Genie installation(1)
Factory set for Natural Gas.
Can be Converted to Propane
with parts provided.
Serial No:
WARNING: If the information in these instructions are not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
-
Do not store or use gasoline or other flammable vapours and liquids in the vicinity
of this or any other appliance.
-
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 neighbour's phone. Follow the gas
supplier's instructions.
-
Installation and service must be performed by a Corgi registered installer.
Operating, Installation and
Servicing Instructions for
Condensing
Pool & Spa Heaters
0087
Genie
Models:
MB35C
MB50C
M1996
TECHNICAL DATA
GENERAL SPECIFICATIONS
WATER CONTENT
MB35C
MB50C
3.75
4.45
Litres
Litres
MAXIMUM WATER PRESSURE
0.83
1.0
gallons
gallons
5 bar (70 psi)
MAXIMUM WATER FLOW TEMP
Pool 32°C (90°F)
ELECTRICAL SUPPLY
Spa 41°C (106°F)
230V 50Hz, FUSED AT 3A, 130W
PROTECTION LEVEL
IP44
FLUE SYSTEM
80/125 PP, to a maximum Flue Equivelant Length of 20m
PERFORMANCE SPECIFICATIONS
II2H3+ G20 @ 20 mbar
GAS CATEGORY, TYPE AND SUPPLY PRESSURE
G31 @ 37 mbar
MODEL
Corgi Work Code
HEAT
INPUT
NATURAL GAS
MB35C
MBC50C
PROPANE
MB35C
MB50C
GROSS
kW
Btu/h
35.5
121,100
51.0
174,000
35.5
121,100
51.0
174,000
NET
kW
Btu/h
31.95
109,000
45.9
156,000
31.95
109,000
45.9
156,600
TYPICAL EFFICIENCY
% gross
% net
97
108
97
108
97
108
97
108
HEAT
OUTPUT
kW
Btu/h
34.43
117,500
49.47
168,000
34.43
117,500
49.47
168,800
GAS RATE (NG)
m3/h
3.37
4.88
1.28
1.9
MAXIMUM RATE, OUTDOOR TOP, CO
COMBUSTION SETTINGS, NG,
CO2
120
8.4
80
9.3
99
9.4
130
10.2
OFFSET SETTING
pA
-3.0
-3.0
-3.0
-3.0
ORIFICE
mm
4.3
5.2
Condensing Pool Heater
UK & Ireland
14/11/06
Contents
Section
TECHNICAL DATA
Page
Inside cover
User Instructions
1
INTRODUCTION
Heater Location
Gas Supply
Conversion
Flueing
Air Supply
Outdoor Heaters
Condensate Drain
Pool Pump & Pipework
Winterisation
Electricity Supply
3
3
4
4
4
4
4
5
5
5
5
INSTALLATION OF HEATER
Procedure
Outdoor Terminal
Flue Systems
Wall Terminal
Roof Terminal
Flue Examples
Plumbing
Pressure Switch
Gas Conversion
Gas Connection
Condensate Connection
Electrical Connection
Commissioning
Control Setup
Multiple Heater Kit
6
6
6
6
6
6
9
12
12
12
12
13
15
15
16
17
FAULT FINDING
20
Operation
20
Safety Controls & Lockouts
20
Engineering Mode
20
Test Temperature Disp.Mode
20
Display Fault Codes
21/22
SERVICING
Routine Service
Changing Components
Spares
Heater Components
23
23
23
26
27
List of Figures
Fig 1.0
Fig 2.0
Fig 3.0
Fig 3.1
Fig 3.2
Fig 3.3
Fig 4.0
Fig 4.1
Page
Terminal Positions
Hydraulic Resistance Graph
Service Access &
Pipe Connections
Wall Terminal Dimensions
Outdoor Terminal Dimensions
Fig 4.3
Fig 5.0
Fig 5.1
Fig 6.0
Fig 6.1
Fig 6.2
Fig 7.0
Fig 7.1
Fig 8.0
Roof Terminal Dimensions
Wall Terminal Installation
Extended Wall Terminal
Installation
Extended Vertical Roof
Installation
Outdoor Terminal Installation
Outdoor Terminal Fixing
Pressure Switch
Venturi Fixing
Orifice Position
Gas Valve Tappings
Condensate Disposal
Condensate Syphon
Heat Exchanger Sight Glass
Fig 9.0
Fig 10.0
Fig 11.0
Fig 12.0
Fig 13.0
Controls
Multiple Heater Install
Schematic Wiring
Electrical Components
Boiler Components
Fig 4.2
4
5
7
7
8
8
9
9
9
9
11
12
13
13
13
14
14
15
16
17
19
26
27
Genie
USER'S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION
MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
This appliance is equipped with an ignition device
which automatically lights the burner.
* Isolate the appliance with the Service
Cock inside. If this is not accessible,
isolate at the gas meter.
* Do not use this appliance if any part
has been under water. Immediately
call a qualified service engineer to
inspect the appliance and to replace
any part of the control system and any
gas control which has been damaged.
BEFORE OPERATING after a prolonged time
off, 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 electric switch
* Do not use any phone in your building.
* Immediately call your gas supplier
from a neighbour's phone. Follow the
gas supplier's instructions.
* If you cannot reach your gas supplier,
call the fire service.
CAUTION: Propane gas is heavier than air and
will settle on the ground. Since it can accumulate
in confined areas, extra care should be exercised
when lighting Propane heaters.
Genie
Before Start Up
Lock/Reset Button - If it is pressed for 2 seconds
it locks the Set Temperature so the Pool Temperature Knob is inoperative. To unlock, press again for
2 seconds.
With a short press the Set temperature is displayed.
It will flash if the Lock is ON.
Keep heater area clear and free from combustibles,
flammable liquids and chemicals.
Water must be flowing through the heater during operation. Ensure that system is filled with water and the
pump is operating.
Pool Temperature Display - This normally
shows the Pool Temperature but also show the
Setting Temperature when the Pool Temperature
Control Knob is moved. A Setting Dot is displayed
whilst it is adjusted. The Display is also used for
commissioning and diagnostic purposes.
(Page 16)
Quick Start
Check that the Electricity and Gas Supplies are on.
Turn on the Pool Pump. Turn on the Heater with the
switch on the Front Panel and set the desired
temperature with the Pool Temperature Knob. In a
few seconds the Heater will fire.
Pool Demand LED - Green
Off - There is no Pool Heating demand, pool heating
is off.
On - There is Pool Heating Demand and the Pool is
not up to temperature.
Flashing - The Pool Heating Demand is met, the
pool is up to temperature.
Summary of Controls (Left to Right)
ON/OFF Switch - Turns the Heater On and Off and
resets the Ignition Control if locked out.
Condensing Pool Heater
1
14/11/06
CAUTION
Elevated water temperature can be hazardous, and
the U.S. Consumer Product Safety Commission
recommends the following guidelines:
Pool Temperature Control Knob
16°C to 32°C or 41°C (60°F to 90°F or 106°F)
(Maximum is changed in Setup Mode, see Page 11)
Rotate clockwise to increase the Pool Temperature.
The Setting Temperature is shown whilst rotating
and for 3 seconds after.
To lock the required Temperature Setting see
Lock/Reset Button Page 1
1. Spa or hot tub water temperatures should
never exceed 40°C (104°F). A temperature of
38°C (100°F) is considered safe for a healthy
adult. Special caution is suggested for young
children.
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
over 39°C (102°F) 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 38°C (100°F) maximum rule.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err
in regulating water temperatures by as much as
2°C (4°F).
5. Persons with a medical history of heart disease, circulatory problems, diabetes, or blood
pressure problems should obtain a doctor’s
advice before using pools or hot tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers,
antihistamines, or anticoagulant, should not use
spas or hot tubs.
