header.

Diagnostic LED

1 Flash - Lockout

2 Flashes - Air Flow Fault

4 Flashes - Erroneous Flame

OPERATION OF IGNITION MODULE

The Ignition Module, (see Figure 31), is microprocessor based and operates on 24VAC supplied by the transformer. The control utilizes a microprocessor to continually and safely monitor, analyze, and control the proper operation of the gas flame holder. The module with the presence of the flame sensor, using flame rectification, allows the heater to operate.

Flame Current

Check Point

Figure 31.

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.

HEATER OFF

TEMP

TEMP

Press this button to switch off the heater.

Press this button to raise the temperature setting.

Press this button to lower the temperature setting.

To toggle the display between degrees Centigrade (°C) and degrees Fahrenheit (°F):

Figure 32.

1. Turn the Operating Control OFF.

2. Press TEMP or TEMP for 5 seconds. The display will flash once and change modes

(°C to °F or vice versa).

3. Turn the Operating Control ON.

When either the

TEMP or TEMP buttons are depressed, the digital display will indicate the temperature setting. After five seconds, the display will return to the actual pool/spa temperature.

In addition to the digital temperature display, there are five indicator lights:

The POOL ON light indicates that the pool water temperature is governing operation of the heater.

The SPA ON light indicates that the spa water temperature is governing operation of the heater.

The

HEATING light comes on and stays on when the burner is firing. This light should be on whenever the burner is on. It blinks when the heater is calling for heat but not firing. If this light is on but the burner fails to come on, one of the “service” lights should come on, indicating a fault in the system.

The SERVICE SYSTEM light indicates that there is insufficient water flow to the heater. If the pump is operating, this usually indicates that the filter and/or skimmers should be cleaned

(some filters may require back-washing). If the light remains on after the filter/skimmers have been serviced, the system should be checked by a qualified service technician.

The

SERVICE HEATER light indicates a fault in the heater or its controls. If this light comes on, shut down the heater (See “TO TURN OFF GAS TO THE APPLIANCE” on page 36), and have a qualified service technician check the system.

!

WARNING

Risk of explosion or fire causing burns or death if safety interlocks are disabled. DO

NOT attempt to operate heater when SERVICE HEATER light is on or if blower or burner will not start. Instead, follow instructions under “To Switch Off Gas to the Appliance,” and call a qualified service technician to repair unit.

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° C (65° F.), or a maximum of 40° C (104° F). If you desire to heat only one body of water, the thermostat is capable of an off mode. As an example, if you only wish to heat the spa and not the pool, simply depress and hold the pool down arrow, and the thermostat will lower its setting to 18.3° C (65° F.) then go to an off mode. See below to change the heater’s

factory set temperature settings.

MAXIMUM TEMPERATURE SET POINT

1. Unbolt and remove the door panels (see Figure

33).

2. Access the control panel board on the underside of the top cover. Locate the yellow button on the corner of the control board.

3. Push the Max. Temp. Set Point button on the back of the control board (see Figure 34).

Top Panel

The following sequence should happen:

A. The unit turns on and the POOL ON light will turn on.

B. Press the TEMP or TEMP pad (on

TOP of the panel) to set maximum pool temperature.

C. Wait up to 30 seconds; the POOL ON light will turn off and the

SPA ON light will turn on.

To override the time delay, push the

Max.

Temp. Set Point button again.

D. Press the TEMP or TEMP button on the control panel and set maximum spa temperature to 40°C (104° F) or less.

E. Wait up to 30 seconds; the SPA ON light will turn off and the unit will shut down.

To override the time delay, push the

Max.

Temp. Set Point button again.

4. Reinstall the access door panels.

Door

Access Panel

S1

Door

Access

Panel

Figure 33.

S1

Figure 34.

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.

IMPORTANT! READ ME FIRST!

READ THE FOLLOWING CAREFULLY:

1. Check the line voltage to your heater. This heater operartes on 240 Volts AC.

2. Remove the covers and check the 12-pin plug in the back of the control box.

The plug must match the voltage in the heater circuit.

3. If the 12-pin plug is not plugged into the back of the control box, plug in the

RED 240 volt plug.

Start here for directions to specific Troubleshooting Chart

Is green “POOL” or “SPA”

LED “on”?

YES

NO

Go to chart “HEATER WILL

NOT FIRE - A”

(Page 41)

Is red “SERVICE SYSTEM”

LED “on”?

NO

Is red “SERVICE HEATER”

LED “on”?

YES

YES

Are any red diagnostic

LED’s on back of board (AGS, AFS,

SFS, HLS, PS or

THERMISTOR) “on”

NO

YES

Go to chart “HEATER WILL

NOT FIRE - B”

(Page 42)

Go to specific safety switch troubleshooting chart

(Pages 45 and 46)

NO

Turn off power to heater for about 5 seconds, and turn back on. Make sure temperature setting is above water temperature. Wait one minute.

