® ® WARNING FOR YOUR SAFETY - This product must be installed and serviced by a contractor who is licensed and qualified in pool equipment by the jurisdiction in which the product will be installed where such state or local requirements exists. In the event no such state or local requirement exists, the installer or maintainer must be a professional with sufficient experience in pool equipment installation and maintenance so that all of the instructions in this manual can be followed exactly. Before installing this product, read and follow all warning notices and instructions that accompany this product. Failure to follow warning notices and instructions may result in property damage, personal injury, or death. Improper installation and/or operation can create carbon monoxide gas and flue gases which can cause serious injury, property damage, or death. For indoor installations, as an additional measure of safety, Zodiac Pool Systems, Inc. strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces. Improper installation and/or operation will void the warranty. Installation and Operation Manual Legacy™ Pool and Spa Heater Model WLRZ Electronic Natural Gas or LP Gas WARNING Read this manual in its entirety. If these instructions are not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. This gas appliance must be installed in compliance with all applicable installation requirements such as the Standard for Gas Installations (AS 5601). Additionally, all requirements of the local authority — local gas fitting regulations, municipal building codes, electrical wiring regulations, and any other relevant statutory regulations must also be adhered to. H0338200 Rev E This heater is certified as complying with the requirements of the Australian Standard for Gas Pool Heaters (AS 4560) for use only as a swimming pool or spa heater. The heater must not be used for any other purpose and must be installed and serviced by a qualified professional. The heater must be operated strictly in accordance with the user's instructions and applicable laws. If the heater is installed in a room, adequate air supply and ventilation must be provided and maintained. Do not store or use gasoline (petrol) or other flammable vapors and liquids in the vicinity of this or any other appliance. DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE. DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 3 ® Table of Contents Section 1. General Information..................... 5 1.1 Introduction........................................................5 1.2 Consumer Information and Safety..................... 5 1.2.1 Spa/Hot Tub Safety Rules........................... 5 1.2.2 Swimming Pool Energy Saving Tips........... 6 1.3 Warranty............................................................6 1.4 Codes and Standards........................................6 1.5 Technical Assistance..........................................6 1.6 Materials Installer Must Provide......................... 6 1.6.1 Materials for All Applications....................... 6 1.6.2 Materials for Special Applications............... 7 1.7 Specifications.....................................................7 1.7.1 General Specifications................................ 7 1.7.2 Performance Specifications........................ 7 1.7.3 Dimensions.................................................7 Section 2. Installation Instructions.............. 7 2.1 Introduction........................................................7 2.2. Statutory Information.........................................8 2.3 General Installation Requirements.................... 9 2.4 Field Assembly .................................................9 2.5 Location Requirements...................................... 9 2.5.1 Introduction.................................................9 2.5.2 Clearances................................................10 2.5.3 Flooring.....................................................10 2.5.4 Outdoor Installation................................... 10 2.5.5 Indoor Installation...................................... 11 Section 3. Venting........................................ 11 3.1 Combustion Air Supply.................................... 11 3.2 Flue System (Indoor).......................................12 3.3 Vent Pipe Sizing and General Installation ...... 12 3.3.1 Outdoor Installations................................. 12 3.3.2 Indoor Installations ................................... 12 3.3.3 Inspection and Replacement of Existing Vent System with New Components ........ 13 Section 4. Gas Connections....................... 13 4.1 4.2 4.3 Gas Supply and Piping....................................13 Manifold Pressure............................................14 Special Precautions for LPG............................ 14 Section 5. Water Connections.................... 14 5.1 5.2 5.3 5.4 5.5 5.6 Water Piping....................................................14 Hydraulic Head Loss........................................14 Check Valve Installation................................... 15 Automatic Flow Control Valve.......................... 15 Reversible Water Connections........................ 16 Connections at Heater.....................................18 5.7 5.8 Pressure Relief Valve......................................18 Auxiliary Components, Chlorinators, Ozone Generators, and Sanitizing Chemicals............ 19 Section 6. Electrical..................................... 19 6.1 General Information.........................................19 6.2 Main Power......................................................19 6.3 Earth Bonding..................................................20 6.4 Optional Remote Controls............................... 20 6.4.1 Connection to a Remote Pool-Off-Spa Selector (3-Wire Connection).................... 21 220.127.116.11 Install the Remote Pool-Off-Spa Selector...............................................21 18.104.22.168 Configure the Control Panel............... 21 6.4.2 Connection to an AquaLink® RS Control System or Remote TSTAT (2-Wire Connection)...............................................21 22.214.171.124 Install the Remote TSTAT................... 21 126.96.36.199 Configure the Control Panel............... 21 6.4.3 Connection to a Secondary User Interface...........................................22 6.5 Functional Test.................................................22 Section 7. Operating Instructions.............. 22 7.1 Normal Operation............................................22 7.2 Start-Up...........................................................22 7.3 Operating the Controller.................................. 23 7.3.1 Off Mode...................................................23 7.3.2 Pool Mode - (Normal Heat)....................... 23 7.3.3 Spa Mode - (Normal Heat)........................ 23 7.4 User Setup Options.........................................23 7.4.1 Language Setup........................................23 7.4.2 Temperature Scale Setup......................... 24 7.4.3 Spa Timer Setup.......................................24 7.4.4 Display Light Setup................................... 24 7.5 Set Point Lockout.............................................24 7.6 Power Supply Interruption............................... 24 7.7 Lighting and Shutdown Procedures................. 24 7.7.1 Lighting the Heater.................................... 24 7.7.2 Shutdown..................................................26 Section 8. Maintenance............................... 26 8.1 Water Chemistry..............................................26 8.2 Seasonal Care.................................................26 8.2.1 Spring and Fall Operation......................... 26 8.2.2 Winterizing................................................26 8.2.3 Spring Start-up..........................................27 8.3 Inspection and Service....................................27 8.3.1 Owner Inspection......................................27 8.3.2 Professional Inspection............................. 28 Page 4 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Table of Contents (Continued) Section 9. Troubleshooting......................... 28 9.1 9.2 General Heater Troubleshooting...................... 28 Service Codes.................................................28 Section 10. Professional Maintenance and Service........................................ 31 10.1 General Information.........................................31 10.2 Natural-Draft Combustion System................... 31 10.3 Heater Components and Their Operation........ 31 10.4 Electrical Troubleshooting................................ 32 10.4.1 Electrical Power Supply.............................. 32 10.4.3 Control Circuit Troubleshooting................. 32 10.4.3.1 Transformer........................................32 10.4.3.2 Fuse....................................................33 10.4.3.3 Water Pressure Switch....................... 33 10.4.3.4 Roll-out Switch (Fusible Link)............. 33 10.4.3.5 Temperature Limit Switches Circuit.... 33 10.4.3.6 Gas Valve Voltage..............................34 10.4.3.7 Igniter/Ignition Control Circuit............. 34 10.5 Adjusting the Water Pressure Switch............... 35 10.6 Temperature Rise............................................35 Section 11. Replacement Parts.................... 37 11.1 11.2 11.3 11.4 Ordering Information........................................37 Parts List..........................................................39 General Exploded View................................... 40 Detailed Exploded View...................................41 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 5 ® Section 1. General Information 1.1 NOTE “Fresh water swimming pools and spas” include systems that utilize saltwater chlorine generator units, such as the Zodiac TRi Chlorine Generator. Please ensure that the salt content of the pool/spa does not exceed 4500 ppm and water flow rate is within 110-470 lpm. 3. Pregnant women take note! Soaking in water above 38.5°C (102°F) can cause fetal damage during the first three (3) months of pregnancy (which could result in the birth of a brain-damaged or deformed child). If pregnant women are going to use a spa or hot tub, they should make sure the water temperature is below 38°C (100°F) maximum. 4. The water temperature should always be checked with an accurate thermometer before entering a spa or hot tub. Temperature controls may vary by as much as 1°C (1°F). 5. Persons with a medical history of heart disease, diabetes, circulatory or blood pressure problems should consult their physician before using a hot tub or spa. 6. Persons taking any medication which induces drowsiness (e.g., tranquilizers, antihistamines, or anticoagulants) should not use spas or hot tubs. 7. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. 8. Prolonged immersion in hot water can induce hyperthermia. Consumer Information and Safety The Legacy Model WLRZ electronic heater is designed and manufactured to provide many years of safe and reliable service when installed, operated and maintained according to the information in this manual and the installation codes referred to in later sections. 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. 1.2.1 Spa/Hot Tub Safety Rules WARNING Elevated water temperature can be hazardous. Consult heater operation and installation instructions for water temperature guidelines before setting temperature. 1. The 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. Introduction This manual provides installation and operation instructions for the Legacy Model WLRZ electronic pool and spa heaters. Read these installation and operation instructions completely before proceeding with the installation. Consult the Zodiac Pool Systems, Inc. ("Zodiac") factory, or local factory representative, with any questions regarding this equipment. The Legacy Model WLRZ electronic heater gets electrical power from an external 220-240VAC, 50 Hz source and provides a dual electronic thermostat control system for pool/spa combinations or preheat convenience. The Legacy Model WLRZ electronic heater is specifically designed for heating fresh water swimming pools and spas, and with proper installation and care, they will provide years of reliable service. Do not use the heater to maintain pool or spa water temperature below 21°C (70°F). Do not use it as a heating boiler or general service water heater or to heat salt water. Consult your dealer for the appropriate Zodiac products for these applications. 1.2 2. Spa or hot tub water temperature should never exceed 40°C (104°F). Thirty-eight degrees celsius (38°C [100°F]) is considered safe for a healthy adult. Special caution is recommended for young children. Hyperthermia occurs when the internal body temperature reaches a level several degrees above the normal body temperature of 37°C (98.6°F). Symptoms include dizziness, fainting, drowsiness, lethargy, and an increase in the internal body temperature. The effects of hyperthermia include: • Lack of awareness of impending hazard • Failure to perceive heat • Failure to recognize need to leave spa • Physical inability to leave spa • Fetal damage in pregnant women • Unconsciousness resulting in a danger of drowning Page 6 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 1.2.2 Swimming Pool Energy Saving Tips Zodiac Pool Systems, Inc. offers the following recommendations to help conserve fuel and minimize the cost of operating your pool heater without sacrificing comfort. 1. As a general pool safety practice, Zodiac recommends a maximum water temperature of 25°C (78°F). Use an accurate pool thermometer. A difference of 2°C (4°F) , between 26°C and 28°C (78°F and 82°F), will use as much as 40% more gas. 2. Carefully monitor the water temperature of your pool in the summertime. You can reduce heater usage due to warmer air temperatures. 3. Find the proper setting on the pool heater temperature control and use the Set Point Lockout feature to discourage further adjustments. 4. Set the pump time clock to start the pump no earlier than 6:00 AM during the pool heating season. This is the time when nightly heat loss balances. 5. 6. If the pool is only going to be used on weekends, reduce the heater temperature control setting by 4 to 5°C (8 or 10°F) during the week. Reset it to the 25°C (78°F) level a day or so before you plan to use the pool. During the winter or when on vacation for longer than a week, shut down the heater by following the shutdown instructions found on the inside of the heater. 7. Where possible, shelter the pool from prevailing winds with well-trimmed hedges or other landscaping, cabanas, or fencing. 8. Always use a pool cover when practical. Besides providing a valuable safety feature, a pool cover will reduce heat loss, conserve chemicals, and reduce the load on filter systems. 1.3 The warranty does NOT cover damage caused by improper assembly, installation, operation or field modification. Also, damage to the heat exchanger by corrosive water is NOT covered by the warranty. See Section 8.1 for maintaining proper pool water chemistry. NOTE Keep this manual in a safe place for future reference when inspecting or servicing the heater. 