Pump Pressure
- Yellow LED, Display, Pool Temperature
On - If the pump is running and there is insufficient
pressure, possibly due to a blocked Pool Filter. The
Heater will not run.
Overheat - Red LED, Display “OH1”
On - This indicates the water in the Heater has
overheated and it has shutdown. Wait for the Heater
to cool then press the Lock/Reset Button to start the
Heater again. If this problem persists this should be
investigated by a Service Engineer.
Overheat - Flashing Red LED, Display “OH2”
Flashing - This indicates the Heater has overheated
and it has shutdown. Wait for the Heater to cool then
press the Lock/Reset Button to start the Heater
again. If this problem persists this should be investigated by a Service Engineer.
Overheat - Red & Yellow LED, Display “GAS”
On - This indicates the Heater Gas Ignition Control
has locked out. Press the Lock/Reset Button to start
the Heater again. If this problem persists this should
be investigated by a Service Engineer.
Cleaning
It is recommended that periodically the casing is
cleaned and sprayed with WD40 or similar liquid, and
any exposed threads are lightly coated in grease.
Condensate - Display “HI”
This indicates that the Condensate drain is blocked
and the Heater has shutdown. When the blockage is
cleared for the Heater will operate again.
Service & Maintenance
It is a mandatory requirement that any gas work
carried out must be by a Corgi registered engineer
with an appropriate accreditation.
It is recommended that the Heater is serviced after
every 2000 hours of operation.
Water Pressure Switch
A water pressure switch is provided in the heater to
shut off the burners in the event that water supply to
the heater is interrupted. The water pressure switch
should be checked and adjusted for proper operation by a qualified service person at the time of
installation, and thereafter checked at each service.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the heater.
Winterisation
If the Pool and Heater are not going to be used for
the cold winter months it is recommended that the
equipment is winterised. Contact your pool installer
for help with this.
Failure to winterise the Heater during a period of
freezing could cause damage to the Heater which
will not be covered by your warranty.
Water Temperature Settings
The Heater is designed to provide the maximum
amount of heat to the pool up to one degree below
the set temperature. For that last degree it reduces
the power to maximise control. For certain installation designs, if the pool is used before it is up to set
temperature, the water entering the pool from the
Heater could be noticeably warmer than the pool.
This is not a fault but part of the design. It will reduce
for the final degree up to set temperature.
Condensing Pool Heater
2
14/11/06
Health and Safety document No 635, “Electricity at
Work Regulations”.
Detailed recommendations are contained in the
following British Standard Codes of Practice.
INTRODUCTION
These Instructions cover a range of direct, floor
mounted, gas fired, condensing pool heaters which
are room sealed and fan assisted. The flue system
available is concentric, left, right, rear, and vertical,
all up to 20 metres ‘FEL’. There is also an Outdoor
Top terminal for use where the Heater is installed out
of doors. The ignition system is fully automatic.
Codes of Practice.
BS.6798 Installation of gas fired hot water boilers of
rated input not exceeding 70kW.
BS.5440: Part1 and Part 2. Flues (for gas appliances of rated input not exceeding 60kW).
BS 6891 Specification for installation of low pressure
gas pipework.
BS5482:1 Code of practice for domestic butane &
propane gas burning installations.
Building Regulations Part L1.
There are two models with different outputs - see
the Technical Data on Inside Cover for details.
Both can be installed in multiples to obtain a larger,
combined output.
IMPORTANT. It is important that no external
The casing is of green and black polyester powder
coated mild steel. The Heaters use a high performance stainless steel heat exchanger and are suitable for connection to pools using chlorinated and
salt chorinated water provided the following levels of
chemicals are maintained.
pH
Total Alkalinity
Calcium Hardness
Salt maximum
Free Chlorine
control devices are directly connected to this appliance - unless covered by these ‘Installation and
Servicing Instructions’ or otherwise recommended
by the manufacturer. If in doubt, please enquire.
Any direct connection of a control device not
recommended by the manufacturer could infringe
the Gas Safety (Installation & Use) Regulations, the
above regulations and the normal appliance warranty.
7.2 to 7.8
80 to 140 ppm
200 to 400 ppm
6000 ppm
1 to 4 ppm
Manufacturer’s notes must NOT be taken, in any
way, as overriding statutory obligations.
All chemicals must be introduced and completely
diluted into the pool water before being circulated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer, high chemical
concentrations will result when the pump is not
running.
Location of Heater
The Heater MUST be installed on a flat and level
floor, capable of adequately supporting the weight of
the Heater and any ancillary equipment.
Provision is provided for the heater to be fixed to the
floor.
It is IP 44 Rated and can be installed out of doors in a
suitable position. In all cases the choice of position
should take into account the flue, the plume and the
condensate drainage.
Chlorinators must feed downstream of the heater
and have an anti-siphoning device to prevent
chemical back-up into the heater when the pump is
shut off.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will
cause corrosion to the heat exchanger in the
heaters. Such damage is not covered under the
warranty.
IMPORTANT NOTICE.
If the Heater is to be fitted in a timber framed building it should be fitted in accordance with the British
Gas publication ‘Guide for Gas Installations in
Timber Frame Housing’, reference DM2. If in doubt,
advice must be sought from the Local Gas Region of
British Gas.
Gas Safety (Installation and Use)
Regulations, (as amended).
It is the law that all gas appliances are installed by a
competent person (e.g. a CORGI registered operative) in accordance with the above Regulations.
Failure to install appliances correctly could lead to
prosecution.
The Heater may be installed in any room or internal
space. Particular attention is drawn to the requirements of the current I.E.E Wiring regulations and, in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland with respect to
the installation of the boiler in a room or internal
space containing a bath or shower.
It is in your own interest, and that of safety, to
ensure that the law is complied with. The installation
of the Heater MUST also be in accordance with the
current I.E.E.. Wiring Regulations, the Local Building Regulations, Building Standards (Scotland), the
Bye Laws of the Local Water Undertaking, any
relevant requirements of the Local Authority, and
Condensing Pool Heater
Where a room sealed appliance is installed in a
room containing a bath or shower then the appliance
and any electrical switch or appliance control,
utilising mains electricity should be so situated that it
3
14/11/06
cannot be touched by a person using the bath or
shower.
Where installation will be in an unusual location then
special procedures may be necessary and BS.6798
gives detailed guidance on this aspect.
A compartment used to enclose the Heater MUST
be designed and constructed specially for this
purpose. An existing cupboard, or compartment,
may be used provided it is modified for the purpose.
Details of essential features of cupboard compartment design, including airing cupboard installations
are given in BS.6798.
In siting the Heater, the following limitations MUST
be observed:
1. The position selected for installation MUST allow
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
2. This position MUST also permit the provision of a
satisfactory balanced flue termination.
Terminal Position
Minimum
Below window or vent
300 mm
Below gutter or pipes
75 mm
Below eaves
200 mm
Below balcony or roof
200 mm
From a window
200 mm
From vertical pipe
75 mm
From corners
300 mm
Above ground, roof or balcony
300 mm
From facing surface
600 mm
From facing terminal
1200 mm
From opening under a car port
1200 mm
Vertically from a terminal
1500 mm
Horizontally from a terminal
300 mm
Fig. 1.0
3. This position MUST also permit the provision of a
satisfactory connection to the condensate drain.
IMPORTANT.
It is absolutely ESSENTIAL to ensure in practice,
that products of combustion discharging from the
terminal cannot re-enter the building, or any other
adjacent building, through ventilators, windows,
doors, other sources of natural air infiltration or
forced ventilation/air conditioning.
If this should occur, the appliance MUST be turned
OFF IMMEDIATELY and the Local Supplier consulted.
Gas Supply
An existing meter (NG) and pipework should be
checked, preferably by the Gas Supplier, to ensure
that they are adequate to deal with the rate of gas
supply required.