Do any diagnostic LED’s on back of board (AGS, AFS, SFS,

HLS, PS, or THERMISTOR) come “on” and stay on?

NOTICE: Any or all of the diagnostic LED’s may come

“on” momentarily when you turn on the power to the heater.

YES

NO

Does red “SERVICE

HEATER” LED come

“on”

YES

Go to chart ‘HEATER WILL

NOT FIRE -C”

(Page 43)

NO

Verify that water temperature setting is above water temperature reading. If it is, and heater either will not fire or no red

LED’s come “on”, replace Control Board.

!

WARNING

Hazardous voltage. Can shock, burn or kill.

Disconnect power before servicing any components.

!

WARNING

Fire and Explosion hazard. Do not jumper switch terminals to remedy a failed safety switch.

Heater Will Not Fire - A

Start

Is green “SPA” or

“POOL” LED “on”

YES

Check that the 12-pin plug is installed (red

240V)

NO

NO

YES

YES

Depress “POOL” or “SPA” ON button on Membrane Pad.

Does “POOL” or “SPA” LED come on?

NO

Check for line voltage to heater.

If plug is not installed:

Install the

240V plug in

120V circuit: Replace transformer, control board and ignition control module (see "HEATER

WILL NOT FIRE-C and

-D", Pages 38 and 39).

Check fuse and all other 24V components for damage.

YES

Check for 24 VAC at secondary of Transformer.

NO

Check for Line Voltage between L1 and L2 terminals on Terminal Board.

YES

Check for Line Voltage at

Transformer primary pins.

White connects to Pin 3 on

Transformer, Black to Pin 2,

Orange to Pin 1.

240V: check Pin1 to Pin 3.

YES

NO

NO

NO

YES

YES

YES

NO

Jumper Fireman’s Switch at

Terminal Board and depress

“POOL” or “SPA” ON button on membrane pad. Does “SPA” or

“POOL” LED come “on”?

NO

Leaving jumper in place, check for 24 VAC between

Fireman’s Switch terminals and ground.

Remove jumper. Check ribbon cable connection between

Membrane Pad and J6 on

Control Board. Depress

“POOL” or “SPA” On pad again. Does “POOL” or “SPA”

LED come on?

Jumper pins 6 and 5 on J6 of

Control Board. Does “SPA”

LED come on?

Jumper pins 6 and 4 on J6 of

Control Board. Does “POOL”

LED come on?

NO

YES

YES

NO

GO TO

“HEATER WILLNOT FIRE - B”

Page 37

Heater should fire on demand for heat.

Restore power to heater.

Check wiring connections between power supply and

Junction Box and between

Junction Box and Terminal

Board; restore continuity.

Check wiring connections between Terminal Board and

Transformer primary and restore continuity.

Replace Transformer.

Check Fireman’s Switch circuit connections (time clock, wiring, external controller relay).

Remove jumper. Check wiring between Transformer and J7 terminals on Control Board and between J7 and

Fireman’s Switch on Terminal

Board, check fuse, and restore continuity.

Heater should fire on demand for heat.

Replace Membrane Pad.

Replace Control Board.

Section 5. Troubleshooting

I pg 44

Heater Will Not Fire - B

Start

Is red “SERVICE

HEATER” LED “on”

NO

YES

CONTINUE

Is red “SERVICE SYSTEM”

LED on?

NO

YES

Verify that pump is on, filter is not blocked, and the water flow is above the minimum requirement.

YES

With pump running, adjust

Water Pressure Switch to lower pressure until ‘SERVICE

SYSTEM” LED goes out. Then verify that “SERVICE SYSTEM”

LED goes on with pump off.

NO

YES

NO

Check that water pressure is within the adjustment range of the Pressure Switch (0-35 kPa).

NO

YES

Verify that switch wiring is OK and Pressure Switch port is not blocked, and replace water Pressure Switch.

Check whether any of the red diagnostic LED’s on back of board (AGS, AFS, SFS,

HLS or PS) are “on”

NO

GO TO

“HEATER WILLNOT FIRE - C”

Page 38

YES

Increase POOL/SPA temperature setting on

Membrane Pad above actual water temperature. Heater should fire on demand for heat.

If not, and no other red LED’s light, replace Control Board.

Service pump/filter and eliminate other flow obstructions.

Heater should fire on call for heat. Re-verify that water flow is above minimum requirement.

Minimum Flow Requirements

Model

175

200

250

300

400

Flow

76 LPM (20 gal/min)

76 LPM (20 gal/min)

95 LPM (25 gal/min)

114 LPM (30 gal/min)

151 LPM (40 gal/min)

If water pressure is outside of adjustment range that will open switch with pump off and close switch with pump on, replace with flow switch set above minimum flow requirement.