1.4 Codes and Standards 1.5 Technical Assistance 1.6 Materials Installer Must Provide The Legacy Model WLRZ electronic heater has been tested and certified by IAPMO R&T OCEANA as complying with the applicable requirements of the Australian Standard for Gas Pool Heaters (AS 4560). All Zodiac heaters must be installed in accordance with the local building and installation codes as per the utility or authorities having jurisdiction. Any changes to the heater, gas controls, gas orifices, wiring, draft hood, vent cap, or improper installation may void the warranty. If change is required to any of the above, consult the factory. Consult your local Zodiac distributor with any questions or problems involving the specifications, installation, and operation of your Zodiac equipment. 1.6.1 Materials for All Applications The following items are needed and are to be supplied by the installer for all Legacy Model WLRZ electronic heater installations: 1. The correct size gas pipe to supply gas from the meter to the heater. See Section 4.1. 2. A manually operated gas cock to be installed in the gas line outside of the heater jacket. 3. Plumbing items needed to provide a sediment trap (drip leg) in the gas line between the manual gas cock and the heater. See Section 4.1. 4. A 220-240VAC, 50 Hz power supply. A junction box is not needed at the heater; connections are made inside of the heater jacket. Warranty The Legacy Model WLRZ electronic heater is sold with a limited factory warranty. Details are specified in warranty included with this appliance. Make all warranty claims to an authorized Zodiac representative or directly to the factory. Claims must include the heater serial number and model (this information can be found on the rating plate), installation date, and name of the installer. Shipping costs are not included in the warranty coverage. Page 7 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 2. 1.6.2 Materials for Special Applications 1.7.2 Performance Specifications In addition to the items listed above, the following items are needed for special applications: 1. The Legacy Model WLRZ electronic heater performance specifications are shown in Table 3. A factory authorized draft hood and any vent pipe needed for indoor installations. See Section 3.2. Draft hoods are available from any Zodiac distributor. 2. 1.7.3 Dimensions See Figure 1 for a diagram showing the heater's exterior dimensions and dimensions to critical connections on the heater. Primer and cement suitable for cementing PVC pipe to the Zodiac CPVC unions supplied with the heater. 3. Section 2. Installation Instructions A noncombustible platform for installation on combustible surfaces. See Section 2.5.3. Noncombustible bases are available from your Zodiac distributor. 4. 2.1 Introduction WARNING Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death. For indoor installations, as an additional measure of safety, Zodiac strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces. The heater may only be installed in a room which complies with the appropriate ventilation requirements and which is separate from living areas. A factory approved vent cap for all outdoor installations where wind conditions may cause downdrafting. Approved vent caps are available from your Zodiac distributor. See Section 11.2, "Parts List", of this manual for the correct part number. 1.7 Minimum Clearance From Combustible Material: See Table 4. Specifications 1.7.1 General Specifications 1. Installation Location: Certified for use: Natural Gas: Indoor and Outdoor LPG: Indoor and Outdoor See Section 4.3 Refer to Table 1. Table 1. General Specifications WLRZ 125 175 250 325 400 Water Capacity (L) 0,81 0,95 1,16 1,35 1,57 Minimum Water Flow (l/min) 75,7 75,7 94,6 113,6 113,6 Maximum Static Head (bar) 5,1 5,1 5,1 5,1 5,1 Maximum Outlet Temp (C) 52 52 52 52 52 Dry Weight (kg) 60 67 78 88 100 Gas Connection 3/4 in Bsp (Rc 3/4) 3/4 in Bsp (Rc 3/4) 3/4 in Bsp (Rc 3/4) 3/4 in Bsp (Rc 3/4) 3/4 in Bsp (Rc 3/4) Water Inlet Connection 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC Water Outlet Connection 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 50 mm unthreaded PVC or CPVC 220-240VAC, 50 Hz, 5 Amps Max 220-240VAC, 50 Hz, 5 Amps Max 220-240VAC, 50 Hz, 5 Amps Max 220-240VAC, 50 Hz, 5 Amps Max 220-240VAC, 50 Hz, 5 Amps Max Electrical Supply Inlet Pressure (kPa): Natural Gas LPG IP Rating Vent Type: Outdoor Flueless Outdoor with Vent Cap Indoor Natural Draft 1,13 minimum, 2,5 maximum 2,5 minimum, 3,5 maximum IPX4 Not to be installed with a balance flue. Page 8 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Install the Legacy Model WLRZ electronic heater, vent caps and draft hoods in accordance with the procedures in this manual, local codes and ordinances, and in accordance with the latest edition of the appropriate national code. See Section 1.4 "Codes and Standards". All gas-fired products require correct installation to assure safe operation. The requirements for pool heaters include the following: 1. Field assembly (if required) 2. Appropriate site location (clearances) and flooring 3. Sufficient combustion and ventilation air 4. Properly sized gas meter and piping 5. Proper electrical wiring (if required) 6. Adequate water flow 2.2. Statutory Information It is required that all gas appliances are to be installed only by competent persons who have been properly authorized by the local jurisdiction in which the appliance is being installed. This gas appliance must be installed in compliance with all applicable installation requirements such as the Standard for Gas Installations (AS 5601/AG 601). Additionally, all requirements of the local authority – local gas fitting regulations, municipal building codes, electrical wiring regulations, and any other relevant statutory regulations must also be adhered to. The Legacy heater, as supplied, has been tested and certified by IAPMO R&T OCEANA as complying with the applicable requirements of the Australian Standard for Gas Pool Heaters (AS 4560) for use with natural and LPG gases. Legacy heaters are only permitted to be installed in the open air or in a room which is separated from living areas and provided with appropriate ventilation directly to the outside. This manual provides the information needed to meet these requirements. Review all application and installation procedures completely before continuing the installation. H A 194 mm 406 mm 1041 mm 264 mm 127 mm 1000 mm 203 mm 724 mm 333 mm Outdoor Flueless Heater Configuration 95 mm Model Indoor Open Flue Configuration with Draft Hood Outdoor Flue Configuration with Vent Cap Venting Dimensions Heater Width Dim "A" Vent Diameter Outdoor Dimension "H" Indoor Dimension "H" mm mm mm mm 125 384 125 441 413 175 460 150 457 613 250 578 175 464 641 325 683 200 479 673 400 822 230 546 699 Figure 1. General Configuration Page 9 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Table 2. WLRZ Performance Specifications WLRZ Size Model Number 125 175 250 325 400 Nat. Gas LPG Nat. Gas LPG Nat. Gas LPG Nat. Gas LPG Nat. Gas LPG Heat Input Gross (mJ/hr) 132 132 185 185 264 264 343 343 422 422 Heat Output (kW) 28,4 28,4 40,9 40,9 59,2 59,2 76,3 76,3 90,9 90,9 Burner Pressure (kPa) 0,75 2,20 0,75 2,20 0,75 2,20 0,75 2,20 0,70 2,20 Gas Rate (m3/h) Nat. Gas 3,5 -- 4,9 -- 7 -- 9,1 -- 11,2 -- -- 1,05 -- 1,48 -- 2,3 -- 2,99 -- 3,47 32,1 -- 44,9 -- 64,1 -- 83,9 -- 102,8 -- Gas Type Gas Rate (m /h) LP Gas 3 Flue Gas Volume 4.5% CO2, 120C (l/sec) Flue Gas Volume 4.5% CO2, 120C (l/sec) G30 Injector Diameter (mm and marking) -- 32,3 -- 45,3 -- 70,3 -- 91,4 -- 106,4 (2,46) Marked 41 (1,51) Marked 53 (2,46) Marked 41 (1,51) Marked 53 (2,46) Marked 41 (1,51) Marked 53 (2,46) Marked 41 (1,51) Marked 53 (2,49) Marked 40 (1,51) Marked 53 WARNING The Legacy heater is certified to applicable Australian requirements for use only as a swimming pool or spa heater. The Legacy heater must not be used for any other purpose and must be installed and serviced by a qualified professional. The Legacy heater must be operated strictly in accordance with the manufacturer's instructions. If the Legacy heater is installed in a room, adequate air supply and ventilation must be provided and maintained. Never store any materials within the area of the heater or ventilation openings. It is important that no external control devices (e.g., flue dampers, economizers, etc.) be directly connected to the Legacy heater unless covered by these installation and servicing instructions or otherwise recommended in writing by Zodiac. If in doubt please ask. Any direct connection of a control device not approved by Zodiac, could invalidate the regulatory certification status, the normal Legacy heater warranty, and could also violate applicable gas safety regulations. 2.3 General Installation Requirements It is required that all gas appliances are to be installed only by competent persons who have been properly authorized by the local jurisdiction in which the appliance is being installed. This Gas appliance must be installed in compliance with all applicable installation requirements such as the Standard for Gas Installations (AS 5601 / AG 601). Additionally, all requirements of the local authority – local gas fitting regulations, municipal building codes, electrical wiring regulations, and any other relevant statutory regulations must also be adhered to. 2.4 Field Assembly 2.5 Location Requirements The Legacy Model WLRZ electronic heater is shipped from the factory with the top assembly in the low-profile configuration for outdoor installation. The Legacy Model WLRZ electronic heater is design certified for indoor installation when equipped with a draft hood, which must be installed without modification. Check the rating plate on the heater or the Parts List (Section 11) of this manual for the correct Zodiac draft hood or vent cap part number. See instructions supplied with the draft hood or vent cap for installation and attachment. When the draft hood is used, locate the heater so as to be in the same atmospheric pressure zone as the combustion air inlet to the heater. 2.5.1 Introduction CAUTION When pool equipment is located below the pool surface, a leak from any component can cause large scale water loss or flooding. Zodiac cannot be responsible for such water loss or flooding or resulting damage. The Legacy Model WLRZ electronic heater may be installed indoors or outdoors as outlined in later Page 10 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® sections. Location of the heater below or above the pool water level affects operation of its water pressure switch. See sections on water piping and heater start-up for more information about this. Avoid placing the heater in locations where it can cause damage by water or condensate leakage. If this is not possible, provide a suitable drain pan to catch and divert any leakage. The pan must not restrict the air flow around the heater. All criteria given in the following sections reflect minimum clearances as stated in the national standards. However, each installation must also be evaluated, taking into account the prevailing local conditions such as wind speed and direction, proximity and height of walls that may block ventilation, and proximity to public access areas. 2.5.2 Clearances The heater must be placed to provide clearances on all sides for maintenance and inspection. There must also be minimum distances maintained from combustible surfaces. See Table 3. At least 450 mm access must be available in front of the heater for burner removal and access to the igniter. If the heater is to be installed in a garage, or similar structure, all burners and burner ignition devices must have a minimum 450 mm clearance above the floor. This heater must be installed at least 3,5 m from the inside wall of a pool unless the heater is separated from the pool by a solid fence, wall or other permanent solid barrier. iron, brick, tile, concrete, slate, glass or plaster. Do not install the heater directly on a combustible wood or carpet floor without placing a noncombustible platform between the floor and the heater. The heater can be installed on a combustible floor if a noncombustible base assembly, available from Zodiac, is used. See the heater rating plate or the Parts List (Section 11) of this manual for the appropriate base part number. Heaters must never be installed directly on carpeting. As an alternative to the Zodiac noncombustible base plate, the heater may be placed on a combustible surface when there is a platform under the heater made of hollow masonry no less than 100 mm thick, covered with sheet metal at least 24 gauge thick and extending beyond the full width and depth of the heater by at least 150 mm in all directions. The masonry must be laid with ends unsealed, and joints matched to provide free circulation of air from side to side through the masonry, see Figure 2. If the heater is installed in a carpeted alcove, the entire floor of the alcove must be covered by a noncombustible panel. 2.5.4 Outdoor Installation The Legacy Model WLRZ electronic heater can be installed in the low-profile configuration as received from the factory, or with an optional factory approved vent cap for high wind applications. Locate the heater in an open, unroofed area. Do not install the heater under a deck. Do not locate the 2.5.3 Flooring The heater must be installed on a level surface of noncombustible construction or on fire-resistant slabs or arches. Noncombustible flooring is defined as flooring material and surface finish not capable of being ignited and burning and with no combustible materials against the underside. Acceptable materials are those consisting entirely of a combination of steel, Sheet Metal Min. Thickness 24 Ga Table 3. Minimum Heater Clearances From Combustible Surfaces SIDE OF HEATER MINIMUM CLEARANCE BLANK SIDE 200 REAR 150 Millimeters PIPING SIDE 350 TOP 1100 FRONT 450 Note: Clearances listed in Table 3 are manufacturer's tested values. These are given as minimum values. Where local codes apply, and values are different than those listed in Table 3, use the greater value to ensure safe operation. Hollow Concrete Block Platform 153mm 153mm Notes: 1. Blocks must provide a solid base and be braced so they cannot slip out of place. 2. Air openings in blocks must be arranged to provide unrestricted opening through entire width or length of base. 3. Sheet metal must be at least 24 ga. and extend 150mm beyond the heater jacket on all sides. Figure 2. Noncombustible Platform Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 11 ® heater below or adjacent to any doors, glass openings, louvers, grills, etc., which connect in any way with an inhabited area of a building, even though the access might be through another structure (e.g., a garage or utility room). The vent system shall terminate at least 2 m below, 2 m horizontally from, any door, operable window, or gravity inlet into any building. See Figure 3. The top surface of the heater must be at least 0.91 m above any forced air inlet, or intake ducts located within 3.0 m horizontally. If the heater is installed under an overhang, there must be a minimum clearance of 1.5 m above the top of the heater and the structure should not overhang the heater more than 0.30 m. The area under the overhang must be open on three (3) sides. This prevents combustion gases from being diverted into living areas through doors, windows, or gravity inlets. If the heater is installed close to a structure, protect it from rain water runoff with rain gutters on the roof or other measures. Do not locate the heater near irrigation sprinkler systems that could spray water on it. Water from sprinklers may cause damage to controls and electronic components. Avoid locations where wind deflection off nearby structures might cause downdraft conditions. Where downdraft conditions exist, locate the heater at least 0.91 m from vertical surfaces (e.g., nearby buildings and walls). 