Supply pipes should be sized to suit installation and
obtain a working pressure of 20 mbar (NG), 37 mbar
(Propane). Installation pipes should be fitted in
accordance with BS.6891.
A Natural Gas Heater must be connected to a
governed meter.
Air Supply
The appliance is supplied for NG and can be converted to LPG by the addition of an Propane Orifice
which is supplied with the heater. See page 12 for
conversion instructions.
It is NOT necessary to have a purpose provided air
vent in the room or internal space in which the boiler
is installed.
Where the boiler is installed in a cupboard or compartment no air vents are required.
However the user may wish to ensure that it is
ventilated to provide air circulation.
Flueing
Outdoor Heaters
Conversion
These Heaters are certified for outdoor installation,
when equipped with the approved terminal.
Only flue components specified by the Manufacturer
should be used with these appliances. Detailed
recommendations for flueing are given in BS.5440:
The following notes are intended for general guidance.
WARNING: The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet openings and into
the heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.
1. Be aware of the plume from the flue and the
wetting effect it can have to adjacent property.
2. The flue can be taken upwards, left, right or to
the rear of the appliance, but never downwards.
3. The Heater is supplied separate to the chosen
flue set. It can be fitted with up to 20 metres
equivalant length of Concentric flue, see the Flue
Section on page 9 & 10 for examples and
parts selection.
Condensing Pool Heater
It is recommended that periodically the casing is
cleaned and sprayed with WD40 or similar liquid, and
any exposed threads are lightly coated in grease.
4
14/11/06
Genie Resistance
12
11
10
m head
9
8
7
6
5
4
3
2
1
0
50
100
150
200
- - - - - - Genie 35
Genie 50
l/m
250
Fig. 2.0
Condensate Drain
Winterisation
See Fig. 7.0, and 7.1
Turn off the Mains electricty and Gas Supply.
Draining the Heater can be achieved by the opening
of an unused pool connection.
If the Heater is below the pool an isolating valve can
be fitted ONLY IF an additional flow switch has been
wired into the Heaters Mains supply.
A 75mm condensate trap is provided on the Heater
and is satisfactory when connected to Soakaways,
Gullies, Rainwater Pipework and Internal Drainage
systems. All pipework and fittings in the condensate
drainage system MUST be made of plastic, unless
they carry other liquid waste. No other materials
may be used. The pipework should be insulated if
run out of doors.
The drain outlet on the boiler is :
Electricity Supply
Wiring external to the appliance MUST be in accordance with the current I.E.E. Wiring Regulations and
any Local Regulations that apply.
Osma, 40 mm waste pipe.
Pool Pump & Pipework
The Heater is supplied with a plug and lead for 230V
~ 50Hz. Single phase. Fuse rating is 3A.
The Heaters are designed using very high performance heat exchangers that have a high hydraulic
resistance. However a bypass is incorporated in the
product and furthermore its controls modulate the
input when approaching the set temperature, if flow
conditions are insufficient.
The method of connection to the mains electricity
supply MUST facilitate complete electrical isolation
of the Heater, preferably by the use of a fused
double pole switch having a 3mm (1/8in.) contact
separation in both poles and servicing only the
Heater and its controls.
The point of connection to the mains should be
readily accessible and adjacent to the Heater.
If a new pump is being fitted consult the Pressure
Loss graph (Fig 2.0) to determine its size.
The Heater is provided with 1½” plastic pool connections to both the left and the right.
With the exception of automatic dosing equipment,
the Heater should be plumbed as the last piece of
equipment before the pool.
It is permissable to fit an isolating valve on the
pipework on the supply side of the Heater.
It is NOT permissible to fit an isolating valve on the
outlet of the Heater UNLESS, an additional flow
switch has been connected on the Heaters Mains
supply.
Condensing Pool Heater
Note. Where a Heater is installed in a room containing a pool or shower, the appliance, any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched
5
17/11/06
Assembly
bINSTALLATION OF HEATER
All items assemble by a push fit/clamp system. If it is
required to lubricate the seals only Centra Cerin
supplied by the manufacturer or Silicone Grease
should be used.
The pipes should be assembled so the socket end is
always furthest from the Heater.
Flues should be supported by brackets every metre of
run.
Horizontal flues should incline back to the Heater by
3 degrees (52mm in 1000mm)
Space Required for Installation and Service.
Left, Right or Above
300 mm
12 in.
In Front
800 mm
40 in.
Suggested procedure:
Site to suit the pool, terminal, plume and condensate
drain limitations.
1. For an indoor installation only : Mark & Drill
Flue hole. (See Fig. 3.1 for dimensions)
2. If required, fix the Heater to the floor using the
holes provided in the front channel.
3. The Heater is provided with an Electrical Plug
and lead. This can be connected to a suitable
supply as detailed on the previous page. If it is
required to separately time the running of the
Heater this can be achieved as follows:
Remove the Front Door for access to the
fixings that retain the Front Top Panel. Remove
Front Top Panel
Remove the Electrical Cover to access the
Mains connector.
Pull out the Mains connector and replace
the Mains lead and link wire with a
Permanent and Switched live supply.
See Fig 11.0
4. Pipe to the 22mm gas connection. A gas isolating
valve is provided on the Heater Gas Valve.
5. Plumb to the Pool Pump and Filter.
6. Test for leaks.
7. Replace the Electrical Cover and Panels.
Wall Terminal
The Horizontal Wall Terminal is supplied with two
rubber wallplates, one for inside and one for the
outside. The core drill diameter required will be
determined by the incline and the wall thickness.
Wall Thickness
150- 240 mm
240- 330 mm
330 - 420 mm
420 - 500 mm
Core Drill diameter
175 mm
185 mm
195 mm
205 mm
Roof Terminal
The Vertical Roof Terminal should be fitted in a
minimum of 300mm clear unobstructed space. It is
not permitted to alter the construction of the Terminal,
above the roof line, however the concentric section
below the roof line can be altered to suit the installation.
It is recommended that:
1. The Installation of the flues are completed before
their connection to the Heater. This will ensure
that any debris that gets into the flues can be
cleared.
2. That bends in vertical flues are always 45 degrees.
3. Flues may be reduced in length by cutting. The
inner Flue pipe should be cut so it is 5 to 10mm
longer than the outer Air duct. It will ease assembly if the cut edges are cleaned, chamfered and
greased before assembly.
Assembly of the Outdoor Terminal
A specific Outdoor Top Terminal must be used for an
outdoor installation.
The Outdoor Top Terminal is a push fit into the Flue
Adapter and locked in position with a clamping ring.
If lubrication is required only Centra Cerin or silicone
grease should be used.
All Other Flue Systems
The maximum Flue Equivalant Length (FEL) permitted is 20 metres, horizontal or vertical. The component parts have the following FELs:
1 metre of concentric flue
2 metres of concentric flue
A 45 degree concentric bend
A 90 degree concentric bend
A concentric Roof Terminal
A concentric Wall Terminal
1.0
2.0
1.1
1.5
3.3
3.9
Sum the Flue Equivalant Lengths used in the design
this must not exceed 20 metres.