Minimum Flow Requirements

Model

175

200

250

300

400

Flow

76 LPM (20 gal/min)

76 LPM (20 gal/min)

95 LPM (25 gal/min)

114 LPM (30 gal/min)

151 LPM (40 gal/min)

Go to “Diagnostic LED’s”,

(Pages 45 and 46)

Heater Will Not Fire - C

Start

Is “SERVICE HEATER” LED

“on”?

YES

If any red diagnostic LED’s

(AGS, AFS, SFS, HLS, PS, or

THERMISTOR) come “on”, go to to Pages 45 and 46.

CONTINUE

Did burner fire at all?

YES

Go to “BURNER

TROUBLESHOOTING”

(Page 47)

NO

NO

stay on?

NO

Turn off power to heater for 5 seconds, and turn back on.

Make sure temperature setting is above water temperature.

Wait one minute.

Does heater fire and

YES

NO

Go to “INITIAL

TROUBLESHOOTING”

Continue to observe heater for several minutes. Cycle heater on and off several times.

Observe for delayed or rough ignition, poor combustion, premature extinction of flame, evidence of boiling, or operation of any diagnostic

LED. Go to pertinent troubleshooting section if any malfunction is observed.

Replace Control Board.

Go to “HEATER WILL NOT

FIRE-D” (Page 44)

YES

Did Blower come on?

YES

Verify that gas is flowing to burner during ignition try. Observe gas meter for movement during ignition try (wait for about 30 seconds after calling for heat).

Replace Ignition Control

Module.

NO

Check for 24 VAC between

VAL and GND terminals on

Ignition Control Module.

SEE NOTE 2.

YES

Check for 24 VAC between

VAL and GND terminals on

Control Board. SEE NOTE 2.

NO

Fix wiring between VAL and

GND terminals of Ignition

Control Module and Control

Board.

YES

YES

Check for 24 VAC between TH and GND terminals on Ignition

Control Module.

SEE NOTE 1.

NO

Check for 24 VAC between TH and GND terminals on Control

Board. SEE NOTE 1.

Check for 24 VAC between GAS terminals on Control

Board. SEE NOTE 2.

NO

Replace Control

Board.

YES

NO

YES

NO

NO

Verify that gas supply is open all the way to Gas Valve, and

Gas Valve is set at “on” position.

Check for 24 VAC to Gas

Valve terminals during ignition try. (Voltage appears about 24 seconds after call for heat).

SEE NOTE 2.

YES

Replace Gas Valve with identical part.

Fix wiring between TH and

GND terminals of Ignition

Control Module and Control

Board.

Replace Control Board.

Fix wiring between GAS terminals on Control Board and Gas Valve.

NOTE 1 : Voltage appears immediately after call for heat, and may be on for only about

30 seconds.

NOTE 2 : Voltage appears about

24 seconds after call for heat, and may be on for only about

7 seconds.

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). If the ICM is bad, your voltmeter will read either 0

VAC or 240 VAC. If your ICM is good, your meter will read some voltage between 0 and 240 VAC. Exactly what reading you get will depend on the meter, but with a good ICM, the reading won’t be 0 VAC or 240

VAC, but somewhere in between.

Start

Gas flows during ignition try, but burner does not fire.

YES

Check voltage across igniter leads; OK?

NO

Replace Ignition

Control Module.

NO

YES

Go back to chart “HEATER WILL

NOT FIRE-C” (Page 44).

Check gas pressure. OK?

NO

Increase gas flow into heater:

• Replace gas line with larger line;

• Replace regulator;

• Replace meter; or

• All of the above.

YES

Replace HSI Igniter.

Diagnostic LED’s: AGS, AFS, HLS, PS, THERMISTOR

AGS or HLS "on"

Replace High Limit

Switch (HLS) or

Automatic Gas

Shutoff (AGS)

CONTINUE

YES

Verify that water flow rate is above minimum required for heater.

YES

Verify that inlet water temperature is below 45° C.

If problem persists, verify proper operation of Internal Bypass Valve and Thermal Governor, and check for Heat Exchanger blockage.

AFS "on"

NO

NO

Service pump and filter to restore proper flow. After servicing, verify proper operation of Pressure Switch (PS).

Replace thermistor or Control

Board to correct overheating.

PS "on"

Verify that wiring is

OK and pressure tap is not blocked. Replace Pressure Switch

CONTINUE

Verify that water flow rate is above minimum required for heater.

NO

Service pump and filter to restore proper flow.

YES

CONTINUE

Adjust Water Pressure Switch to close with pump running and open with pump off.

YES

Replace Blower.

Verify that wires BM and F1 are correctly connected at the terminal strip (see

Heater Connection

Diagram, Page 28).

YES

YES

YES

NO

Does Blower operate?

NO

Disconnect Blower and check for line voltage between pins

1 and 3 of Blower Connector on ignition try.

NO

Check for 24 VAC between

24 VAC and GND terminals on Ignition Control Module on ignition try. Check that IND wire is correctly connected.

NO

Verify correct connection of wiring between

24 VAC and IND terminals on

Ignition Control Module and

Control Board, and replace

Control Board.