2.5.5 Indoor Installation 2m Figure 3. Outdoor Heater Installation These codes, standards and Zodiac, require that the heater be properly vented as outlined in this manual. Proper ventilation of exhaust and combustion air are essential for the safe and efficient operation of the heater. 3.1 Combustion Air Supply WARNING To avoid risk of carbon monoxide gas which can result in serious injury, property damage, or death, this heater is NOT suitable for use with a balanced flue. Additionally, only use vent piping which is certified/approved for the specific application. The heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area. In general, the room in which a heater is installed should be provided with two (2) permanent air supply openings; one (1) within 300 mm of the ceiling, the other within 300 mm of the floor. All indoor installations must have uninterrupted openings to outside air for combustion, ventilation, and dilution of flue gases from inside the building, see Figure 4 and Table 4. Zodiac does not recommend indoor installations that do not provide combustion air from outside the building. Minimum free ventilation area for each opening shall be calculated using the following formula: Table 4. Free Ventilation Area The Legacy heater can be installed indoors using the draft diverter available from Zodiac, and a flue system complying with the national and local applicable standards in addition to the Building Regulations. See Section 2. 2m Section 3. Venting 2m A= 3 x T A= the minimum free ventilation area (cm^2) T= the total gas consumption of all appliances (MJ/h) It is recommended that if the ventilation openings are louvered or screened that openings size are increased by 50 percent. Exhaust Fans or Vents: Any equipment which exhausts air from the room where the heater is installed can deplete the combustion air supply or reverse the natural draft action of the venting system. This could cause flue products to accumulate in the room. Additional air must be supplied to compensate for such exhaust. The information in Table 4 is not applicable in installations where exhaust fans or blowers of any type are used. Such installations must be designed by qualified engineers. The heater must be completely isolated and protected from any source of corrosive chemical fumes such as those emitted by trichlorethylene, perchloroethylene, chlorine, etc. WARNING Do not store any chemicals, cleaners, or other corrosive material near combustion air openings or in the room. Avoid locating appliance vents in the vicinity of combustion air openings. Failure to prevent corrosive materials from mixing with combustion air can result in reduced heater life and unsafe heater operation. Page 12 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 3.1 m VENT TERMINATED AT LEAST 600 mm ABOVE ANY OBJECT WITHIN 3.1 m Notes: 1. Use approved roof jack. LISTED FLUE TERMINAL 20 mm minimum pitch per meter of horizontal pipe AT LEAST 600 mm OF VERTICAL FLUE ABOVE THE DRAFT HOOD BENDS SHOULD NOT EXCEED 45° DRAFT HOOD 4) NON-COMBUSTIBLE BASE Figure 4. 3.2 Indoor Installation Venting or Outdoor Shelter Venting Flue System (Indoor) WARNING To avoid risk of carbon monoxide gas which can result in serious injury, property damage, or death, this heater is not intended to be installed with, and has not been qualified for installation with a side-wall venting system. This heater is a natural draft appliance that must be installed with a draft diverter. This heater is not suitable for use with a balanced flue. Connect the draft diverter to a flue system of at least the same diameter, and end at least 0.6 meters above the highest point of the roof or other object that is within 3.1 m of the vent. Install a certified terminal which allows a full equivalent opening for flue products, see Figure 4. There must be at least 600 mm of vertical flue above the draft hood. Bends in the flue should not exceed 45° to the vertical. To make sure the heater operates safely and satisfactorily, the flue system must be able to completely remove combustion products at all times. The number of bends and lengths of horizontal flue pipe used should be kept to a minimum in order to reduce gas flow resistance. Compliance with all national and local applicable installation codes and regulations should be strictly observed. The flue design should avoid the formation of excessive quantities of condensate. For this reason, it is recommended that all flues be insulated and lined. For brick or similar structures, a stainless steel rigid or flexible flue liner (Grade 304/316) may be used in conjunction with a 50 mm (minimum) thick layer or vermiculite or perlite granules between the liner and the inner skin of the chimney body. Liners should be sealed at both top and bottom. Drainage points should be provided at the bottom of all vertical flue sections. Drain pipes should be: 1. 2. No less than 25 mm inside diameter. Made from acid condensate resistant material (e.g., stainless steel). Positioned so that pipe runs and discharge points are not subject to the effects of frost and flue gases cannot leak into the boiler room. 3. 3.3 Vent Pipe Sizing and General Installation 3.3.1 Outdoor Installations For outdoor installations, exhaust venting considerations will determine the placement of the heater, see Section 2.5.4. If the heater cannot be placed so as to meet the requirements stated in Section 2.5.4, a vent pipe and cap may be added to the heater to move the exhaust vent opening to a position that complies with the requirements. When the heater is installed in areas of high wind or when unavoidably installed near a vertical obstruction where downdrafting may occur, it may be desirable to add a vent cap directly to the top of the heater. In all cases, vent pipes and caps must be of the same diameter as the exhaust outlet of the heater. Approved vent caps may be obtained through your Zodiac distributor. 3.3.2 Indoor Installations WARNING Vent pipe diameter must be as required by applicable local gas appliance installation codes such as AS 5601 / AG 601. Undersized pipe can result in inadequate venting and oversize pipe can result in vent condensation. In either case the result can be the release of combustion products to the indoors. This can cause serious injury or death by carbon monoxide poisoning or asphyxiation. Page 13 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® All indoor installations and outdoor shelter installations require a factory approved draft hood. The draft hood must be installed without modification. All vent installations must be made in accordance with all local, state or provincial codes. Avoid long horizontal runs of the vent pipe, and 90° elbows, reductions and restrictions. Horizontal runs should have at least a 20 mm rise per meter in the direction of flow. Avoid terminating heater vents near air conditioning or air supply fans. The fans can pick up exhaust flue products from the heater and return them inside the building, creating a possible health hazard. Do not locate the vent terminal where flue products could strike against building materials and cause degradation. Vent opening should be well away from trees or other obstructions that would prevent free air flow to and from vent terminal. Do not terminate the vent under decks, stairways, or car ports. Be sure to support all venting so that connections will not separate and so that the weight of the vent pipe does not rest on the heater draft hood. All connections should be made with rustproof sheet metal screws. Do not weld or fasten the vent pipe to the heater draft hood. The draft hood and heater top must be easily removable for normal heater service and inspection. The draft hood outlet is to be connected to an unobstructed vent pipe of the same diameter, terminating outside the building. The vent must terminate at least 0.6 m above the highest point of the roof or other object that is within 3.1 m of the vent termination. The vent pipe must have a listed vent cap which allows a full equivalent opening for flue products, see Figure 4. The top of the vent cap must be at least 1.5 m in vertical height above the draft hood outlet. Type “B” double wall or equivalent vent pipe is recommended. IMPORTANT NOTE: Do not use sheet metal screws at the snap lock joints. When venting multiple appliances through one common duct, each appliance must have its own vent temperature limit switch. All vent limit switches must be wired in series so as to prevent any appliance from firing in the event of a blocked vent. Refer to national and local installation codes for more information on multiple venting. is in good condition and continues to be appropriate for the Legacy Model WLRZ electronic heater. Replace any parts that are not in good and serviceable condition with new parts before completing the pool heater installation. Section 4. Gas Connections 4.1 WARNING The Legacy Model WLRZ pool and spa heaters are built at the factory for use with ONLY ONE type of gas - either Natural or LPG. DO NOT ATTEMPT TO CONVERT THIS HEATER FOR USE WITH ANY OTHER TYPE OF FUEL WITHOUT THE PROPER R-KIT AVAILABLE FROM ZODIAC. CAUTION Permanent damage to the gas valve will occur if the following procedures are not followed. 1. 2. 3. 4. Gas piping installation must be in accordance with all applicable local rules and regulations such as Gas Installations (AS 5601 / AG 601). Use rigid piping only for connection to this heater. Check the gas supply to be sure that it is the same as the gas indicated on the heater's rating plate. If there is any doubt regarding the capacity of any existing service pipes or the size required for new service pipes then the advice of the gas supplier should be requested. Installation pipework should be fitted and tested for gas soundness. Zodiac recommends the gas inlet pipe sizes listed in Table 5. Use the figures in Table 5 to size the gas inlet piping from the gas meter to the heater. Check all local codes for compliance before installing the heater. Table 5. Pipe Size Requirements Distance from Gas Meter Heater Size 0-15 m 15-30 m 30-60 m mm mm mm 125 20 25 25 175 25 25 32 250 25 32 32 325 32 32 40 400 32 40 40 3.3.3 Inspection and Replacement of Existing Vent System with New Components If the Legacy Model WLRZ electronic is being installed to replace an existing pool heater, it is recommended that a new appropriate venting system be installed with the new heater. However, if an existing venting system must be used, be sure to carefully inspect the venting system to ensure that it Gas Supply and Piping Review the following general instructions before continuing the installation. 5. Before operating the heater, test for gas soundness. Do not use a naked flame. Page 14 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® so can result in damage to property or injury or death. With the heater firing, the pressure must be within the range shown in Table 2. Also check the pressure with the heater off. Gas Cock 4.3 Manifold Pressure Test Point Figure 5. 6. 4.2 Fitting a Gas Service Cock If the gas supply pressure is less than required, check for undersized pipe between the meter and the heater, a restrictive fitting, or an undersized gas meter. Gas supply pressures to the heater are listed in Table 1. Manifold Pressure Confirm that gas supply pressure is correct. If the gas supply pressure is less than required, check for undersized pipe between the meter and the heater, a restrictive fitting, or an undersized gas meter. Gas inlet pressures to the heater, when it is operating, are listed in Table 1. CAUTION Manifold gas pressure for the Legacy Model WLRZ should be set at the values listed in Table 2. The manifold pressure may be checked by connecting a manometer to the pressure port on the manifold. Refer to Figure 5. The pressure will be zero when the heater is not running. When the heater is operating the manifold gas pressure should be set to the values listed in Table 2. If the manifold pressure indicated above is not correct, check the gas train for possible problems. Check the meter, gas line, gas fittings, and gas shut off for under sizing. Check the gas valve inlet for excess pipe dope, if all is correct, then it may be necessary to adjust the gas valve regulator. To adjust the manifold gas pressure, first remove the slotted cap next to the inlet pressure port on the inlet side of the gas valve. Under the slotted cap is a slotted plastic screw which increases the manifold pressure when turned clockwise and decreases the manifold pressure when turned counterclockwise. After measurements and adjustments, if necessary, have been made, make sure to replace the test point plugs on the inlet and manifold pressure ports, and the cap on the manifold pressure adjustment screw. It is extremely important to replace these parts before leaving the installation. Failure to do Special Precautions for LPG LPG is heavier than air and can therefore more readily collect or “pool” in enclosed areas if provision for proper ventilation is not made. Installation of pool heaters in enclosed areas such as pits is not recommended. However, if such an installation is required, be sure to pay special attention to proper ventilation requirements for LPG. Locate heaters a safe distance from LPG cylinders and filling equipment. Consult local codes and fire protection authorities about specific restrictions in your area. Section 5. Water Connections 5.1 Water Piping 5.2 Hydraulic Head Loss Figure 6 illustrates typical piping for pool equipment in pool/spa combination pools. For normal installations, do not install a shutoff valve or any kind of variable restriction in the water piping between the heater outlet and the pool/spa. In special installations where a shut-off valve, diverter valve or other variable restriction is required in the plumbing between the heater outlet and the pool, Zodiac recommends the installation of a pressure relief valve on the heater. See Section 5.7. Arrangement of pool system components other than as illustrated in these diagrams can affect the operation of the heater’s water pressure switch. Location of the heater above or below the pool water surface can also affect operation of the switch. In general, the pressure switch can be adjusted to accommodate this effect if the heater water connections are no more than 1.8 m below the pool water surface and no more than 4.5 m above it. See instructions for pressure switch adjustment, Section 7.7, in the heater start-up section of this manual for more information about this. Note that when pool equipment is located below the pool surface a leak can result in large scale water loss or flooding. Zodiac cannot be responsible for such water loss or flooding or the damage caused by either occurrence. For special installations such as water connections below the water level of the pool, or for other questions consult your local Zodiac dealer. To verify that the minimum flows required for the heater are met, a hydraulic head loss curve is shown in Figure 7. This should be checked when installing this heater into a new or existing piping system. This should also be consulted when installing a new pump. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 15 ® AQUAPURE MANUAL BY-PASS DETAIL MANUAL BY-PASS IS USED WHEN FILTRATION RATE EXCEEDS 475 LPM Figure 6. Typical Piping Installation LRZ Pressure Drop vs Flow 5 4.5 LRZ400 Pressure Drop (m H2O) 4 LRZ325 LRZ175 3.5 LRZ250 LRZ125 3 2.5 2 1.5 1 0.5 0 0 100 200 300 400 500 Water Flow (LPM) Figure 7. 5.3 Hydraulic Head Loss Curve Check Valve Installation WARNING A check valve can interfere with the proper operation of certain Suction Vacuum Release System (SVRS) products. To avoid possible entrapment hazard, serious injury, or death, make sure to review the operation/owners manual of your particular SVRS product before installing the check valve. The heater must be protected from backsiphoning of water, which can result in dry starts. If there is any chance of back-siphoning, provide a check valve between the pool and the filter pump inlet. When an automatic chemical feeder is installed in the plumbing, it must be installed downstream of the heater, see Section 5.8. A check valve must be installed between the heater and the chemical feeder to prevent back-siphoning of chemically saturated water into the heater where it will damage the components. 5.4 Automatic Flow Control Valve The inlet/outlet header of the Legacy Model WLRZ electronic heater comes equipped with an automatic flow control valve. The automatic flow control valve maintains the proper flow through the heater at rates up to approximately 475 lpm. If the filter system flow rate is higher than approximately 475 lpm, install a manual bypass valve, as shown in Figure 6, then perform a temperature rise test, see Section 7.8 and adjust the flow using the bypass valve until the proper temperature rise is obtained. Page 16 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 5.5 Reversible Water Connections IMPORTANT NOTE Reversing the header requires a longer syphon tube, order part number R0483601. The Legacy Model WLRZ electronic heater is shipped with water connections on the right side, but can be modified in the field to provide left-side water connections. This procedure involves removing the heat exchanger headers and reinstalling them on opposite ends of the tube assembly. Some of the heater wiring must be disconnected and re-routed, so this procedure must be done only by a trained service technician. Heat exchanger reversals are generally done before the installation of power and water to the heater. If you need to reverse the heat exchanger on a previously installed heater be sure that all electrical power, the gas supply and water supply have been turned off before starting the procedure. These instructions have been written to include the steps needed when reversing the water connections on an existing installation. If you are reversing the headers on a new installation, some steps will be ignored. Water connection reversal is illustrated in Figures 8 and 9. Proceed as follows: 1. For an existing installation, drain the heater by removing the two (2) drain plugs on the inlet/ outlet header and the drain plug on the return header. 2. Remove the heater front panel (door). 3. Remove the I/O header side cover plates, top and bottom. See Figure 10. 4. Remove the return header side cover plates, top and bottom. See Figure 10. 5. Disconnect the blue "HiLimit" two-pin connector from the Power Interface board on the raceway. Clip any wire ties attached to the harness. Feed the "HiLimit" two-pin connector and wiring back through the way it is routed to the header so that the harness hangs free from the header, outside of the cabinet. 6. Disconnect the water pressure switch tubing. 7. Disconnect the two "WATER TEMP" temperature sensor leads from the Power Interface board on the raceway. Clip any wire ties attached to the harness. Pull the wires out of the cabinet so that they hang free from the header, outside of the cabinet. 8. Disconnect the yellow "Water Press" two-pin connector from the Power Interface board on the raceway. Clip any wire ties attached to the harness. Feed the "Water Press" two-pin connector and wiring back through the way it is routed to the water pressure switch so that the harness hangs free from the water pressure switch, outside of the cabinet. Figure 8. Water Connections as Shipped ® NOTE: When reversal is complete the water temperature sensor wires and the syphon loop tube will exit the inlet/outlet header at the back of the heater and the drain plugs are facing down. Figure 9. Bypass Assembly Water Connections Reversed VENT TOP RETURN HEADER SIDE COVER PLATES TOP AND BOTTOM TOP PANEL REAR PANEL LEFT SIDE PANEL CONTROL PANEL BASE FRONT PANEL (DOOR) IN/OUT HEADER SIDE COVER PLATES TOP AND BOTTOM RIGHT SIDE PANEL Figure 10. Legacy Model WLRZ Panel Identification Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 17 ® CAUTION In order to prevent property damage or injury, ensure that the wiring is handled and routed carefully so as not to cause any damage to it. Additionally, be careful not to create any kinks in the water pressure switch copper tubing when handling the header. 9. For an existing installation, remove the coupling nuts from the header and disconnect the water supply from the heater. 10. Remove the 10 bolts and washers from the inlet/ outlet header and remove the header from the tube assembly. 11. Remove the 10 bolts and washers from the return header and remove the header from the tube assembly. 12. For an existing installation, remove the tube gaskets and clean the header's mating surface of any corrosion or debris. Replace the tube gaskets with new ones. Do not use any metal tools on the header surface. Scratches may compromise the seal integrity. WARNING To avoid product failure which can cause property damage, serious personal injury or death, install the inlet/outlet header with the high limit devices on the bottom. 13. Place the inlet/outlet header over the bolts and gasketed tubes on the left side of the tube assembly. Make sure the high limit devices are on the bottom. Refer to Figure 9. Align the bolt and tube holes in the header with the bolts and tubes in the header bar and slide the assembly together. 14. Thread on the 10 bolts and washers and hand tighten. 15. Place the return header over the bolts and gasketed tubes on the right side of the tube assembly. Align the bolt and tube holes in the header with the bolts and tubes in the header bar and slide the assembly together. 16. Thread on the 10 bolts and washers and hand tighten. See Figure 11. 17. Use a torque wrench to tighten the bolts on each header to 5.4 Nm (4 ft-lbs). The bolts must be tightened in the sequence indicated in Figure 11. CAUTION Failure to tighten the header as indicated in step 16 may cause the header to leak or become permanently damaged from warping. 18. Remove the 19 mm (3/4 inch) button plug located in the left side panel below the inlet/ outlet header and replace with the 19 mm (3/4 inch) wire grommet from the right side panel below the return header. The high limit leads were routed through this grommet prior to removal in step 5. Install the 19 mm (3/4 inch) plug in the opening where the 19 mm (3/4 inch) wire grommet was removed. 19. Route the blue two-pin connector attached to the high limit switches back to the Power Interface board in the raceway. Reconnect the blue "HiLimit" two-pin connector to the blue "HiLimit" connector on the Power Interface board. 20. Route the wires that attach to the temperature sensor back to the Power Interface board in the raceway. Reconnect the wires to the "WATER TEMP" terminals on the Power Interface board. 21. Install a new longer water pressure switch (siphon loop) tubing. The kit is available from your Zodiac distributor. Refer to the parts list in section 11.2. 22. Route the yellow two-pin connector that connects to the water pressure switch back to the Power Interface board in the raceway. Reconnect the yellow two-pin connector to the yellow "Water Press" connector on the Power Interface board. 23. Use plastic wire ties to refasten the temperature sensor, high limit switch and water pressure switch wires to each other. Bundle the wires near the control panel and fasten them with a wire tie. CAUTION In order to prevent property damage or injury, be sure that none of the wires are in contact with a sharp edge or a hot surface. 7 8 3 4 2 1 6 5 10 9 Figure 11. Header Bolt Tightening Sequence 24. Install the return header side cover plate on the right side of the unit. 25. Install the I/O header side cover plates, top and bottom on the left side of the unit. 26. Replace the front panel (door). Page 18 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 5.6 Connections at Heater The Legacy Model WLRZ electronic heater has a header and coupling design. The couplings can accommodate a 50 mm pipe or 65 mm pipe. The pipe material must be PVC or CPVC. However, by installing the appropriate pipe adapters (supplied by the installer), any size existing pipe may be fitted to the heater. To connect a section of PVC or CPVC pipe to the heater, prepare the end of the pipe with the proper PVC/CPVC primer and glue. Follow the manufacturer’s instructions provided with the primer and glue for preparation procedures and curing times. Apply the slip-fit side of the coupling to the end of the pipe, see Figure 12. Allow the glue to cure completely. Set the o-ring into the groove on the face of the coupling. Slide the coupling nut up to the coupling and tighten it to the threaded connection on the header. See Figure 12. 5.7 3. Open the hole by reaming it with a 9.5 mm (3/8 inch) drill bit. 4. Open the hole again by reaming it with a 12.7 mm (1/2 inch) drill bit. CAUTION Initially drilling a 12.7 mm (1/2 inch) hole without reaming may cause the bit to "grab" on the plastic. This may cause personal injury or damage the plastic header. 5. Remove the brass adapter and clean the cuttings out of the hole. 6. Install the rubber washer at the bottom of the hole. See Figure 14. 7. Thread the adapter into the hole and tighten so that it seals against the rubber washer. Pressure Relief Valve A pressure relief valve (PRV) is recommended in all installations, and is mandatory in any installation in which the water flow can be shut off between the heater outlet and the pool/spa. A pressure relief valve is not supplied with the Legacy Model WLRZ electronic heater. However, it is recommended that a pressure relief valve be installed and may even be required by local codes. Be sure to check any applicable installation codes in your area to determine whether a pressure relief valve is required. See Section 11.2 (Parts List) of this manual for the appropriate kit part number. The pressure rating of the valve should be at or below the lowest working pressure of any component in the system. The maximum working pressure of this heater is 5.1 bar. Any pressure relief valve installed must comply with AS 1271 or an equivalent standard. Follow these steps to install a pressure relief valve: 1. To protect the threads while drilling, screw the brass adapter (included with the Zodiac PRV kit) into the blind threaded hole on the top of the inlet/outlet header. 2. Using the countersink in the center of the blind hole as a guide, drill a 6.4 mm (1/4 inch) hole through the plastic. See Figure 13. START WITH A 1/4" BIT THEN OPEN HOLE WITH A 3/8" BIT THEN OPEN HOLE WITH A 1/2" BIT TEMPORARILY INSTALL BRASS ADAPTER TO PROTECT PLASTIC THREADS Figure 13. Drill Hole for Pressure Relief Valve PRESSURE RELIEF VALVE HAND TIGHTEN ONLY RUBBER WASHER BRASS ADAPTER PVC OR CPVC PIPE O-RING COUPLING COUPLING NUT Figure 12. Piping to Heater Figure 14. Pressure Relief Valve Installation Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 19 ® 8. With a permanent marker, place a mark on the adapter so that the mark faces the same direction as the water connections on the header. 9. Remove the adapter from the hole. 10. Coat the threads of the pressure relief valve (PRV) with an appropriate metal to metal thread sealant. 11. Install the adapter on the PRV and tighten using two (2) wrenches. Use the mark made earlier on the adapter to orient the PRV to the desired direction in relation to the water connections on the header. 12. Reinstall the adapter, with the PRV, into the plastic threaded hole and tighten it until the mark on the adapter is once again facing the same direction as the water connections on the header. CAUTION Do not use any pipe compound or pipe dope on the threads of the adapter or any part that comes in contact with the plastic headers. These compounds may damage the header over a period of time. CAUTION In order to prevent property damage, do not overtighten. Overtightening may crack the header. DO NOT TIGHTEN WITH A WRENCH. Overtightening may crack the header. Route the discharge piping so that discharge from the pipe does not endanger anyone near the heater. Refer to your local installation codes for more detailed information. The valve setting should be at or below the maximum working pressure of any component in the filter system. The maximum working pressure of the Legacy Model WLRZ electronic heater is 5.1 bar. 5.8 Auxiliary Components, Chlorinators, Ozone Generators, and Sanitizing Chemicals The Legacy Model WLRZ electronic heater is manufactured with materials that are not compatible with high concentrations of ozone, chlorine, bromine, or other sanitizing chemicals. Heater damage caused by excessive chemicals or improper ozonization is not covered by the Zodiac warranty. Be sure to adhere to the following: • When ozone is injected upstream of the heater, install an offgas mixing chamber, or an ozone bypass system between the heater and the ozone injector to prevent ozone and air from entering the heater. • When chemical feeders are used, plumb the feeder downstream of the heater and install an • • in-line check valve between the heater and the feeder (a minimum of 46 cm is required between the heater and the check valve). Wire any electrical chemical feeder so that it cannot operate unless the filter pump is running. If the feeder has an independent clock control, synchronize it with the filter clock. Never deposit chemicals directly in the pool skimmer. Section 6. Electrical WARNING Installation must be carried out by a competent person (e.g. electrician). This gas appliance must be installed in compliance with all applicable installation requirements such as the Standard for Gas Installations (AS 5601). Additionally, all requirements of the local authority — local gas fitting regulations, municipal building codes, electrical wiring regulations, and any other relevant statutory regulations must also be adhered to. WARNING ELECTRICAL SHOCK HAZARD. This heater contains wiring that carries high voltage. Contact with these wires may result in severe injury or death. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 6.1 General Information 6.2 Main Power Wiring connections must be made exactly as shown in the wiring diagram found on the inside of the heater door, see Figure 15. The heater must include a definite means of grounding. There is an earth bonding lug on the right side of the heater, where a bond wire must be attached. Electrical wiring must be in accordance with the latest edition of all applicable national and local installation codes and regulations. The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection may be via a fused pole isolator with a contact separation of at least 3 mm in all poles The heater comes factory-wired intended for use with 220-240 Volt, 50 Hz AC field electrical supply. This unit is fitted with a flexible electric cord and 3-pin plug for connection to a 220-240V 10 ampere (A) power outlet. The power outlet must be effectively earthed. Page 20 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® R 24 VAC FC+/- IGN 240 IGNITER / IGNITION CONTROL CIRCUIT L1 L2 IGN FS W/R W/BK GY W Y/BK BK VAL BR GND BL BL BR G/Y HOT SURFACE IGNITER W/R W/BK GAS VALVE FLAME SENSE BL BR BK 6 12 R BK 5 2 11 BK R G/Y FUSE 8 1 7 G/Y 220-240 VAC HEATER POWER SUPPLY BL BL TRANSFORMER WATER TEMP SENSOR BK BK BR BL WATER TEMP PUMP BK O BL R HIPRESS HILIMIT BK LOPRESS FUSELINK BK BL O GY 42°C LIMIT SWITCH R BL Factory Wired 24V Factory Wired 220-240V BK - BLACK BL - BLUE BR - BROWN G/Y - GREEN WITH YELLOW TRACE GY - GRAY O - ORANGE R - RED V - VIOLET W/BK - WHITE WITH BLACK TRACE W/R - WHITE WITH RED TRACE Y/BK - YELLOW WITH BLACK TRACE V BL 52°C LIMIT SWITCH TO PUMP STARTER CONTACTS (IF USED) REMOTE SPA POOL COM WATER PRESS BK O BL R POWER INTERFACE UNIVERSAL CONTROLLER USER INTERFACE Y/BK COMP/IGN 24 VAC GAS VALVE USER INTERFACE TO COMBUSTION AIR LOUVER STARTER (IF USED) FAN/LOUVER UNIVERSAL CONTROLLER POWER INTERFACE 152°C ROLL-OUT SWITCH (FUSIBLE LINK) WATER PRESSURE SWITCH 240°C VENT TEMPERATURE LIMIT H0335000 Rev E Figure 15. Legacy Model WLRZ Electronic Connections/Schematic Wiring Diagram 6.3 Earth Bonding CAUTION To prevent premature failure of the appliance resulting from stray voltages and voltage differentials, the heater must be bonded to other equipment which is part of the pool plumbing system with a solid copper wire not smaller in diameter than 8 AWG (10 mm2). Zodiac requires that the appliance be connected to an "earth bonding loop" that includes all electrical equipment in the system and on the equipment pad. Earth bonding lugs must be connected with a solid copper wire not smaller than 8 AWG (10 mm2). Failure to do so will void warranty. Additionally, all metallic components of a pool structure, including reinforcing steel, metal fittings and above ground components be bonded together (forming an “earth bonding grid”) with a solid copper conductor not smaller than a 8 AWG (10 mm2). The equipment and/or appliances associated with the pool water circulating system, including, but not limited to, pump motors and heaters must also be bonded together as part of the equipotential bonding grid. Zodiac provides a special labeled earth bonding lug on the right side of the heater to accommodate this requirement. Consult your local applicable installation codes/regulations for additional requirements that may apply. 6.4 Optional Remote Controls WARNING RISK OF ELECTRIC SHOCK, WHICH CAN RESULT IN SERIOUS INJURY OR DEATH. Before attempting installation or service, ensure that all power to the device is disconnected/turned off at the circuit breaker. Electrical wiring must be in accordance with the latest editions of all applicable national and local installation codes and regulations. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 21 ® 6.4.1 Connection to a Remote Pool-Off-Spa Selector (3-Wire Connection) 188.8.131.52 Install the Remote Pool-Off-Spa Selector 1. Turn off the power to both the pool/spa control system and the heater unit. 2. Remove the front panel door from the front of the heater to access the raceway. 3. Run the wires from the pool/spa control system through the opening, located on the lower right or left hand side of the heater. 4. Connect the wiring from the pool/spa control system to the heater remote control terminal. See Figure 16. 5. Restore power to the heater and the pool/spa control system. 4. Connect the wiring from the pool/spa control system to the heater remote control terminal. See Figure 17. 5. Restore power to the heater and the pool/spa control system. NOTE If you install a time clock to control the filter pump operation, it is recommended that the time clock have its own low voltage (Fireman’s) switch to turn off the heater before turning off the pump. The switch should shut off the heater about 15 minutes before the filter pump shuts off. This will allow for a more efficient operation by removing any residual heat contained in the heat exchanger back to the pool. 184.108.40.206 Configure the Control Panel 1. Make sure the control is in the OFF mode. 220.127.116.11 Configure the Control Panel 1. Make sure the control is in the OFF mode. 2. To enter the Service Setup mode, press and hold the MENU button and then the POOL and SPA buttons for 5 seconds. NOTE The display will revert back to OFF after 1 minute since the last key press. 3. Press the Up or Down button to display REMOTE. Press the MENU button. The SELECT REMOTE OFF (default remote) appears. Use the Up or Down button to scroll through the Remote options. When you reach HILO-COM, press the MENU button to select the remote. Press POOL or SPA to exit the Service Setup mode. Figure 16. Remote Pool-Off-Spa Connection (3-Wire Connection) 6.4.2 Connection to an AquaLink® RS Control System or Remote TSTAT (2-Wire Connection) 18.104.22.168 Install the Remote TSTAT 1. Turn off the power to both the pool/spa control system and the heater unit. 2. Remove the front panel door from the front of the heater to access the raceway. 3. Run the wires from the pool/spa control system through the opening, located on the lower right or left hand side of the heater. Figure 17. AquaLink RS or Remote TSTAT Connection (2-Wire Connection) Page 22 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 2. To enter the Service Setup mode, press and hold the MENU button and then the POOL and SPA buttons for 5 seconds. NOTE The display will revert back to OFF after one minute since the last key press. 3. Press the Up or Down button to display REMOTE. The SELECT REMOTE OFF (default remote) appears. Use the Up or Down button to scroll through the Remote options. When you reach REMOTE TSTAT, press the MENU button to select the remote. Press POOL or SPA to exit the Service Setup mode. 4. Press SPA. Adjust the setpoint to the maximum setting of 40°C (104°F). 6.4.3 Connection to a Secondary User Interface The Legacy Model WLRZ electronic pool/spa heater can also be controlled remotely by installing a second wall mountable User Interface. Please order part number R0467500. This kit contains the second User Interface, wall mounting backplate, and necessary hardware. 6.5 Functional Test After the installation is complete, the installer must test the appliance to ensure it operates properly. Refer to Section 7, Operating Instructions. Section 7. Operating Instructions 7.1 Normal Operation WARNING Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death. For indoor installations, as an additional measure of safety, Zodiac Pool Systems, Inc. strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces. The Legacy Model WLRZ electronic ignition heater is capable of automatic operation based on a call for heat at a preset temperature. The heater has an internal safety system which allows operation in a variety of conditions and prevents operation when certain adverse conditions are encountered. The heater is capable of diagnosing problems within the safety control scheme, enabling faster service and less down time in the event of a failure. When the heater's transformer is provided with a 220-240 VAC supply, it in turn provides a 24 VAC signal to the safety circuit. When water is flowing through the heater, and the temperature of the water entering the heater is below the temperature control setting, an operating cycle is initiated by the automatic control. The control circuit is closed, the igniter is energized. After a 40 second igniter heat-up, the gas valve is opened. Gas flows through the burners, is mixed with air in the combustion chamber, and is ignited by the hot surface igniter. Operation will continue until the temperature of the water entering the heater reaches the temperature control setting. If ignition is unsuccessful, or if the flame fails during normal operation, the ignition control shuts off the gas valve then tries the ignition two (2) more times and finally locks out. To reset the Legacy heater to provide three (3) additional attempts without waiting an hour, turn the control off and return it to either Pool or Spa. The ignition control will automatically reset itself and restart the ignition after one hour. 7.2 Start-Up WARNING For your safety, when starting the heater, keep your head and face well away from the burner area to prevent any risk of personal injury. WARNING Vent pipes, and heater tops get hot! These surfaces can cause serious burns. Do not touch these surfaces while the heater is in operation. CAUTION Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water. CAUTION Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater. CAUTION Do not attempt repairs on the gas controls or appliance. Tampering is dangerous and voids all warranties. CAUTION Keep all objects off the top of the heater. Blocking air flow could damage the heater, and may void the warranty. Be sure that there is water in the pool and that the surface level is above the skimmer or other inlet of the pool's filter system. Confirm that pool water is flowing normally through the pool system and equipment. With any new pool or spa installation, operate the filter pump with the heater off long enough to clean the water completely. This will remove any installation residue from the water. Clean the filter at the end of this operation before starting the heater. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 23 ® Start the heater in accordance with the Operating Instructions section of this manual, with particular attention to the lighting and shutdown instructions and temperature control operation. The heater may not start on the first try. Air in the gas line or other start-up situations may cause it to cycle. It will lock out if ignition is not achieved in three (3) attempts, see Section 9.2, "Service Codes". To reset the Legacy Model WLRZ electronic heater to provide three (3) additional attempts, turn off the control and then put it back in either the Pool or Spa mode. When the heater starts, immediately feel the outlet header of the heater to confirm that there is adequate water flow. The header should not be hot. Normally, water temperature will rise only a few degrees as it passes through the heater, and a "hot" header or pipe indicates low water flow. WARNING When the heater is fired for the first time, the combustion chamber refractory binder material is driven out by the heat of the flame. White smoke and/or sharp odors may be emitted from the vent during this period. Do not inhale combustion product fumes at any time, and especially when these fumes are being emitted. This "burn-in" period will last only a few minutes. When raising the temperature of a cold pool, program the time clock to turn the pump off 23 hours after the start time (e.g., If the start time is 2:00 PM, then set the stop time at 1:00 PM.). This lets the filter system and heater operate continuously until the water reaches the temperature setting on the temperature control. When that happens, the heater will automatically shut off, but the filter pump will keep running. 7.3 Operating the Controller Your new Legacy Model WLRZ electronic Pool Heater is controlled by an advanced microprocessor based controller that provides a sophisticated yet simple interface to operate your heater for maximum efficiency and enjoyment of your pool. To locate the control buttons, see Figure 18. 7.3.1 Off Mode When the control panel is turned off, the screen displays GAS HEATER is OFF pRESS Pool or Spa. 7.3.2 Pool Mode - (Normal Heat) To enable the pool mode, press POOL. The associated left green LED indicator will light and the unit will display SET:xxx°. Note XXX represents the current temperature setting on the control. The default setting for pool temperature is 26°C (80°F). You can change the temperature set point by pressing the Up or Down button. Repeatedly press the Up or Down button until you reach the desired temperature set point. After 5 seconds of inactivity, the new set point is stored in memory. When the water temperature falls to 1 degree below the temperature setting, the control will start the heater and the associated right LED will light RED. 7.3.3 Spa Mode - (Normal Heat) To enable the spa mode, press SPA. The associated left green LED indicator will light and the unit will display SET:xxx°. Note XXX represents the current temperature setting on the control. The default setting for spa temperature is 38°C (102°F). You can change the temperature set point by pressing the Up or Down button. Repeatedly press the Up or Down button until you reach the desired temperature set point. After 5 seconds of inactivity, the new set point is stored in memory. When the water temperature falls to 1 degree below the temperature setting, the control will start the heater and the associated right LED will light RED. 7.4 User Setup Options The User Setup options allow the user to select specific Languages, Temperature Scale, Spa Timer, and Display Light options. 7.4.1 Language Setup GAS HEATER IS OFF PRESS POOL OR SPA 1. Make sure the control is in the OFF mode. 2. To enter the User Setup mode, press and hold the MENU button for 5 seconds. NOTE The display will revert back to OFF after one minute since the last key press. 3. Figure 18. Main Control Panel To select a language, use the Up or Down button to display SELECT USER SETUP LANGUAGE. Press the MENU button. The SELECT LANGUAGE ENGLISH (default Page 24 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® MENU button. The SELECT DISPLAY LIGHT 2 MIN TIMEOUT: (default display light setting) is displayed. This option allows the display light to turn off after 2 minutes. Press the MENU button to select. Use the Up or Down button to scroll to display SELECT DISPLAY LIGHT LIGHT OFF:, this option allows the display light to turn off, press the MENU button to select. Use the Up or Down button to scroll to display SELECT DISPLAY LIGHT LIGHT ON:, this option allows the display light to turn on, press the MENU button to select. Press POOL or SPA to exit the User Setup mode. language) appears, use the Up or Down button to scroll through the language options. When you reach the desired language, press the MENU button to select the language. Press POOL or SPA to exit the User Setup mode. 7.4.2 Temperature Scale Setup 1. Make sure the control is in the OFF mode. 2. To enter the User Setup mode, press and hold the MENU button for 5 seconds. 3. To select temperature scale, use the Up or Down button to scroll through to display SELECT USER SETUP TEMPERATURE SCALE. Press the MENU button. The SELECT TEMP SCALE °F: (default temperature scale) appears, use the Up or Down button to scroll to display SELECT TEMP SCALE °C:. When you reach the desired temp scale, press the MENU button to select. Press POOL or SPA to exit the User Setup mode. 7.4.3 Spa Timer Setup 1. Make sure the control is in the OFF mode. 2. To enter the User Setup mode, press and hold the MENU button for 5 seconds. 