Condensing Pool Heater
6
14/11/06
Heater Dimensions
400
157
Pipe Connections
& Locations
D
E
990
950
F
G
J
H
217
126
C
351
K
101
Fig. 3.0
A
291
B
559
Dimensions
Model
Genie 35
Genie 50
505
A
B
C
165mm
385mm
197mm
449mm
lh side
252mm
C
rh side
270mm
Connections
Service Access
D
E
F
G
H
J
K
Left, Right or Above
In Front
Multi Heater Connection
External Control (CCP01)
Electric In
Gas Supply - 22mm Copper
Condensate Drain - 40.1mm Hunter Plastic
From Pool - 1½” Plastic Demountable Fittings
To Pool - 1½” Plastic Demountable Fittings
Rear Flue
WT
Left/Right Flue
157
200
SW
WT
52mm
°
93
93
°
3°
Horizontal Wall Terminal
Dimensions
300mm
800mm
1000mm
1065
1065
Horizontal Wall Terminal
(MBHT)
Fig. 3.1
Condensing Pool Heater
7
14/11/06
Outdoor Flue Terminal
(MBOT)
550
Outdoor Terminal
Dimensions
Clamp Assembly
Screw
Fig. 3.2
Flat Roof
Installation
500
Pitched Roof
Installation
500
Vertical Roof Terminal
Dimensions
Use Seldeck Flashing
System for all Roof
Installations
Vertical Roof Terminal
(MBVT)
1 metre Horizontal/
Vertical Extension Pipe
(MBHVE)
45 degree bends
(MB45DB)
Fig. 3.3
Condensing Pool Heater
8
14/11/06
Flue Examples
Outdoor Terminal
Extended Horizontal
Wall Terminal
Extended Vertical
Roof Terminal
MBOT
MB90DB
MBHVE
MBHT
(not shown)
MBVT
MBHVE
TO OFFSET
USE MB45DB
TO OFFSET
USE MB45DB
Fig.4.3
Horizontal Wall Terminal
MB90DB
MBHT
(not shown)
Fig.4.1
Fig.4.2
Fig.4.0
Flue Kit Part Codes
Determine the type of Flue system you require and
choose from the list of kits available below:
Type of Flue System
Kit Code
Description
Outdoor Kit
Horizontal Terminal
Vertical Terminal
MBHT
Horizontal Wall Terminal
n/a
Yes
n/a
MBHVE
1 metre Horizontal/Vertical Extension Pipe
n/a
Optional
Optional
MBVT
Vertical Roof Terminal
n/a
n/a
Yes
MBOT
Outdoor Terminal
Yes
n/a
n/a
MB45DB
45 degree bend
n/a
Optional
Optional
MB90DB
90 degree bend
n/a
Optional
n/a
Condensing Pool Heater
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14/11/06
Flue Kit Part Codes (cont.)
The Maximum Flue Equivalent Length (FEL) permitted is 20 metres, horizontal or vertical. The Flue Kits available
below list the FEL for each component. Add up all the FEL’s used in your design and check that this does not
exceed 20 metres. (see page 6)
Kit Code
Description
FEL
Photo of Kit
Flue
Equivalent
Length (m)
MBHT
Horizontal Wall Terminal
3.9m
MBHVE
1 metre Horiz./Vertical Extension Pipe
1.0m
MBVT
Vertical Roof Terminal
3.3m
MBOT
Outdoor Terminal
n/a
MB45DB
45 degree bends (pair)
1.1m
(per bend)
MB90DB
90 degree bend
Condensing Pool Heater
1.5m
10
14/11/06
Flue Parts Assembly
Outdoor Terminal
All items assemble by a push fit/clamp system. If it is
required to lubricate the seals only Centra Cerin
supplied by the manufacturer or Silicone Grease
should be used.
The pipes should be assembled so the socket end is
always furthest from the Heater.
Flues should be supported by brackets every metre of
run.
Horizontal flues should incline back to the Heater by
3 degrees (52mm in 1000mm)
A specific Outdoor Top Terminal must be used
for an outdoor installation.
The Outdoor Top Terminal is a push fit into the Flue
Adapter and locked in position with a clamping ring
(See Fig 3.2 and 5.0) with the fastener at the back. If
lubrication is required only Centra Cerin or silicone
grease should be used.
It is recommended that:
1. The Installation of the flues are completed before
their connection to the Heater. This will ensure
that any debris that gets into the flues can be
cleared.
2. That bends in vertical flues are always 45 degrees.
3. Flues may be reduced in length by cutting. The
inner Flue pipe should be cut so it is 5 to 10mm
longer than the outer Air duct.
4. It will ease assembly if the cut edges are cleaned,
chamfered and greased before assembly.
Wall Terminal
The Horizontal Wall Terminal is supplied with two
rubber wallplates, one for inside and one for the
outside. (See Fig 3.1)
If drilled at 3 degrees the core drill diameter required
is 175 mm. If a level hole is being drilled its size will
be determined by the wall thickness.
Wall Thickness
150- 240 mm
240- 330 mm
330 - 420 mm
420 - 500 mm
Fig. 5.0
Core Drill diameter
175 mm
185 mm
195 mm
205 mm
Because of the incline of the flue the height of the
centre of the flue hole on the inside will be determined
by the distance the heater is from the wall.
1. Ensure the required service clearance is available.
2. Fit the 90 degree elbow to the heater and measure
from its outlet face to the wall.
3. Add 52 mm for every 1000 mm distance to
1065 mm.
Example:
Distance maeasured = 480 mm
(52 x 480) / 1000 = 25 mm
Flue centre 1065 + 25 = 1090mm
Roof Terminal
The Vertical Roof Terminal should be fitted in a
minimum of 300mm clear unobstructed space. It is
not permitted to alter the construction of the Terminal,
above the roof line, however the concentric section
below the roof line can be altered to suit the installation.
Condensing Pool Heater
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14/11/06
Plumbing
The heater requires water flow and pressure to operate
properly. It must therefore be installed downstream of
the filter and pump. A typical installation is plumbed as
follows:
1. The Pump outlet is plumbed to the inlet of the Filter.
2. The outlet side of the Filter is then plumbed to the
inlet of the Heater.
3. The outlet of the Heater is plumbed to the return line
to the pool or spa. The Pump, Filter and Heater are
plumbed in series.
Plumbing from the heater back to the pool must not
have any valves or restriction that could prevent flow
when the pump is operating. If it is necessary to install
a valve on the return to the pool then it is essential that
a flow switch is installed and interlocked with the
Heater supply.
The Heater must be located so that any water leaks will
not damage the structure of adjacent area. There is no
requirement for heat shunt connections to the Heater,
plumbing can be made in standard plastic 1½” pipe
from the supplied demountables
Fig. 5.1
NG to LPG Conversion
The Heater can be converted to LPG on site. It
should be done before the Heater is piped to its
supply.
1.
2.
Use the pressure loss chart on page 5 to specify a
suitable pump.
Connection to the Heater can be made from either
the left or the right, it is supplied to be connected on
the left. To change, undo the demount connection on
the right, complete with blanking plates, and swap
with the connections on the left.
Flow Rate
The Heaters are built with an internal fixed bypass
that ensures the correct flow through the heat
exchanger for a wide range of conditions.
The minimum permitted flow is: 80 litres/min
Pressure Switch
The Heater is protected by an adjustable water
pressure switch that has to close before the Heater
will operate. It is very important to verify that it turns
off when the water flow is interrupted.
It has an adjustment range equivalant to ±1.5
metres. The switch is factory set for most conditions
but can be altered if required:
3.
4.
5.
With the Gas and Electrical supply off, undo
the three screws that hold the Venturi to the
Gas Valve. (See Fig.6.0)
Allow the Gas valve to drop and gently hang
on its cables.
Fit the Conversion Orifice into the Rubber
Seal that sits in the Gas Valve. (See Fig.6.1)
Re-assemble the Gas Valve and Venturi.
Affix the new Propane Serial Number Data
Label supplied over the existing.
LPG to NG Conversion
The method is as detailed above except the Orifice is
removed and the Venturi and Gas Valve reassembled
with just the Rubber Seal between them. A new Serial
Number Data Label should be obtained from the
manufacturer and affixed over the existing.