Verify that there is no blockage in Blower intake, Heat

Exchanger, and exhaust.

Verify correct connection of wiring and that pressure taps to AFS are OK.

Verify that vinyl tubing to AFS and Blower is not misrouted, kinked, disconnected, or punctured.

Replace Air Flow Switch

(AFS).

If problem persists, replace

Blower.

Connect correctly and retry.

Does Blower start?

Disconnect wires F1 and F2 from Ignition

Control Module and short them together.

Does Blower come on?

YES

NO

NO

NO

Replace Blower. Does Blower start on ignition try?

Replace Ignition Control

Module.

THERMISTOR "on"

Verify Thermistor wiring. If

OK, replace Thermistor.

CAUTION

Do not jumper a safety switch to remedy a failed switch.

NOTE: ES1 is a spare and should be jumpered.

Section 5. Troubleshooting

I pg 48

Diagnostic LED’s: SFS

SFS "on"

Heater starts and runs OK, but temperature of exhaust climbs to 204°–260°C in

3-5 minutes.

NO

Heater starts after several tries, exhaust temperature stays below 121.1 °C.

OR

Heater doesn’t start at all

(exhaust stays cold).

YES

Check Heat Exchanger

Coil for leaks, liming, soot, or low flow.

YES

Check Thermal

Regulator: Open at

48.9°C?

NO

YES

NO

Correct problem;

Heater should fire.

NO

YES

Check Thermal-Regulator:

Seats correctly?

NO

(HD)

Replace Heater

Membrane Pad.

DONE

Replace Heater

Control Board.

DONE

Check pressure and volume of fuel supply

OK

Disconnect the sensor and check continuity across its terminals. Resistance should be 3.5-4.0 megaohms.

= open circuit;

0 = shorted.

Does sensor check OK?

NOT OK

NO

Correct Fuel Supply, reset

Heater and retry. Heater should fire correctly.

NO

Replace Stack Flue Sensor

DONE

Reset power to Heater and retry. Heater should fire.

NO

YES

YES

Check continuity in wiring harness between Control

Board and Probe.

Continuity OK?

NO

Check the J3 and J6 connectors for corrosion/ looseness on the male pins.

YES

Clean/tighten pins as needed.

DONE

Reset power to Heater and retry. Heater should fire.

NO

NO

Repeat checks on fuel supply, Thermal Regulator, check for correct orifices, etc.

YES

Does the Digital

Temperature Display show

Error Code “E05” or “E06”?

NO

(Basic)

Reset power to Heater and retry. Heater should fire.

NO

Check Heat Exchanger Coil for leaks, liming, soot, or low flow.

Replace Heater Control Board.

DONE

Reset power to Heater and retry. Heater should fire.

NO

Replace Heater Membrane Pad.

DONE

Reset power to Heater and retry. Heater should fire.

Burner Troubleshooting

SYMPTOM

Loud, high-pitched whine

CAUSE

Flame is too rich.

Flame is “fluttery .”

Exhaust may have acrid smell or burner may fail to stay lit.

Combustion appears normal, but flame does not stay lit.

Flame is too lean.

Flame current is not being sensed.

REMEDY

Verify pressure tap between gas valve and blower inlet.

Verify that the gas regulator setting is 11 ±

5 Pa.

Contact a qualified technician or service agency to replace the gas orifice.

Verify that the gas regulator setting is 11 ±

5 Pa.

Contact a qualified technician or service agency to replace the gas orifice.

Check for wet or damaged igniter with low resistance to ground. Replacewith new igniter.

Verify burner flameholder is properly grounded.

Replace Ignition Control Module.

Heat Exchanger Troubleshooting

SYMPTOM

Boiling in heat exchanger. May be accompanied by

“bumping” sounds.

CAUSE

Low water flow to heater.

Heat exchanger plugged.

Bypass valve stuck open.

Thermal governor stuck closed.

Sweating.

Thermal governor failed.

REMEDY

Service pump and or filter.

Service heat exchanger. Correct water chemistry.

Service bypass valve.

Replacethermal governor.

Replacethermal governor.

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.

The following maintenance is recommended every six months and at the start of every swimming season:

1. Inspect the heater panels and venting system to make sure that there are no obstructions to the flow of ventilating air or burner exhaust.

2. Keep the area in and around the heater clear and free from combustible materials, gasoline and other flammable vapors and corrosive liquids.

3. If applicable, test the operation of the pressure relief valve by lifting the valve lever. (See below for “PRESSURE RELIEF VALVE” instructions.)

4. Test for proper operation of the pressure switch. (See “WATER PRESSURE SWITCH” for testing instructions.)

5. Check pipe and fittings for cracks or breaks. The combustion air blower is permanently lubricated, and does not require periodic lubrication. The burner does not require maintenance or adjustment by the user. Call a qualified service technician if you suspect that the burner may require maintenance.