3. To select spa timer, use the Up or Down button to scroll through to display SELECT USER SETUP SPA TIMER. Press the MENU button. The SELECT SPA TIMER CONTINUOUS: (default spa timer setting) is displayed. To turn the spa on or off indefinitely, press the MENU button to select. To select the length of time for the spa to run, use the Up or Down button to scroll to display SELECT SPA TIMER TIME SELECTION. Press the MENU button to select. The display SELECT SPA TIME 01:00 HRS: (default time setting) is displayed. Use the Up or Down button to select the length of time for the spa to run (between 00:15 to 23:00 hours incremented by 00:15 minutes). Press the MENU button to select how long the spa will run. Press POOL or SPA to exit the User Setup mode. 7.4.4 Display Light Setup 1. Make sure the control is in the OFF mode. 2. To enter the User Setup mode, press and hold the MENU button for 5 seconds. 3. To select display light setup, use the Up or Down button to scroll through to display SELECT USER SETUP DISPLAY LIGHT. Press the 7.5 Set Point Lockout Make sure the control is in the ON mode (POOL or SPA), press and hold the Up and Down buttons for 5 seconds. The set point will be locked and the control will operate in the mode it was in when the Set Point Lockout occurred. If an attempt to change the set point is made while the control is in Set Point Lockout, the control will display SET POINT LOCKED. To unlock the Set Point Lockout, press and hold the Up and Down buttons for 5 seconds. The unit will display SET POINT UNLOCKED. 7.6 Power Supply Interruption 7.7 Lighting and Shutdown Procedures In the event of a power supply interruption, the heater will shut down. Once the power has been restored to the appliance the unit will return to the operating state when the power was interrupted. For example, if the unit was firing when the power was interrupted, the unit will return to the firing mode once the power is reinstated. A power interruption will not affect any of the controls programming or set points. The controls utilize non volatile memory. WARNING Do not attempt to light the heater with the door off. Doing so may cause severe bodily injury. Before starting your heater, be sure that all of the functions and limits of the Legacy controller have been set according to the previous sections of this manual. Once the control is set to your preferences, follow the instructions outlined below. Read and follow all safety instructions first. A more detailed set of lighting and shutdown instructions are listed on the label located on the inside of the heater door or refer to Figure 19 of this manual. 7.7.1 Lighting the Heater Lighting instructions are as follows: 1. Turn off all electrical power to the heater at the main junction box. Page 25 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® WARNING LP Gas Models: To avoid possible injury, fire and explosion, read and follow these precautions and all instructions on this appliance before starting the heater. LP (propane) gas is heavier than air and will remain at ground level if there is a leak. Before lighting, sniff at ground level. If you smell gas, follow these rules: 1. DO NOT light matches. DO NOT turn electric lights or switches on or off in area. DO NOT use an electric fan to remove the gas from area. 2. Shut off gas at LP tank. 3. Telephone gas company and fire department for instructions. Give your name, address and phone number. If your LP tank runs out of fuel, turn off gas at the appliance. After the tank is refilled, the appliance must be re-started according to the instructions located on the inside of the door. WARNING Natural Gas Models: To avoid possible injury, fire and explosion, read and follow these precautions and all instructions on this heater before lighting the pilot. If you smell gas, follow these rules: 1. DO NOT light matches. DO NOT turn electric lights or switches on or off in area. DO NOT use an electric fan to remove the gas from area. 2. Shut off gas at gas service cock. 3. Telephone gas company and fire department for instructions. Give your name, address and phone number. DO NOT attempt repairs on the gas control or heater. Tampering is dangerous and voids all warranties. 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. CAUTION: Keep all objects off the top of the heater, and do not obstruct louver vents or openings in the heater rear panel. Blocking ventilation airflow may damage the heater and void the warranty. A. This appliance does not have a pilot light. It is equipped with an ignition device which automatically lights the heater. 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 electric 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. Do not use this appliance if any part has been under water. Immediately call a qualiﬁed service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2.* Set the thermostat for POOL and SPA to 70°F (21°C) or the lowest possible setting and switch the controller mode to OFF. 3. Turn on all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the heater. Do not try to light the burners by hand. 5. Turn on (open) external gas supply valve to the heater. 6. Turn on the ﬁlter pump. 7.* Set thermostat to desired settings for "Pool and Spa" and switch the controller mode from OFF to either POOL or SPA. 8. If the appliance will not operate, check that the ﬁlter pump is on, the ﬁlter is clean and water is ﬂowing to the pool. Otherwise, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier. TO TURN OFF GAS TO APPLIANCE 1.* Set the thermostat for POOL and SPA to 70°F (21°C) or the lowest possible setting and switch the controller mode to OFF. 2. Turn off all electric power to the appliance if service is to be performed. 3. Shut off the external gas supply valve to the heater. *See manual for details of operation of thermostat control. H0320500 Rev B Figure 19. Lighting and Shutdown Instructions Page 26 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 2. Turn on the filter pump. 3. Turn on the external gas supply to the heater. 4. Turn on electrical power to the heater. 5. 6. Turn on the filter pump. Set the heater control to the "SPA" mode. If the temperature of the water exceeds the thermostat setting it is necessary to increase the thermostat setting to exceed the water temperature. Adjust the thermostat setting (desired temperature) to be greater than the water temperature. The igniter lights the burner when the thermostat calls for heat. 7. Set the time clock, if one is installed. 7.7.2 Shutdown 1. 2. 3. 4. Complete shutdown instructions are as follows: Set both temperature controls to their lowest setting. Turn off the control. Make sure the display shows that the heater is OFF. Turn off all electrical power to the heater at the junction box. Shut off the external gas supply valve to the heater. Section 8. Maintenance 8.1 Water Chemistry The mineral content of swimming pool water increases daily due to natural evaporation and the addition of sanitizing chemicals. If the mineral concentration in the pool gets too high, the excess minerals will deposit on the walls of the pool, in the filter system, and in the heater tubes. The proper chemical balance in spa water is more critical than in a swimming pool heater operation. Due to the spa's size, high water temperature and heavy usage, chemical values in a spa can vary greatly. This chemical imbalance can result in unsanitary water conditions, and affect the life of the heater. Proper chemical balances are necessary for sanitary bathing conditions as well as ensuring your heater's long life. Kits are available from your local pool supply dealer for making the various tests for mineral content. One of these kits will detect copper in the system. This is usually a warning that corrosion is taking place, possibly due to a low pH value combined with other chemistry problems. The condition can be corrected by changing the spa water and closely monitoring the pH factor and chemical properties of the water. Be sure to keep your chemical levels within the values indicated in Table 6. Zodiac does not warrant heat exchangers damaged by corrosive chemical levels or excess dissolved solids in pool or spa water. For spas, it is also necessary to perform water changes in addition to chemical treatment. It is recommended to change the spa water every 60 days for light usage and every 30 days if usage is heavy. Table 6. Optimal Water Chemistry Ranges* Test Recommended Level Free Chlorine 1.0 to 3.0 ppm Bromine 2.0 to 4.0 ppm pH 7.4 to 7.6 Total Alkalinity (TA) 80 to 120 ppm Calcium Hardness (CH) 175 to 400 ppm Cyanuric Acid 10 to 50 ppm Total Dissolved Solids (TDS) 1000 to 2000 ppm (Excluding dissolved NaCl from a Salt Chlorine Generator) * Concentration levels taken from "Basic Pool and Spa Technology" published by APSP (Association of Pool and Spa Professionals). 8.2 Seasonal Care CAUTION Do not operate this heater outdoors at temperatures below -7°C (20°F). 8.2.1 Spring and Fall Operation During periods when the pool is only going to be used occasionally, set the pool and spa control temperatures to 21°C (70°F) on the Legacy. See Section 7.3.2. This prevents the pool water from becoming chilled, and minimizes the time required to raise the pool water back up to the desired temperature. If the heater is not going to be used for a long period of time, shut it down completely. Follow the instructions found on the inside of the heater, or Figure 19. 8.2.2 Winterizing In areas where freezing temperatures occur in winter and the pool or spa will not be used, have your service technician perform the following steps: 1. Turn off the main gas valve to the heater, outside the heater jacket. 2. Remove heater door. 3. Shut down the heater following the shutdown instructions found on the inside of the heater or refer to Figure 19. 4. Remove the drain plugs from the inlet/outlet header as shown in Figure 20, and completely drain the heater before the first frost. 5. After all water has drained from the heater, check for mineral buildup in the openings. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 27 ® 6. Use compressed air to blow out any standing water remaining in the heat exchanger. 7. Inspect the gaskets on the drain plugs and reinstall plugs, but do not tighten. 8. Disconnect the pressure switch from the copper tubing. See Figure 21. 8.3 Zodiac designs and constructs the heater to provide long performance life when installed and operated properly under normal conditions. Periodic inspections, especially at spring start-up, are important to keep your heater running safely and efficiently through the years. 8.2.3 Spring Start-up WARNING Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death. To restart the heater in the spring, have a qualified professional technician reassemble the heater as follows: 1. Inspection and Service Attach the copper tubing to the pressure switch. See Figure 21. 2. Tighten the drain plug. 3. Make sure that power is supplied to the pump. Turn on the filter pump and circulate water through the heater for five (5) minutes. Check for leaks while circulating. 4. Turn on the main gas supply to the heater at the gas cock outside the heater jacket. 5. Turn on the heater following the lighting instructions found on the inside of the heater, or Figure 19 of this manual. 8.3.1 Owner Inspection Zodiac recommends that you inspect the heater on a continual basis and especially after abnormal weather conditions. The following basic guidelines are suggested for your inspection: 1. Keep the top and surrounding area of the heater clear of all debris. 2. Keep the area around and beneath the heater clean and free of all combustible materials such as paper, leaves, etc. CAUTION Do not store or use gasoline or other flammable vapors, liquids or chemicals in the vicinity of this or any other appliance. WARNING Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water. O-RING DRAIN PLUG 3. If the heater is equipped with a pressure relief valve, check for corrosion in and around the valve. Twice a year, with the filter pump on, lift the release lever on the top of the valve to make sure that water runs freely through it. If corrosion is found, replace the pressure relief valve. When replacing the valve, be sure that the pump is off. Install the valve so that the discharge is directed away from any area that may be damaged by water. 4. Be sure all combustion air and ventilation openings are not blocked. Check for spider webs and other debris inside the heater, in the vents on all sides of the heater jacket and in the exhaust outlet – especially after a long period of nonuse. Figure 20. Draining the Heater COPPER TUBING Figure 21. Pressure Switch Copper Tubing Page 28 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 8.3.2 Professional Inspection Inspections performed at least once a year by a qualified technician are required to maintain your heater's safe and efficient operation. The following basic safety checks must be performed: 1. Inspect the venting system for blockage, leakage, and corrosion. 2. Check for spider webs or other obstructions in the main burner orifices – especially at spring start-up. Clean with wire brush if necessary. 3. Check for loose or broken wires and terminal connections. 4. Inspect the electrical controls, specifically the following: a. High limit controls. b.Water pressure switch. c. Power interface/Temperature control. d.Ignition control e. Automatic gas valve. f. Roll-out switch (fusible link). g.Control circuit fuse. f. Vent temperature limit. 5. Inspect the external surfaces of the heat exchanger tubes for black carbon soot buildup by placing a mirror between and under the burners when the heater is firing. Remove any soot that has collected on the tubes, and correct the cause. NOTE After installation and first start-up, check the heat exchanger for black carbon soot buildup after the following periods of operation: 24 hours, 7 days, 30 days, 90 days, and once every 6 months thereafter. 6. Inspect the internal surfaces of the heat exchanger for scale buildup. Inspection is done by removing one of the heat exchanger headers and inspecting the internal surfaces of the tubes with a flashlight. If any scale build up is found, it will have to be removed using the descaling procedures in Section 10.6. 7. Make sure that the pressure switch operates properly by shutting the filter pump off and on a few times. The burner should go off immediately after the pump stops. An ignition sequence should start shortly after the pump is turned back on. 8. Conduct a normal operating cycle and observe that the sequence proceeds as intended. CAUTION For your safety, when starting the heater, keep your head and face away from the burner area opening to prevent any risk of personal injury. 9. Make a visual check of the main burner flame. The flame can be seen in a mirror arrangement held beneath the burners. The flame should be: a. Blue in color. b. Twenty-five mm to 100 mm above burner surface. See Figure 22. 