Gas Connection
The 22mm copper gas connection provided can be
positioned to exit the Heater from either the left or
the right. A minimum of 20mb. (NG), 37mb (LPG)
must be available at the Heater inlet, with the Heater
and other connected appliances firing. Check for gas
tightness (B.S. 6891: 1988) in pipework to boiler
using a manometer.(See Fig. 6.2) Gas soundness
within the Heater should be checked using sense of
smell and leak detection fluid. Check the maximum
rate and combustion are to specification,
(See Datatable Inside Cover.)
1. With the pump on turn the knurled nut clockwise
until a click is heard.
2. Turn the nut anti-clockwise a quarter of a turn.
3. Turn the pump on and off to check the switch
operates correctly.
Condensing Pool Heater
12
14/11/06
Condensate Connection
Throttle
Adjustment
The direction of the plastic condensate drain pipe
connection can be altered from the factory position on
the left, to the right.
Remove the blanking plate from the left hand
side (See Fig. 3.1)
Loosen the two screws holding the Trap
bracket and swivel the trap through 90 degrees.
Secure the bracket and fit the supplied 40 mm
pipe.
Example installations are shown in Fig 7.1.
Fit blanking plate to the right hand side.
(See Fig 7.1)
Fig. 6.0
Fig. 6.1
Orifice in position
Where possible an internal termination of the condensate discharge pipework should be used.
. If this is not psossible external pipes should be kept
as short as possible and insulated.
Where fitted in pipework that includes another trap an
Air Break should be fitted between the Heater and
that trap.
Avoid connecting to a kitchen sink trap as the solids
and fats in the drain will cause a blockage.
It is permissible to connect to an external gully or rain
water hopper provided they connect to a combined
system.
The condensate should not be run into a ‘grey water’
system.
If the condensate pipe is connected to a stack it
should join not less than 450 mm above the foot of
the stack. In addition it should be positioned so there
no chance of cross-flow to another connection.
Installation pipework must be in Osma 40 mm plastic
pipe to a suitable drain location with a gradient of 2.5°
(45mm/ metre run) minimum. If connected to another
drainage trap, an air break is required between the
Heater drain and that trap. (See Fig.7.0 & 7.1).
External runs, should, if possible, be insulated to
defer problems from freezing.
Check during commissioning to prove there is a
leakfree working connection from the Heater to the
drain. The simplest way to do this is to carefully pour
some water into the boiler flue and check it emerges
at the drain.
Inlet pressure
tapping
Offset
connection
Rating Table
Fig. 6.2
(1040 Btu/ft³) (38.8 MJ/m³)
kW gross
Btu/h
sec/ft³
m³/2 mins
7.5
25590
145
0.023
12.5
42650
87
0.039
20
68240
55
0.062
34.6
108055
31.5
0.107
52
177420
21
0.161
Condensing Pool Heater
The “Guide to the Condensing Boiler Assesment
Procedure for Dwellings” can be refered to, see
http://www.planningportal.gov.uk/england/professionals/en/1115314255842.html
13
17/11/06
Example Condensate Disposal Methods
Note: Do not reduce the pipe size below the 40mm provided.
Soakaway
Insulate against
freezing
200mm Land Drain
Filled with Lime
chippings 400mm
deep
Stack Attachment
Strap-On
Boss
1:20 Fall ( 2.5 Degrees )
Soil Pipe or
Drain
Fig.7.0
Condensate Syphon (75 mm)
Condensate Pressure Switch
Pipe Connection
Condensate
Drain from
Heater
Connect To Waste
(Option to exit Heater
left or right)
Removable Plate
(Use to close off unused
Waste exit on panels)
Fig.7.1
Drain Cap
Condensing Pool Heater
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14/11/06
Electrical Connections
WARNING: The appliance MUST be earthed.
All wiring for the Heater and system controls MUST
conform to I.E.E. Wiring Regulations, and work
should be tested using a suitable meter, for Earth
Continuity, Polarity, Short Circuit and Resistance to
Earth.
The Heater supply must be through a common
isolator, a double pole 3A fused isolating switch with
a contact separation of 3mm minimum on both
poles.
The cable used should be no less than 0.75mm2 to
BS.6500 PVC, 3 core, and fixed ensuring the earth
connection is longer than the Live and Neutral.
The boiler is fitted with automatic ignition and will
start when the gas cock is open, mains is connected
and the Pressure Switch is activated by the pool
Pump. (for greater detail about the internal controls
see the Maintenance section, Fault Diagnosis)
If the Heater fails to light the gas it will shutdown and
try again. It will repeat this a total of 5 times and then
lock out. This will show as the Red LED lit and
‘GAS’ on the display.
Press the Lock/Reset button to start another 5
attempts.
Access to the Heater connections is made by the
removal of the Front Top Panel and the Electrical
Chassis cover, two screws.
The Heater’s internal wiring is shown in Fig.11.0.
Connections are as follows :-
4 Way Terminal
N
SL
L
Fig. 8.0
Supply Connection
Earth
Mains Neutral
Switched Live
Permanent Live
A factory installed link has been fitted between SL
and L which should be removed if the Heater is to
have its own switched supply.
For systems using an external programmer, the
electrical wiring should follow the relevant control
manufacturer’s recommendations, with the switched
live from the controls returning to SL in the 4 way
push-fit connector.
It is possible to connect several Heaters together
using the Multiple Heater Kit. Details for the parts and
installation of this kit are given on Page 17.
Commissioning
General
The elimination of air from the heat exchanger is
essential to maximise the life of the Heater.
It is strongly recommended that the Heater is first
run with the GAS OFF until the air has been purged.
If air has not been released then there is a possiblity
of the Heater overheating and triggering one of its
safety thermostats.
Commissioning Procedure
It is possible with the front door off to see when the
burner is lit through the sight glass. (See Fig. 8.0)
After the burner has been lit for a few minutes the gas
rate and combustion should be checked, see the
Technical Data on Inside Cover for details.
The Heater is factory set and should not require
adjustment. When the Heater has been running for at
least 10 minutes check all joints, gas and water, for
leaks, and correct where necessary.
Note: The boiler is fitted with a syphon trap that includes a blocked drain detection device. This is to safeguard the boiler and help defer the effects from the
possible freezing of the condensate pipework in extreme weather.
Should this happen the control will lockout and the display will show ‘HI’, as in “condensate level is high”.
See the Fault Finding section for more details.
This will have to be corrected before the Heater will
run.
The user should be made aware of this feature and,
that in the event of blocked or frozen condensate
pipework, the boiler will automatically stop functioning.
It will start again as soon as the blockage has cleared.
Finally, instruct the user on Heaters operation and
controls.
The Heater Control is factory set to display in Fahrenheit and work to a maximum temperature of 90°F
(32°C). If a Centigrade display or higher, Spa temperature 106°F ( 41°C) maximum is required, enter
Setup Mode. (See Page 16)
Condensing Pool Heater
15
14/11/06
5
4
6
7
3
2
Genie
1
Fig. 9.0
On / Off
Switch
Setup Mode Setting
Lock/Reset
Button
Temperature
Display
Pool Temperature
Setting Knob
Factory Setting
Alternative
Setting
Position
Display Indicator
1
Display units
° F = Fahrenheit
° C = Centigrade
2
Maximum temperature
32 °C (90 °F)
41 °C ( 106 °F)
PL or SPA
3
Pressure Log
Number of Operations
Resets to zero
Yellow LED ON
4
Overheat Log
Number of Operations
Resets to zero
Red LED ON
5
Combustion Gas Log
Number of Operations
Resets to zero
Red LED flashing
6
Gas Lockout Log
Number of Operations
Resets to zero
Red & Yellow LED ON
7
Hi-Limit Log
Number of Operations
Resets to zero
Red PCB LED ON
8
Unused
Number of Operations
Resets to zero
Red PCB LED ON
9
Version number
-
-
° F or ° C
e.g. 008
Setup Mode
Switch on with the panel switch whilst pressing the Lock/Reset button.