DE-LIMING THE HEATER

!

WARNING

Working with muriatic acid can be dangerous. When cleaning elements always wear rubber gloves and eye protection. Add acid to water, do not add water to acid. Splashing or spilling acid can cause severe personal injury and/or property damage.

Should a heater require de-liming, this may be accomplished by circulating a solution of 30%

Muriatic Acid. This process should only be performed by a person of sufficient skill. The heater

MUST be disconnected from the pool plumbing, gas plumbing, and electric. The heater may be placed on its side with the water manifold “up”. The diluted muriatic acid may be recirculated until visible bubbles are no longer produced. Before being restored to service, the heater water ways should be completely rinsed with regular tap water.

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.

The relief valve must be installed vertically. To install the valve, use a 19 mm x 5 mm brass nipple at the manifold, the two brass elbows and nipples are (user supplied), as illustrated in Figure 35. No valve is allowed to be placed between the manifold adapter and the relief valve.

To avoid water damage or scalding from operation of the relief valve, install a drain pipe in the outlet of the pressure relief valve that will direct water discharging from the valve to a safe place for disposal. Do not install any reducing couplings or valves in the drain pipe. The drain pipe must be installed so as to allow complete drainage from the valve and drain line.

The relief valve should be tested at least once a year by lifting the valve lever.

Drill thru the NPT Port, then use a 19 mm Brass Nipple and

Elbow (user supplied) for a

PRV Installation.

Figure 35.

!

WARNING

Explosion hazard. Any heater installed with restrictive devices in the piping system downstream from the heater, (including check valves, isolation valves, flow nozzles, or therapeutic pool valving), must have a relief valve installed as described above.

AFTER START-UP

CHECKING WATER FLOW

!

WARNING

Fire or flooding hazard. If the unit overheats and the burner fails to shut off, follow instructions under “To Turn Off Gas to the Appliance”, page 36, and call a qualified service technician to repair unit.

After start-up, the outlet water pipe should feel slightly warmer than the inlet pipe. If it feels hot, or if you hear the water in the heater boiling, there may not be enough water flow to the appliance. Make sure that the filter is not plugged. If water temperature remains high but the unit continues to operate, turn off the appliance and call your service technician.

SPRING AND FALL OPERATION

If the pool is only used occasionally, lower the pool thermostat to 20° C (68° F) and leave the heater on. This will keep the pool and the surrounding ground warm enough so that the heater should restore the pool to a comfortable temperature within about one day.

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.

• Water trapped in the heat exchanger can result in freeze damage to the exchanger or headers. Freeze damage is specifically not covered by the warranty.

• When starting the heater for the swimming season with a water temperature below

10° C (50° F), the heater may be used to heat the water; however, make sure that the heater operates continuously until the water temperature reaches the heater’s minimum setting of 20° C (68° F). During cold weather, if there is no danger of freezing, operate the filter pump continuously even if the heater is not operating.

If air temperatures are expected to drop below freezing 0° C (32° F), shut down the heater and winterize it.

For outdoor heaters in freezing climates, shut the heater down and drain it for winter as follows:

1. Turn off electrical supply to the heater and pump.

2. Close the external manual shut-off gas valve (located outside the heater).

3. In colder climates where they may be required, open drain cock located on the bottom of the manifold adapter, and drain the heat exchanger and manifold adapter completely. If heater is below pool water level, be sure to close isolation valves to prevent draining the pool (isolation valves are not required and should not be used on heaters installed above pool water level except when needed for winterizing valves). Assist the draining by blowing out the heat exchanger through the pressure switch fitting with low pressure compressed air

(less than 35 kPa or 5 PSI).

!

WARNING

Explosion hazard. Purging the system with compressed air can cause components to explode, with risk of severe injury or death to anyone nearby. Use only a low pressure (below

35 kPa or 5 PSI), high volume blower when air purging the heater, pump, filter, or piping.

4. Remove the Water Pressure Switch. Plug the port in the manifold to prevent bugs and dirt from getting into the manifold.

5. Drain the plastic inlet/outlet manifold through the outlet pipe. If the pipe does not drain naturally to the pool, install a drain cock in the outlet pipe to drain the manifold.

6. Cover air inlet grate with a plastic bag to prevent bugs, leaves, etc., from getting into the heater.

NOTICE: Water trapped in the heater can cause freeze damage. Allowing the heater to freeze voids the warranty.

To return the heater to service after winterizing:

1. Close drain cock and fittings.

2. Before starting the heater, circulate water through the heater for several minutes until all air noises stop. See also “BEFORE START-UP” (page 34) and “CARE AND MAINTENANCE”

(page 48).

(See additional notes under Important Notices in Introduction.)

MAINTAINING POOL TEMPERATURE

To maintain pool temperature, make sure that the heater switch and valving are reset to pool settings after using the spa.