10. Perform a temperature rise test in accordance with Section 7.8. FLAME BURNER Figure 22. Main Burner Flame Section 9. Troubleshooting 9.1 General Heater Troubleshooting 9.2 Service Codes Table 7 lists some of the more common problems, causes and solutions encountered when running the heater. Most problems occur when the heater is being started for the first time after installation or at spring start-up. Careful installation and maintenance will help ensure years of trouble free use from your Legacy heater. In the event that the heater cannot be adjusted to perform safely and correctly, please shut down the heater. Turn off the gas supply using the manual shutoff valve located just outside the heater jacket. After disabling the heater contact Zodiac Pool Systems. The Legacy Model WLRZ electronic controller monitors several functions of the heater. In the event of a malfunction, the Legacy controller will display a FAULT message. Table 8 lists the Legacy Model WLRZ electronic Heater Service Codes along with potential causes and remedies. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 29 ® Table 7. Legacy Model WLRZ Electronic Troubleshooting Guide # Symptom Cause Remedy 1. No Water Flow A. B. C. D. E. F. No power. Pump defective. Incorrectly wired. Pump relay defective. Time clock settings not synchronized with actual time. Controller Defective. F. Replace controller.* 2. Flame roll-out on start-up A. B. C. D. E. F. G. Blocked flue on start-up. Igniter out of position (delayed ignition). Blocked heat exchanger. Refractory blanket out of place. Altered draft hood. Downdraft conditions. Low gas pressure. A. B. C. D. E. F. G. Remove blockage.* Correct igniter position.* Clean and correct as necessary.* Correct or replace blanket as necessary.* Install factory-provided draft hood.* Install vent cap.* Adjust manifold or supply pressure.* 3. Spillage at vent cap A. Cold chimney. B. C. D. E. Vent pipe pitches down to chimney. Blocked chimney. Draft hood altered. . Prefabricated chimney with incorrect cap. A. B. C. D. E. Allow heater to operate five (5) minutes to create draft action.* Reinstall vent pipe to pitch up from heater to chimney. Remove blockage.* Install factory-provided draft hood*. Install a Zodiac approved vent cap.* Low primary air. Incorrect manifold pressure. 4. Flame has lazy yellow tip A. B. 5. Not enough heat A. Inadequate gas supply. B. Low manifold gas pressure. C. D. Heater size inadequate. Temperature rise set incorrectly. A. B. C. D. E. Check circuit breakers and power source. Replace.* Recheck wiring.* Replace pump relay.* Check time clock setting and current time. A. Check for internal burner obstructions.* B. Adjust manifold pressure according to rating plate. Clean burner ports if dirty.* A. B. C. D. Gas meter too small. Gas line from meter to heater too small.* Gas pressure on heater manifold, should be adjusted to values listed in Table 2.* Replace with heater of higher input.* Adjust temperature rise according to Section 10.6 of this manual.* 6. Heater pounding or knocking A. Low water flow through heater. A. Check temperature rise between inlet and outlet heater piping. See Section 7.8 for recommended range of temperature rise. If temperature rise is above the maximum recommended, adjust the bypass. Check for closed valve in system.* 7. Heater condensing A. Low water temperature. B. Heater plumbed backwards. A. B. Flue product moisture will condense at the start-up until the pool water temperature reaches the normal operating conditions.* Correct Plumbing.* A. B. C. Gas valve not at “on” position. Air in gas line. Gas valve failed. A. Turn knob to “on” position. B. Cycle ignition sequence until air is out of the gas line.* C. Replace gas valve.* 8. Igniter lights but main burners will not come on * Must be performed by a qualified professional pool technician. Page 30 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Table 8. Legacy Model WLRZ Electronic Heater Service Diagnostic Guide DISPLAY FAULT Display shows NO FLOW CAUSE 1. Pump is not running. 2. Low pump pressure. 3. Pressure switch fault. FAULTHIGH LIMIT 1. Water temperature in heater exceeds the internal limit. 2. Limit switch fault. FAULTFUSELINK/FIELD 1. Roll-out switch (fusible link). 2. Vent temperature limit fault. FAULTCHECK IGN CONTROL 1. Air flow restricted at intake or discharge. 2. Oscillating pump pressure. 3. Low gas supply pressure. 4. No flame at burners. FAULTSHORTED H2O SENSOR or FAULTOPEN WATER SENSOR 1. Faulty wiring or connection. 2. Failed sensor. REMEDY 1. 2. 3. This is a normal display when the pump is OFF. No Service Required. Clean filter or clear blockage, check position of valve in plumbing system. Adjust or replace pressure switch. Refer to qualified service personnel. 1. Verify function of high limit switches. Perform temperature rise test. Identify and correct cause of overheating. Refer to qualified service personnel. 2a.Identify and correct loose connections or replace switches. Refer to qualified service personnel. 2b.Reset the manual reset high limit by pushing the red button located on the high limit. After resetting high limit, the cause of this over temperature condition needs to be thoroughly investigated. Refer to qualified service personnel. 1. 2. Identify and correct loose connections or replace roll-out switch (fusible link). Check for and correct any down draft condition. Refer to qualified service personnel. Identify and correct loose connections or replace vent temperature limit. Refer to qualified service personnel. 1. 2. 3. 4. Check for proper clearances around heater and for adequate room ventilation if enclosed. Inspect for blockage or restriction at discharge of flue. Refer to qualified service personnel. Clean filter or identify and repair cause of pump oscillation. Identify and repair incorrect supply pipe size or pipe line blockage. Identify and correct loose wiring connections, or problems with igniter, flame sensor, gas valve, or ignition control. Refer to qualified service personnel. 1. 2. Inspect sensor wiring. Ensure sensor is connected into Power Interface Board. Replace temperature sensor. Refer to qualified service personnel. Page 31 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Section 10. Professional Maintenance and Service WARNING SERVICING SAFETY Some of the servicing procedures for the Legacy Model WLRZ electronic heater are hazardous because they involve fuel gas, electricity, moving parts and procedures which require testing or temporary bypass of safety controls. For this reason, the heater must be serviced only by a qualified professional service technician. IMPROPER SERVICE HAZARD The Legacy Model WLRZ electronic heater incorporates unique design features. Incorrect service of this heater can result in property damage, serious personal injury or death. To avoid such hazards, the heater must be serviced only by a qualified professional service technician. exchanger. Combustion products then enter a flue collector and are directed to the outdoors through the top of the heater or a vent pipe and cap. 10.3 Heater Components and Their Operation 1. 2. 10.1 General Information A qualified professional technician must service the Legacy Model WLRZ electronic pool heater using Zodiac's service procedures. Before calling for service, however, the owner should check for obvious problems. The other components in the pool system, including pump, filters and strainers, water valves, gas supply, electrical power and time clocks, have an affect on heater operation. Confirm that the heater control is set to either POOL or SPA and that the corresponding temperature set point is set high enough to make the heater operate. Make sure the pump is operating, that the filter and strainers are not clogged, that there are no mispositioned water valves, that the gas or electric power supplies are not shut off and that time clocks are properly adjusted. Also be sure that there is no blockage of the exhaust vent grill or rear louvers, which supply combustion air to the burners. 10.2 Natural-Draft Combustion System The Legacy Model WLRZ electronic pool and spa heater has an atmospheric combustion system. This system is illustrated in Figure 23. As the heated exhaust gases rise out of the combustion chamber, flow is created through the system and fresh combustion air is drawn into the heater through the louvers cut into the front and sides of the heater. Gas is forced through an orifice into the open end of a burner. When the gas flows into the burner, a “negative” pressure is created at the opening of the burner. This negative pressure pulls air into the burner with the gas and mixes the two together. As the gas/air mixture flow through the burner ports it is ignited in the combustion chamber. Hot combustion products then rise through a highly efficient heat 3. 4. Gas Valve / Regulator - The gas valve controls gas flow into the manifold. It provides flow only when the temperature control requires heat and only if all safety controls enable operation. It is also a positive pressure regulator. It regulates the gas pressure in the manifold to specifications addressed earlier in this manual. This is necessary for proper operation of the burner system. Temperature Control - The Legacy Models are equipped with an electronic control which senses water temperature by means of a thermistor and controls heater operation to bring the water to the temperature selected. It has an option for two (2) separate thermostat settings which are typically used to set pool and spa temperatures. Ignition Control - The ignition control provides energy for ignition of the air/gas mixture, monitors the flame and controls the gas valve. Then it applies electrical power to a "hot surface" igniter. When the igniter is hot enough, the ignition control opens the gas valve. It has sophisticated means to sense ignition and flame condition so that unburned gas will not escape. Once the ignition control has sensed flame, it deenergizes the igniter. After the burner is shut off, the ignition control provides a post-purge period. Igniter - The hot surface igniter is a ceramic element which becomes very hot when electrical power is applied to it. The hot surface igniter directly ignites the air/gas mixture in the combustion chamber. VENT TOP FLUE COLLECTOR HEAT EXCHANGER COMBUSTION CHAMBER BURNER BURNER TRAY SHELF Figure 23. Atmospheric Combustion System Page 32 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 5. Flame Sensor - The flame sensor is the electrode through which the ignition control detects "rectification" of current passed through the flame. Inadequate rectification indicates an unsatisfactory flame condition. The rectification signal can be measured by attaching the leads of a DC ammeter to the two (2) pins on the connector of the ignition control labeled "FC". A wire harness, available from Zodiac, makes it easier to attach the voltmeter leads. The flame current should not be less than 1.5 micro-amps. If the flame signal is less than 1.5 micro-amps, verify correct gas supply and manifold pressures. 6. Limit Switches - Two (2) limit switches prevent excessive water temperature - one (1) at the heat exchanger outlet and one (1) for water leaving the heater. If either senses excessive temperature, burner operation is interrupted. 7. Water Pressure Switch - This control senses whether or not water is available to the heater by measuring back pressure inside of the heat exchanger. If the pool water pump fails or the water filter is blocked, the pressure switch prevents operation of the burner. 8. Roll-Out Switch (Fusible Link) - This is a single-use switch which detects abnormal temperature in the component compartment of the heater. The roll-out (fusible link) is held to the combustion chamber just above the burner tray by a sheet metal bracket. Excessive temperature in the component compartment, possibly due to a blocked flue or flame roll-out, will cause the link to fail. This opens the safety circuit which shuts off the gas valve and shuts the heater down. 9. Vent Temperature Limit - This is a single-use switch which detects abnormal temperature in the vent system. It is mounted to the flue collector assembly. Excessive temperatures will cause the switch to open. Excessive temperatures can be caused by inadequate water flow or a damaged heat exchanger. The vent temperature limit will open the safety circuit which shuts off the gas valve and shuts down the heater. 10.4 Electrical Troubleshooting This section describes procedures for checking the electrical power and control components of the heater one at a time and in the order they appear in the control circuit. It is important to follow the sequence of this troubleshooting guide because the safety circuit is connected in series. NOTE Pump must be running during the troubleshooting procedure. These procedures require a Volt-Ohm meter with a minimum 0-250VAC voltage range, and 1-1000 Ohm resistance range. Figure 26 shows the power and control circuits and where to take measurements. Location numbers in circles have been added, and will be referenced in the following sections. Where test points are shown at circuit board connectors, the probe of the meter can be carefully pushed into the connector along side of the wire at the connection to be measured. The electrical power supply can be checked with the heater not set to fire. All other procedures need to be checked with power correctly supplied to the heater, all external devices set so that the heater is allowed to fire and the heater's thermostat set so that there is a call for heat. As stated at the beginning of the manual, some of these procedures are hazardous. Only a qualified service technician should service the heater. 10.4.1 Electrical Power Supply The electrical components of the Legacy Model WLRZ electronic pool heaters are designed to operate with supply voltage ranging from 204V to 264V at 50 Hz if connected to a nominal 220-240 Volt power supply. Measure supply voltage at the power supply leads where they enter the heater to verify that the correct voltage is supplied to the heater. If no voltage is present, correct this external power supply problem to the heater. Circuit breakers, time clock settings or similar devices may be the problem. Voltage outside of the above ranges may be due to poor wiring, poor connections, other loads such as air conditioning compressors or an electric utility company problem. Arrange for correction of the voltage as appropriate. The controller must be operational in order to check the control circuits of the heater. 10.4.3 Control Circuit Troubleshooting The heater controls are arranged in several 24V 50Hz circuits with some operating and safety controls arranged in series circuits. Troubleshooting is done by probing for voltage between the common and various points in the circuit to determine which component is preventing operation. Check points are indicated on Figure 26. The black lead of the meter should be attached to the common tap on the secondary side of the transformer and may be left there throughout most of the procedure. The recommended procedure steps through each circuit in a sequential way, and each section assumes that components from all previous sections have been tested and are operational. However, verifying voltage at any of the numbered points in that circuit confirms that all prior components of the circuit are operational. 10.4.3.1 Transformer Attach the black lead of the voltmeter to the terminal on the secondary side of the transformer of the transformer with a yellow wire attached to it Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 33 ® (common). This is test point 1 on Figure 26. Touch the free red lead of the voltmeter to the terminal on the secondary side of the transformer with a red wire attached to it (24V tap), test point 2. The voltmeter should read between 20-28 Volts AC. If the voltage does not fall within the limits mentioned above, replace the transformer. 