Setup Mode.
then release. The control is now in
The control can now be altered by rotating the Pool Thermostat Knob to a certain position and then pressing the
Lock/Reset button,
then swiching off. (See Fig. 9.0)
Example:
To change from Fahrenheit to Centigrade:
Turn Panel Switch OFF then back ON whilst pressing the Lock/Reset
Turn the Pool Thermostat Knob until the display shows ‘F’.
Press the Lock/Reset button
once and the display will show ‘C’.
Switch the Panel Switch OFF then back ON again.
The Control will now display in Centigrade.
Condensing Pool Heater
16
button.
14/11/06
Installation Instructions
Multiple Heater Kit
Overview
It is possible to connect together several Heaters
and by doing so obtain a larger output with an
economical and a fail-safe design. The Multiple
Heater Kit enables 2 or more Heaters to be connected to obtain the necessary Load Sharing,
automatically. This works by one Heater being a
Master and the others being Slaves. The Master is
set for the required pool temperature and it then
controls as many of the Heaters as necessary to
obtain the temperature. It also equalises the running
time of every Heater so they all do the same amount
of work.
Kit Part Codes:
2 Heaters: MBMIK2
3 Heaters: MBMIK3
4 Heaters: MBMIK4
5 Heaters: MBMIK5
6 Heaters: MBMIK6
7 Heaters: MBMIK7
8 Heaters: MBMIK8
Individual Part Numbers
1
1
1
1
per Heater,
off per Installation
off per Installation,
less than Heaters,
M5160 Adapter PCB.
M5161, Terminator Plug, Red.
M5162, Terminator Plug, Yellow
M5163, 4m Interconnection Cable
Disconnect the Heater from the Mains then
remove the Top Panel and the Electrical Chassis
Cover.
Remove Pool Thermostat Control Knob
Remove Pool Thermostat Board by removing
retaining plate and carefully slide out until fully
accessible. (Fig. 10.0)
Carefully fit the Adapter PCB in the space behind
the Pool Temp. Display on the Board (Fig. 10.0)
ensuring that the six pins on the Board pass
through the underside of the Adapter PCB
and, that the plastic locking pillars snap into
place. Refit Pool Thermostat Board and Knob.
Repeat steps 1) and 2) for all the Heaters.
Using the supplied cables, pass them through the
upper side panel grommet and daisy chain the
Heater Adapter PCBs together.(Fig. 10.1) The first
and last Heater in the ‘chain’ will use the Termina
tor Plugs
to fill their 2 unused sockets. There are
2 different coloured Terminators, they can go in
either the first or last Heater. NB. Ensure the
connectors are fully home (Fig. 10.2)
Choose which Heater is to be the Master and
then make the rest Slaves by disconnecting their
Pool Temp Sensors. Remove the orange
connection to the Pool Temp Sensor located on
the rear heat exchanger connection (Fig. 10.3)
Any external electrical control should only be
connected to the Master, Pool Demand.
Remove any Pool Demand links from the Slaves.
Turn on the Mains, then switch on all the
Heaters. After a short self-test the Master should
show the actual temperature, and the Slaves
three dashes “---”. If a Slave continues to show a
moving display of dashes this indicates it not
correctly connected to the Master, check the
Interconnection cable plugs are fully home.
Replace the panels.
Fig. 10.1
Fig. 10.2
Side Panel
Grommet
Fig. 10.0
Adapter PCB
Connectors
Interconnection Cables
Photo 2
Condensing Pool Heater
Disconnected
Orange Wire
on Pool Temp
Sensor
(Slaves Only)
Fig. 10.3
17
14/11/06
Operation
Turn on all the Heaters with their Pool Tempera
ture Controls.
The Master will show temperatures and the Slaves
“---”.
Set the required temperature on the Master and
provided there is an electrical demand at the
Master’s Pool Demand connection, the Heaters will
run.
Features
A Master is the only Heater with a Pool Sensor
connected, move the sensor and the Master
changes.
If the Master Pool Temperature Control is turned
off, none of the Heaters will run.
If a Slave’s Pool Temperature Control is turned
off it will not operate. The Master will know and
alter its control accordingly.
If a safety device on the Master operates it will
not run but will continue to control the Slaves.
If a safety device on any of the Slaves operates
that Slave will not operate.
If a Slave has Flow fault which its Pressure
Switch detects the burner will stop immediately
and the Filter LED will light. It will no longer be
available to the group. It will then check every 3
minutes or so to see if the problem has been
corrected, the Filter LED will flash. It will put itself
back in the group if flow is satisfactory.
The Master display can be altered in Setup Mode
like a single Heater. (see Page 16)
Unlike a single Heater, there is no modulation of
individual burners.
Displays
The Master display is just like a single Heater.
A Slave will display “---” when working as part of
the group. It will show all the fault conditions of a
single Heater except “P/oc”, the Pool Sensor Open
Circuit fault. If this is displayed it indicates a
interconnection problem, check the cables and con
nectors.
The Pool Demand LEDs work as a Single Heater.
On when running, Off when off, and Flashing if not
needed by the Master.
The warning LEDs work for all in a group, as per a
single Heater.
Condensing Pool Heater
18
14/11/06
Schematic Wiring
FAN -ve
X12.13
HI LIMIT
X12.12
Bk
X12.14
X12.11
RESET -ve
X12.10
MODULATION +ve
X12.8
Gy
Bk
Y
Flue
FAN +ve
Bk
CVBC
W
X12.5
FAN PWM
910 ohms
1%
X12.16
Hi Limit
MODULATION -ve
X12.4
Gy
X12.3
HI LIMIT
RESET +ve
X12.2
FAN TACHO
X12.1
R
V
X1.10
X1.9
X1.8
X1.7
N
N
HEAT DEMAND
Bk
FAN
W
Br
B Blue
Bk Black
Br Brown
G/Y
R Red
R/B Red/Blue
G
W
V Violet
W
G
W
Br
B
24 V
B
Br
Y
Y
Br
Gy/Bk
CONDENSATE PS
R/B
WATER PRESSURE SWITCH
R/B
Gy
Or
Gy
POOL SENSOR
Or
V
P
P
Y
Gy
FLOW SENSOR
V
P
21
EXCHANGER SENSOR
P
Pool Thermostat
22
Gy/Bk
9
Bk
R
10
Gy
ON/OFF
SWITCH
8
7 6
230V/50Hz
Y
4
Bk
5
Br
Br
3 Amps
20 19 18 17 16 15 14 13 12 11
N
L
SL
B
Br
2D 2C 2B 2 1
B
G/Y
B
White
Y Yellow
3
TRANSFORMER
WITH THERMAL FUSE
230 V
Orange
P Pink
60C
Stat
LINK: Remove if seperate
switched live provided
Green/Yellow
Gy Grey
Gy/Bk Grey/Black
Or
Gy/Bk
X1.3
X1.2
X1.1
FAN 230v
LOCKOUT ALARM
240v 3 Wire
B
X1.5
L
V
B
Bk
30/11/06
Fig.11.0
Condensing Pool Heater
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30/11/06
FAULT FINDING
WARNING: BEFORE COMMENCING OR COMPLETING ANY ELECTRICAL WORK ON THE APPLIANCE, IT IS
RECOMMENDED THAT THE BASIC SAFETY CHECKS FOR EARTH CONTINUITY, SHORT CIRCUIT, POLARITY AND RESISTANCE TO EARTH ARE MADE. ALL WORK CARRIED OUT SHOULD FOLLOW GUIDELINES
LAID DOWN BY THE I.E.E.
Operation
The Heater requires Mains on both the Live (L) and Switched Live (SL) connection to be able to run. It is delivered
with a link between them which can be removed if a separate Heater switched live is going to be used.