ENERGY SAVING TIPS

1. Keep the pool or spa covered when not in use. This will reduce heating costs, reduce water evaporation, conserve chemicals and reduce load on the filtering system.

2. Reduce pool thermostat to 26° C (78° F) or lower; reduce spa temperature to 38° C (100° F).

This is accepted as being the most healthy temperature for swimming by the American Red

Cross.

3. Use a time clock to start the filter pump at 6 a.m. or later. The swimming pool loses less heat after daybreak.

4. For pools used only on weekends, lower the thermostat setting by -12° C to -9° C (10° F to 15° F) during the week to reduce heat loss. A properly sized heater will restore normal temperature within one day.

5. Turn the heater off when the pool will not be used for an extended period.

6. Follow a regular program of preventive maintenance for the heater each new swimming season. Check operation of the heater and its controls.

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.

Install a corrosion resistant positive seal “Check Valve”, (P/N R172288), between the heater and the chlorinator to prevent concentrated chemicals from back-siphoning into the heater. Backsiphoning is most likely to occur when the pump stops, creating a pressure-suction differential.

Do NOT sanitize the pool by putting chlorine tablets or sticks into the skimmer(s). When the pump is off, this will cause a high concentration of chlorine to enter the heater, which could cause corrosion damage to the heat exchanger.

Three major items that can cause problems with your pool heater are: improper pH, disinfectant residual, and total alkalinity. These items, if not kept properly balanced, can shorten the life of the heater and cause permanent damage.

!

CAUTION

Heat exchanger damage resulting from chemical imbalance is not covered by the warranty.

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.

Chlorine and bromine are universally approved by health authorities and are accepted disinfecting agents for bacteria control.

WHAT IS A DISINFECTANT RESIDUAL?

When you add chlorine or bromine to the pool water, a portion of the disinfectant will be consumed in the process of destroying bacteria, algae and other oxidizable materials. The disinfectant remaining is called chlorine residual or bromine residual. You can determine the disinfectant residual of your pool water with a reliable test kit, available from your local pool supply store.

You must maintain a disinfectant residual level adequate enough to assure a continuous kill of bacteria or virus introduced into pool water by swimmers, through the air, from dust, rain or other sources.

It is wise to test pool water regularly. Never allow chlorine residual to drop below 0.6 ppm (parts per million). The minimum level for effective chlorine or bromine residual is 1.4 ppm.

pH - The term pH refers to the acid/alkaline balance of water expressed on a numerical scale from 0 to 14. A test kit for measuring pH balance of your pool water is available from your local pool supply store; see Table 10.

Muriatic Acid has a pH of about 0. Pure water is 7 (neutral). Weak Lye solution have a pH of 13-14.

RULE: 7.4 to 7.6 is a desirable pH range. It is essential to maintain correct pH, see Table 10.

If pH becomes too high (over alkaline), it has these effects:

1. Greatly lowers the ability of chlorine to destroy bacteria and algae.

2. Water becomes cloudy.

3. There is more danger of scale formation on the plaster or in the heat exchanger tubing.

4. Filter elements may become blocked.

If pH is too low (over acid) the following conditions may occur:

1. Excessive eye burn or skin irritation.

2. Etching of the plaster.

3. Corrosion of metal fixtures in the filtration and recirculation system, which may create brown, blue, green, or sometimes almost black stains on the plaster.

4. Corrosion of copper tubes in the heater, which may cause leaks.

5. If you have a sand and gravel filter, the alum used as a filter aid may dissolve and pass through the filter.

CAUTION: Do not test for pH when the chlorine residual is 3.0 ppm or higher, or bromine residual is 6.0 ppm or higher. See your local pool supply store for help in properly balancing your water chemistry.

RULE: Chemicals that are acid lower pH. Chemicals that are alkaline raise pH.

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.

A total alkalinity test is simple to perform with a reliable test kit. You will need to test about once a week and make proper adjustments until alkalinity is in the proper range. Then, test only once every month or so to be sure it is being maintained. See your local pool dealer for help in properly balancing the water chemistry.

WATER CHEMISTRY PARAMETERS

Disinfectant levels

Free Chlorine, ppm

Combined Chlorine, ppm

Bromine, ppm

Other Sanitizers

Table 10.

Minimum

1.0

None

2.0

Ideal

2.0 - 4.0

None

4 - 6

Maximum

5.0

0.2

10.0

Levels not established. Consult local health department before use.

Chemical Values

pH

Total Alkalinity (Buffering), ppm as

CaCO3

Total Dissolved Solids, ppm

7.2

60

N/A

7.4 - 7.6

80 - 100

N/A

7.8

180

Calcium Hardness, ppm, as CaCO3

Heavy Metals

Biological Values

Algae

Bacteria

150

None

None

None

200 - 400

None

None

None

1,500 ppm >

TDS at startup*

500 - 1,000

None

None

Refer to Local

Code

NOTICE: Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger and will

void the warranty.

*Start-up TDS includes source water TDS and any other inorganic salt added at start-up.

Section 6. Maintenance

I pg 56

TURBOTEMP REPLACEMENT PARTS

For complete

Electrical System parts breakdown

(Key Nos. 1 through 4), see Page 44.

3

7

2

5

6

1

9

For complete

Burner System parts breakdown

(Key Nos. 5 through 7), see Page 42.

8

4

For complete

Water System parts breakdown

(Key Nos. 8 through 9), see Page 43.

Repair Parts are available from your Pentair dealer.

If your dealer cannot supply you, call Customer Support

If your dealer cannot supply you. Call Customer Support.

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)

Section 6. Maintenance

I pg 58

TURBOTEMP REPLACEMENT PARTS

REPAIR PARTS – BURNER SYSTEM

•

8

9

10

11

12

13

•

14

15

6

7

•

5

•

Key

No.

3

4

1

2

•

•

•

•

Part

Description

Gas Valve Assembly [Australia]

19 mm Union

Gas Orifice

Gas Orifice O-Ring

Gas Orifice Kit – NG (Incl. Key Nos. 3 and 4)†

Gas Orifice Kit – Propane (Incl. Key Nos. 3 and 4)†

NG to Propane Conversion Kit

(Incl. Key Nos. 3 and 4)†

Propane to NG Conversion Kit

(Incl. Key Nos. 3 and 4)†

Air Blower [50 Hz]

Air Orifice Kit (Includes Key Nos. 6 and 7)

Air Orifice

Air Orifice Grill

Blower/Adapter Plate Gasket Kit

(Includes Key Nos. 8, 9, 10, 12)

Flameholder Kit (Includes

Key Nos. 10, 11, 12, 13 and on 300 & 400

Models Only - Flameholder Insert)

Blower/Adapter Plate Gasket

Blower Adapter Plate

Flameholder/Adapter Plate Gasket

Flameholder Assembly

Flameholder/Combustion Chamber Gasket***

Flameholder Insulation Cap

Flameholder Insert

Condensate Evaporator Plate

One Piece Metal Chamber/Combustion Chamber

Assembly

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

200NA

200LP

474133Z

38404-4097S

474136

474139

474142

474145

474104Z

474107Z

77707-0011

77707-0202

Model

300NA

300LP

474133Z

38404-4097S

474135

474138

474141

474144

474104Z

474106Z

77707-0011

77707-0203

1 474095** 474095**

474957 474957*

400NA

400LP

474133Z

38404-4097S

474134

474137

474140

474143

474104z

474105Z

77707-0011

77707-0204

474095**

474957*

•

16

17

18

19

•

20

•

21

Insulation Kit (Includes Key Nos. 13, 14, 16, 17, 18 and 19)

Bottom Outer Insulation Blanket***

25.4 mm Bottom Inner Insulation

25.4 mm Top Insulation

Top Outer Insulation Blanket***

Lower Enclosure Insulation

One Piece Metal Elbow/Combustion Chamber

Cover Assembly

Combustion Chamber Gasket

Metal Vent Cover Assembly

1

1

1

1

1

77707-0008 77707-0008 77707-0008

42001-0074S 42001-0074S 42001-0074S

474958* 474094** 474958* 474094** 474958* 474094**

474952* 474201** 474952* 474201** 474952* 474201**

474172Z 474172Z 474172Z

22

26

27

28

23

24

25

Heater Top

Side Panel {Service Panel}

Side Panel {Manifold}

Heater Bottom

Side Panel {Flue Stack}

J-Box Cover

Screw Kit, Panel

1

1

1

1

1

1

1

42002-0034Z

42002-0039Z

42002-0033Z

42002-0031Z

42002-0032Z

42002-0041Z

474292

42002-0034Z

42002-0039Z

42002-0033Z

42002-0031Z

42002-0032Z

42002-0041Z

474292

(*) For heaters manufactured after 10/31/2013 (new 9-bolt tub design)

(**) 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.

(***) Not available separately

(†)

Not included with heater. Order separately.

42002-0034Z

42002-0039Z

42002-0033Z

42002-0031Z

42002-0032Z

42002-0041Z

474292

TURBOTEMP REPLACEMENT PARTS

1

3

4

5

6

7

8

2

9

10

11

12

13

14

15

16

17

18

19

22

2

11

12

13

14

7

8

9

10

•

5

3

4

6

Key

No.

1

15

19

20

21

22

16

17

•

18

21

20

REPAIR PARTS – WATER SYSTEM

Part

Description

Tube Sheet Coil Assembly Kit ( HD Series)

(Includes Key No.3)

Manifold Kit (Includes Key Nos. 3-14, 21, and

Key Nos. 5-7, 17 in “Electrical System”, Page 51

Coil/Tubesheet Sealing O-Ring Kit

Manifold Bottom Plate

Manifold O-Ring

O-Ring Kit (Incl. Key Nos. 3, 5)

Manifold Insert*

Manifold Baffle Plate

Manifold Bypass Valve

Water Pressure Switch

Manifold

5/16" Washer, S.S.