To run, the Heater must have a Mains supply, Gas, Pool Pump pressure sufficient to activate the Pressure Switch,
all safety switches closed and a pool temperature below the set point.
If all the above are correct then the Gas Ignition Control starts the Ignition sequence:
1. The Fan runs as a pre-purge of the Heat Exchanger
2. After a few seconds a spark is created at the electrode and the burner is lit.
3. The burner flame is sensed and the spark is removed.
4. The Fan speed is then changed to the required speed according to the modulation curve.
5. If it fails to light the burner the spark will stop and the Fan will run on as a post-purge of the Heat Exchanger.
6. The ignition sequence will be repeated up to five times, then the control will lockout and will require
a reset to start again.
Safety Controls & Lockouts
The Pool Thermostat Control indicates the actual and set temperature of the pool and also displays all the
lockouts. The next pages detail the fault conditions, the indicators, the display and the actions required.
Setup Mode
Turn off on the Panel Switch. Turn on with the Panel Switch whilst pressing the Lock/Reset Button.
The Control is now in Setup Mode. See Page 16 for details.
Engineering Mode
This is a special mode used to set the operation of the Control and to investigate fault conditions, it requires a
Special Connector available from your supplier. It is recommended that none of the settings are altered without
consultation with the manufacturer.
Turn the Heater OFF with Panel Switch
Remove the Front Top Panel and the Electrical Chassis Cover.
Pull off the PCB connector for the Sensors and replace with the Special Connector.
Turn the Heater back ON.
It is now possible to change some of the Control’s parameters. Press the Lock/Reset button
to display
them. To show the alternative, rotate the Pool Thermostat Potentiometer
1. bt1 or bt3. The Control Heater personality. bt1 are traditional non-condensing Pool Heaters,
bt3 is the Condensing Pool Heater. Default is bt3.
2. td0 and td1. The Test Temperature Display Mode. Default is td0. td1 is a special diagnostic mode
which shows all the sensor temperatures to one decimal place, for each press of the Lock/Reset
button.
3. 0.0 to 7.9. Proportional band.
Default 1.0.
4. 0 to 50. DeltaT modulation point. Default 12.
After making the selections required, power off, replace sensor connector and power back on.
Test Temperature Display Mode 1 (td1).
Temperatures are displayed to 0.1 degree resolution, not the normal 1 degree.
The display will now show each sensor temperature and cycle around them for each press of the Lock/Reset
button.
1. Pool Temperature as normally displayed.. The Green LED will be alight.
2. Pool Temperature is dispayed to 0.1 degrees. The Green LED will be alight.
3. Heat Exchanger Flow Temperature. The Yellow LED will flash rapidly.
4. Heat Exchanger Combustion Temperature. The Red LED will flash rapidly.
Rotating the potentiometer will change the set temperature. Pressing and holding the button whilst one of the
temperatures is displayed will ‘lock/unlock’ it on the display for continuous observation.
Condensing Pool Heater
20
14/11/06
LOCK / RESET DISPLAY
FRONT PANEL
ON PCB
Condensing Pool Heater
21
‘HI’ Condensate level high. Blocked? Clear
obstruction and allow control to auto reset .
‘GAS’ Gas Control Lockout. Unable to light
burner, reset with Button. OR Flue Stat tripped.
Investigate cause. Reset on Flue Stat
‘OH2’ Flue gas over temperature. Allow to
cool then investigate in Engineering Mode.
Reset with Button
‘OH1’ Water Over temperature. Allow to cool
then investigate in Engineering Mode. Reset
with Button
Insufficient water pressure. Filter?, Blockage?
Up to temperature, 28°C
Running, raising pool temperature to 28°C
OFF, no mains supply or failed power supply
Flashing
EXPLANATION
Fault Codes
RED
LED2
RED
LED1
RED
YELLOW
GREEN
14/11/06
LOCK / RESET DISPLAY
FRONT PANEL
ON PCB
Condensing Pool Heater
RED
LED1
RED
YELLOW
GREEN
22
For all of the above. Turn off, correct problem and turn back on
again and the display and operation will be normal.
RED
LED2
‘Err’ alternating with ‘5’ = Pool potentiometer short circuit
‘Err’ alternating with ‘4’ = Pool potentiometer open circuit
‘F’ alternating with ‘oc’ = Heat Exchanger Flow sensor open circuit
‘F’ alternating with ‘cc’ = Heat Exchanger Flow sensor short circuit
‘H’ alternating with ‘oc’ = Heat Exchanger
Combustion sensor open circuit
‘H’ alternating with ‘cc’ = Heat Exchanger
Combustion sensor short circuit
‘P’ alternating with ‘cc’ = Pool sensor short circuit
‘P’ alternating with ‘oc’ = Pool sensor open circuit OR No
network detected if a Master in a multiple heater installation
EXPLANATION
Fault Codes
14/11/06
SERVICING
Health and Safety Statement :
This Heater contains no asbestos.
Routine Service
To ensure continued efficient operation of the appliance it is recommended that it is checked and
serviced at regular intervals.
The frequency of servicing will depend upon the
particular installation and usage but in general every
2000 hours of operation should be the maximum.
It is law that any service work should be carried out
by Corgi registered personnel.
1. Clean burner and combustion chamber.
2. Check condition of ignition spark and sensing
probe.
3. Check boiler pipework joints for leaks.
4. Check the Air duct and Flue seals.
5. Check condensate syphon and pipework for leaks.
6. Check the Gas Rate.
7. Check the combustion CO and CO2.
Follow the procedures given in Changing Components
for parts removal in addition to the following notes.
In all cases, before work commences turn off the
Mains Electrictity and Gas Supply.
Burner & Combustion Chamber
To view the burner and the inside of the Heat
Exchanger it is suggested you remove the front of
the Heat Exchanger complete with the Fan and Gas
Valve:
Pipework
IMPORTANT. The Heat Exchanger connections are
made using O rings and retaining clamps and should
not be strained in any direction. Any strain will result
in damage to the Heat Exchanger and will not be
covered by the warranty.
All plastic pipework joints are solvent welded and
cannot be remade but have to be replaced.
Condensate Syphon
The lower bowl of the Syphon can be unscrewed,
examined and cleaned.
Air Duct & Flue Seals
A visual inspection should establish there are no
leaks around any of the seals, including the flexible
Air Duct to the Venturi.
Gas Rate & Combustion
See the Datatable on Page 1 for the correct values.
A Combustion sample point is provided on the front
of the Flue Adapter. (See Fig.13.1)
Changing Components
THERE IS ONE FUSE, THE REMAINDER OF THE
CONTROLS ARE NOT REPAIRABLE AND IF NOT
WORKING MUST BE REPLACED.
In all cases, before work commences turn off the
Mains Electricity and Gas Supply.
The following items can be replaced:
Fuse, 24V supply.
Transformer.
Pool Thermostat.
Condensate Pressure Switch.
Pool Temperature Sensor.
Heat Exchanger Flow Sensor.
Water Pressure Switch.
Control Thermostat.
Overheat Thermostat.
Heat Exchanger Combustion Temperature
Sensor.
Flue Thermostat
Ignition Control.
Gas Valve.
Fan.
Heat Exchanger.
Remove Door and Front Top Panel
Disconnect Gascock flange form Valve.
Unplug Fan electrical connectors.
Remove Air tube from Flue Adapter.
Undo cover over Ignition Control connections and
remove the two connectors.
Pull off the Earth Lead connection on the
Valve and Heat Exchanger.
Undo the four nuts holding the Heat Exchanger
front and withdraw.
Assembly is the reverse.
Spark & Sense Electrode
Turn off the Heater.
Pull off the HT Lead.
Undo the two screws retaining the electrode
assembly and withdraw.
Assembly is the reverse.
On the Electrical Chassis
To access these items first remove the Front Top
Panel and then the Chassis Cover.