5/16"-18 x 2-3/4" Hex Cap Screw

Connector Tube O-Ring

Connector Tube Kit (Includes 1 Connector Tube and 1 O-Ring)

Thermal Regulator Kit

(Incl. Key Nos. 16, 17, 18, 19 and Spring Clip)

Thermal Regulator (Includes Spring Clip)

Thermal Regulator Spring

Thermal Regulator Cap O-Ring

Thermal Regulator Spring Clip

Thermal Regulator Cap

Drain Plug

3/4" Pipe Plug

Pressure Relief Valve (Recommended -

Purchase Separately)

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

10

10

2

1

( )

1

1

1

1

1

2

1

200NA

200LP

474062

474391

77707-0117(6)

77707-0120

42001-0060S

77707-0017

77707-0010

38000-0007S

35505-1313

U178-920P

U78-60ZPS

38674-0719

Model

300NA

300LP

474064

474392

77707-0118(10)

77707-0120

42001-0060S

77707-0017

77707-0010

38000-0007S

35505-1313

U178-920P

U78-60ZPS

38674-0719

400NA

400LP

474065

474392

77707-0119(12)

77707-0120

42001-0060S

77707-0017

77707-0010

38000-0007S

35505-1313

U178-920P

U78-60ZPS

38674-0719

•

* Not available separately.

Not illustrated.

Section 6. Maintenance

I pg 60

TURBOTEMP REPLACEMENT PARTS

15

1

14

13

10

11

12

16

2

3

4

17

5

9

8

7

6

Key

No.

Part

Description

REPAIR PARTS – ELECTRICAL SYSTEM

QTY.

200NA

200LP

Model

300NA

300LP

400NA

400LP

1 Heater Display Cover 1 42002-0035 42002-0035 42002-0035

2 Igniter Bracket 1 42001-0030S 42001-0030S 42001-0030S

3 Igniter/Igniter Gasket Kit Incl. Key Nos. 3 and 4)

4 Igniter Gasket

1 77707-0054 77707-0054 77707-0054

1 42001-0066S 42001-0066S 42001-0066S

5 Automatic Gas Shutoff Switch (AGS)

6 High Limit Switch

1 42002-0025S 42002-0025S 42002-0025S

1 474171Z 474171Z 474171Z

7 Thermistor 1 42001-0053S 42001-0053S 42001-0053S

8 Terminal Board 1 42001-0056S 42001-0056S 42001-0056S

9 Fireman’s Switch Fuse (31.75mm X 6.35 mm) 1 32850-0099 32850-0099 32850-0099

10 Fenwal Ignition Control Module 1 474103Z 474103Z 474103Z

11 Transformer, 120/240V 1 42001-0107S 42001-0107S 42001-0107S

12 Air Flow Switch 1 42001-0061S 42001-0061S 42001-0061S

13 Control Board Kit (NA, LP Series) 1 42002-0007S 42002-0007S 42002-0007S

• Heater Wiring Harness 1 474163Z 474163Z 474163Z

14 Heater, Top 1 42002-0034Z 42002-0034Z 42002-0034Z

15 Membrane Pad (NA, LP Series) 1 472610Z 472610Z 472610Z

16 Stack Flue Sensor 1 42002-0024S 42002-0024S 42002-0024S

17 Inlet Temperature Control Switch 1 474363Z 474363Z 474363Z

OFFICES - AUSTRALIA

NSW - Sydney

(HEAD OFFICE)

Tel : +61 2 9898 8686

VIC/ TAS - Melbourne

Tel : +61 3 9764 1211

WA - Perth

Tel : +61 8 9273 1900

QLD - Brisbane

Tel : +61 7 3299 9900

SA/ NT - Adelaide

Tel : +61 8 8244 6000

ACT Distributor

Tel : +61 2 6280 6476

OFFICES - OVERSEAS

Waterco USA

Augusta, USA

Tel : +1 706 793 7291

Waterco Canada

Longueuil, Qc, Canada

Tel : +1 450 748 1421

Waterco (Europe) Limited

Sittingbourne, Kent. UK

Tel : +44(0) 1795 521 733

Waterco France

SAINT PRIEST, France

Tel : +33 (0)4 72 79 33 30

Waterco (NZ) Limited

Auckland, New Zealand

Tel : +64 9 525 7570

Waterco (C) Limited

Guangzhou, China

Tel : +8620 3222 2180

Waterco (Far East) Sdn. Bhd.

Selangor, Malaysia

Tel : +60 3 6145 6000

PT Waterco Indonesia

Jakarta, Indonesia

Tel : +62 21 4585 1481

Waterco International Pte Ltd

Singapore

Tel : +65 6344 2378

Waterco Limited ABN 62 002 070 733

ZZM1439_02/2014