Fuse (See Fig. 12.0)
There is one inline 3A 1¼” fuse on the 24V supply
between the Transformer and the Pool Thermostat.
The Fuse Holder bayonets apart to allow its replacement.
Condensing Pool Heater
23
14/11/06
Transformer (See Fig. 12.0)
The Transformer includes its own, internal thermal
fuse on the primary. If this has gone open circuit the
cause should be established before replacing the
Transformer.
Disconnect from the terminal strip and fuse
holder.
Undo the two screws holding it to the chassis and
replace.
Pool Thermostat (See Fig. 12.0)
Pull off the Pool Thermostat Knob.
Release the Rear Retainer by undoing the Wing
Nut.
Pull off all the PCB connectors.
Slide out the Thermostat.
Replacement is the reverse.
Condensate Pressure Switch
(See Fig. 12.0)
Undo the single fixing screw.
Pull off the two electrical connectors and transfer
to the new Switch. They connect to the ‘C’ and
‘NO’ connections.
Replacement is the reverse
Heater Components
The remainder of the parts can be accessed
through the front.
Heat Exchanger Combustion
Temperature Sensor
This is located on the top of the Heat Exchanger, on
the right hand side. (See Fig.13.1)
Release the electrical connector by pressing the
latch and pulling up.
Twist the Sensor a quarter turn clockwise and
withdraw.
IMPORTANT Ensure the O ring seal is fitted correctly
to the replacement before fitting.
Replacement is the reverse.
Flue Thermostat
This is located on the Flue Adapter. (See Fig.13.1).
Pull off the electrical connectors.
Slide out from under the clip.
Replacement is the reverse.
Ignition Control (See Fig.13.3)
Undo the single screw holding the Ignition Control.
Release the two electrical connectors by pressing
the latch and pulling apart.
Pull the Ignition Control away from the Gas Valve.
Replacement is the reverse.
Gas Valve (See Fig.13.3)
Remove the Ignition Control, see above.
Release the Gascock by undoing the four shoulder
bolts holding it to the Gas Valve.
Remove the Offset tube from the Gas Valve and
unscrew the Offset Connector and transfer to the
new Gas Valve.
Release the Gas Valve from the Venturi by
undoing three screws. (See Fig.13.3)
Pool Temperature Sensor &
Heat Exchanger Flow Sensor
These are located on the connections to the Heat
Exchanger and are the same items. (See Fig.13.4)
Unclip the sensor from the connections.
Transfer the push on electrical connectors to the
replacement and clip back on.
Water Pressure Switch
This is located on the Inlet connection to the Heat
Exchanger and its removal will require the draining
of the Heater. (See Fig.13.4)
Pull off the Electrical Connectors
Unscrew from the Heat Exchanger connections.
Replacement is the reverse.
If the Water Pressure Switch needs adjustment See
Page 12 for details.
IMPORTANT Ensure the rubber seal (and orifice if
Propane) is transfered from the old Valve and placed
between the Venturi and Gas Valve before assembly.
Replacement is the reverse.
Fire the Heater and check for gas leaks.
After five minutes check the rate and combustion
is correct to the Datatable. (inside cover). Adjust
using the throttle on the Gas Valve, (See Fig. 13.3).
Fan (See Fig.13.2)
Remove the two electrical connectors on the Fan.
See (See Fig.13.2)
Remove the two screws holding the Venturi to the
Fan.
Undo the four nuts holding the Fan to the Heat
Exchanger and withdraw. (See Fig.13.2)
Transfer the Venturi gasket to the new fan.
Replacement is the reverse.
IMPORTANT. It is essential that all the air is
removed from the Heat Exchanger before the
Heater is fired. Running the Heater with air still in
it will damage the Heat Exchanger and invalidate
the warranty.
Control Thermostat
This is located on the Outlet connection of the Heat
Exchanger. (See Fig.13.4)
Unclip the sensor from the connection.
Transfer the push on electrical connectors to the
replacement and clip back on.
Condensing Pool Heater
24
14/11/06
Venturi (See Fig.13.2)
Remove the Ignition Control and Gas Valve, see
above.
Pull off the Air Tube (See Fig.13.3)
Undo the two screws holding the Venturi to the
Fan and remove.
Ensure the gasket is transferred to the new venturi
or positioned on the Fan before positioning the
replacement.
Replacement is the reverse.
Fire the Heater and check for gas leaks.
After five minutes check the rate and combustion
is correct to the Datatable. (inside cover). Adjust
using the throttle on the Gas Valve, (See Fig. 13.3).
Heat Exchanger (See Fig.13.0)
The removal of the Heat Exchanger will require the
draining of the Heater.
Undo both the Demountable connections to the
Pool pipework. (See Fig.13.5)
Undo the screws holding the panels around the
Demountable connections. (See Fig.13.5)
Release Heat Exchanger from the pipework by
removing the screw holding the retaining clips.
(See Fig.13.4)
Lower the pipework away from the Heat Exchanger.
Remove the Front Top Panel and disconnect the
Flue Thermostat connections.
Pull the Air Duct and Flue up and away from the
Heater Flue Adapter.
Disconnect the Heat Exchanger Combustion
Sensor by pressing the latch and pulling off.
Remove the four screws holding the Rear Top
Panel.
Remove the Rear Top Panel with the Flue
Adapter.
Remove the Fan, Gas Valve and Ignition Controller.
The Heat Exchanger is now only retained by the
two side brackets and releasing the four front
screws will enable it to be lifted away. Before
releasing ensure there is support available.
Replacement is the reverse.
Condensing Pool Heater
25
14/11/06
Spares
1st Line Spares:
Item
Part Number
SPMBG
Primary Heat Exchanger (35 kW)
Primary Heat Exchanger (50 kW)
Propane Orifice 35kW
Propane Orifice 50kW
Fan
Gas Valve
Ignition Control
Pool Thermostat PCB
Water Pressure Switch
HT Lead
Condensate Syphon
Condensate Pressure Switch
Ht Exchanger Combustion Sensor
Spark & Sense Electrode
Flue Thermostat
Control Thermostat
Pool Temperature Sensor
Ht Exchanger Flow Sensor
M2136
M2139
M2150
M2151
M2138
M2140
M2141
M2155
650634
M2142
M2143
M2144
M2145
M2146
M2147
M2148
M2149
M2149
SPMBG001
SPMBG002
SPMBG014
SPMBG015
SPMBG003
SPMBG004
SPMBG005
SPMBG016
SPMB506
SPMBG006
SPMBG007
SPMBG008
SPMBG009
SPMBG010
SPMBG011
SPMBG012
SPMBG013
SPMBG013
Electrical Components
Condensate
Pressure Switch
Pool Thermostat
Retainer
Fuse
Transformer
Fig. 12.0
Condensing Pool Heater
26
14/11/06
Heater Components
Combustion
Sample Point
Flue Adapter
Flue Thermostat
Fig.13.1
Heat Exchanger
Combustion
Temp Sensor
Condensate
Pressure
Switch
Heat
Exchanger
Spark & Sense
Electrode
Fig.13.2
Fan
Fixing
Nuts
Fan
Venturi
Fan Electrical
Connectors
Air Tube
Condensate
Syphon
Fig.13.3
Venturi
Throttle
Offset
Tube
Gas Valve
HT Lead
Fig.13.0
Gas Cock
Shoulder
Bolts
Ignition
Control
Fig.13.5
Heat Exchanger
Retaining Clips
Fig.13.4
Heat Exchanger
Flow Sensor
Pool
Te m p
Sensor
Water
Pressure
Switch
Demountable
Pool Connections
Control
Thermostat
Condensing Pool Heater
27
14/11/06
Station Lane
Industrial Estate
Witney
Oxon.
Tel. 01993 778855
Fax. 01993 703407
22/11/06
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