10.4.3.2 Fuse Leave the black voltmeter lead in place at test point 1. Touch the free lead of the voltmeter to test point 3, which is on the Power Interface Board where the red wire from the transformer enters the end of the connector. You will need to push the voltmeter lead into the back of the connector along side of the wire pin. The meter should read 20-28 Volts AC. If there is no voltage, the fuse has failed. Inspect the rest of the wiring, especially the safety circuit, to be sure that there is no “short” such as contact of a terminal with the heater chassis or another terminal which may have caused the fuse to fail. Correct any such condition and replace the fuse. Use only a 2 amp, 1 1/4 inch long x 1/4 inch diameter, quick acting, glass tube type fuse. 10.4.3.3 Water Pressure Switch Start by checking the voltage at the two (2) legs of this circuit on the controller, see test points 4 and 5 in Figure 26. Check the voltage at test point 4, where the violet wire from the pressure switch enters the two-pin connector on the controller. If there is not 20-28 Volts AC nominal at this point, either the controller or the two-pin wire harness is faulty and must be replaced. If 20-28 Volts AC nominal is detected at test point 4, then move the red lead of the meter to test point 5 where the gray wire from the Pressure Switch enters the two-pin connector. If 20-28 Volts AC nominal is detected at this point, the devices in this circuit are closed and the circuit is working properly. If there is no voltage the pressure switch contacts are open. This is almost always due to a water flow deficiency, the most common one being a blocked water filter or defective pump. However, sometimes it is due to blockage of the copper siphon loop tube or mis-adjustment of the switch. Investigate thoroughly, referring to Section 7.7 on “Adjusting the Water Pressure Switch”. If there is no problem with the pool system or pressure switch adjustment, replace the pressure switch. 10.4.3.4 Roll-out Switch (Fusible Link) To check the roll-out switch (fusible link)/air louver/field interlock circuit, place the red lead at test point 6. If there is not 20-28 Volts AC nominal, either the controller or the two-pin wire harness is faulty, or the water pressure switch is open. If 20-28 Volts AC nominal is detected at test point 6, then move the red lead of the meter to test point 7. If 28 Volts AC nominal is detected, the circuit is closed and working correctly. If the proper voltage is not detected, the roll-out switch (fusible link) or vent temperature limit has opened, or the wire harness is faulty. If no voltage is detected at test point 7, the roll-out switch (fusible link) or vent temperature limit has failed. This indicates higher than normal temperatures in the component compartment (vestibule). The normal component compartment temperature is well below 300°F (148.9°C). The roll-out switch (fusible link) is designed to fail at temperatures above 305°F (151.7°C). Excessive temperature might be due to a blocked flue or heat exchanger. Clean the heat exchanger and clear the flue and vent of any restrictions. Sometimes the roll-out switch (fusible link) fails due to flame roll-out. Flame roll-out may be caused by delayed ignition or downdrafting in windy areas. Thoroughly investigate the causes for flame roll-out and correct the problem when replacing the roll-out switch (fusible link). The vent temperature limit will fail due to abnormal temperatures in the vent system. Excessive temperatures will cause the switch to open. The vent temperature limit is designed to open at temperatures above 464°F (240°C). Excessive temperatures can be caused by inadequate water flow or a damaged heat exchanger. Thoroughly investigate the causes for roll-out switch (fusible link) opening and correct the problem when replacing the vent temperature limit. 10.4.3.5 Temperature Limit Switches Circuit Since the limit switches are not easily accessible, the voltage can be checked at the two (2) legs of the circuit at the controller. See test points 8 and 9 in Figure 26. Check the voltage at test point 8. If there is not 20-28 Volts AC nominal at this point, either the controller or the two-pin wire harness is faulty, or one (1) of the two (2) safeties (water pressure and fuselink) before it are open. If 20-28 Volts AC nominal is detected at this point, then move the red lead of the meter to test point 9 where the black wire from the 42°C (108°F) limit enters the two-pin connector. If 20-28 Volts AC nominal is detected at this point, the devices in this circuit are closed and the circuit is working properly. If there is no voltage, one (1) of the limit switches is open. This is normally due to excessive water temperature, which should be thoroughly investigated before replacement of limit switches. Excessive water temperature may be caused by low water flow. Water flow deficiency may be due to obvious problems such as a defective pump or blocked water filter. Alternatively, excessive water temperature may be due to over-firing, or to a problem with the water piping or the heater's internal bypass control. Over-firing might be a result of an incorrect gas orifice or supply of propane gas to a heater intended for natural gas. Page 34 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® If there are no such fundamental problems, identify which of the switches is open. Limit switch access is through the limit switch plugs on the side of the heater to which water pipes are connected. Remove the limit switch plugs from the bottom of the header and gently remove the switches from the wells. Note that the limit switches have different trip points, and it is important that replacements are correct. The 52°C (126°F) switch is located on the water outlet side of the heater. This switch is an automatic reset switch and it does not have a red button located between the electrical terminals. The 42°C (108°F) switch has a red button located between the electrical terminals. This switch is located on the water inlet side of the header. Move the red meter lead to the terminal connection on the 52°C (126°F) switch that is connected back to the controller. The voltmeter should read 20-28 Volts AC nominal. No voltage here means that the two-pin wire harness is bad and should be replaced. If voltage is detected at this point move the lead to the other terminal of the switch. If the voltmeter does not show voltage then the 52°C (126°F) limit is bad and should be replaced. If the meter reads 20-28 Volts AC nominal, move the lead to the terminal of the 42°C (108°F) manual reset limit that is connected to the wire that jumps between the two limit switches. No voltage here means that the wire assembly is bad and needs to be replaced. 20-28 Volts AC nominal shows that the wire between the two (2) limits is making a good connection. Now move the lead to the other connection terminal on the 42°C (108°F) limit. No voltage at this point indicates that the limit switch has opened. This switch has a red manual reset button. Push the button in and recheck the voltage at the second connection terminal. No voltage again means a failed switch. Replace the switch. If there is still no voltage at test point 9 then the wire harness is faulty and needs replacement. 10.4.3.6 Gas Valve Voltage The gas valve will operate only when there is a call for heat, all safety circuits have been satisfied and the hot surface igniter has had power for approximately 35 seconds. If the gas valve does not operate under these conditions, check the voltage going to the gas valve. Place one (1) voltmeter lead on the connector on the ignition control where the yellow wire is connected (test point 15). Touch the free lead of the meter to the gas valve terminal where the brown wire is attached at the gas valve. This test point will have voltage present only during a trial for ignition or during normal operation. The meter should read 20-28 Volts AC. If there is no voltage, then there is a bad connection between the gas valve and the ignition control. Replace the wire harness. Listen closely to the gas valve when it is first energized (24V first appears at test point 14 during the trial for ignition). There should an audible "click" when the valve opens. If there is voltage at the gas valve terminal where the brown wire is attached, but the gas valve does not open, replace the valve. 10.4.3.7 Igniter/Ignition Control Circuit WARNING The igniter, power supply circuit board and some terminals of the ignition control utilize 220-240V power and require appropriate servicing precautions. Note that wires and terminals of these components may be “hot” even when the component is not operating. With the igniter energized, there will be voltage of 105-130 VAC supplied by the ignition control, test point 13 and test point 12, with the igniter energized. This voltage will be applied only during igniter heat up or trial for ignition. Even if voltage has been confirmed at the end of the safety circuit, the “trial for ignition” sequence is imposed by the ignition control. This sequence consists of a 15 second period of pre-purge, a 40 second period for heat-up of the igniter and a 7 second trial for ignition. During this last 47 seconds there is voltage between test point 11 and test point 10, or between test point 12 and test point 13. If satisfactory ignition is not achieved, the igniter is turned off and the system waits for a 15 second inter-purge period. The system may go through this cycle as many as three (3) times, but thereafter it is “locked out” by the ignition control for a one (1) hour period. Additional attempts will be made only if the call for heat is interrupted by turning off electrical power or setting the control to “Off” and then back to "Pool" or "Spa" or after the one (1) hour delay. To trouble shoot the ignition control's igniter circuit, connect the voltmeter leads at test points 10 and 11, and set the control to call for heat. Observe that the normal ignition sequence takes place. After the 15 second pre-purge, note the voltage between test points 10 and 11, or test points 13 and 12. Then look for the glow of the igniter by looking upwards through the burner tray opening. If the correct voltage is detected between points 10 and 11, or points 13 and 12 during the trial for ignition but the igniter does not glow, check igniter as follows: Check the igniter with the ohmmeter. Disconnect the igniter terminals from the igniter at test points 10 and 11. Place one (1) lead of the meter on each wire to the igniter. The resistance should read between 40 and 75 Ohms at ambient air temperature. If the meter reads outside of this range or shows an open or short circuit, replace the igniter. If a short circuit is indicated, it is necessary to investigate further to find if the short is from the igniter or the flame sense circuit. If voltage does not appear between points 12 and 13, or points 10 and 11 during the trial for ignition, there may be a bad connection, faulty transformer, or Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual Page 35 ® a short on the ignition control. Check all connections, the transformer, and the ignition control for loose or corroded connections or failure and replace as necessary. 10.5 Adjusting the Water Pressure Switch CAUTION The water pressure switch should be adjusted to turn the heater off when the pump is off. Setting the switch too close at too low of a flow can damage the appliance. Adjust the switch to turn the heater off, not on. The pressure switch is preset at the factory for activation at 14 kPa. Do not adjust the pressure switch if the heater is installed more than 4.57 m below the pool surface. Consult your local Zodiac representative for recommendations. On some installations, the piping from the heater to the pool is very short. The back pressure could be too low to trigger the pressure switch. If this happens, it may be necessary to install a directional fitting or elbows where the return line enters the pool. This will increase back pressure enough for the heater to operate properly. Make sure the pool filter is clean before making any pressure switch adjustment. A dirty filter will restrict the water flow and the pressure switch cannot be adjusted properly. To adjust the pressure switch, see Figure 24 and proceed as follows: 1. Set the heater control to OFF. 2. It may be necessary to remove the side panel above the front header to access the water pressure switch. 3. Start the filter pump and confirm by means of a voltmeter that the pressure switch closes (if the switch fails to close, either replace it with a SLOWLY TURN ADJUSTMENT SPROCKET CLOCKWISE UNTIL HEATER GOES OFF. Figure 24. Adjustment of Pressure Switch switch that has a lower minimum setting or add additional back pressure by reducing the eye ball fittings in the pool). 4. Set the heater to either POOL or SPA. Heater should start. 5. With your fingers, turn the adjustment sprocket very slowly clockwise until the heater goes off. 6. Slowly turn the pressure switch adjustment sprocket counterclockwise one-quarter turn. The heater should come back on. 7. Check the adjustment by turning the filter pump OFF. The burners should shut off immediately. If they do not, restart the filter pump and repeat Steps 6 and 7. Check the adjustment again. 8. Return the pool temperature control to the desired temperature. It may be necessary to repeat these steps to get a proper setting. The switch must be set so that the heater will not fire unless the pump is running. If a proper setting cannot be reached, contact the factory service department. 10.6 Temperature Rise The Legacy pool and spa heaters have an internal bypass which accommodates a wide range of water flow. The bypass is easily adjustable to change the temperature rise for optimum performance and length of heater life. The bypass assures constant heat exchanger flow even though flow through the filter system will vary depending on how dirty the filter is. For most installations, an external bypass valve is not needed in the heater water piping. This is due to the large size of the heater's internal bypass valve. If the pump flow rate is known to exceed 475 lpm, an external bypass may be needed to assure proper heater operation. Water flow should be confirmed upon start-up of the heater and in most servicing situations. If the flow is not normal, corrections must be made to the pool system. Flow is evaluated by determining the water temperature rise through the heat exchanger. Before checking the temperature rise, make sure that the pool filter is clean and that gas supply and manifold pressures are correct. If necessary, clean all components of the filter system. Temperature rise is measured in the return header of the Legacy. To measure the temperature rise, turn off the filter pump and remove the plastic plug protruding through the cabinet on the return header side of the heater. See Figure 25. With the plug removed, install the special thread adapter and Pete’s Plug® fitting and insert a pocket thermometer. A temperature rise measurement kit is available through your Zodiac distributor. See Section 11 of this manual for the correct kit number. Page 36 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® BYPASS ADJUSTMENT SCREW 8. If it was necessary to adjust the external bypass as outlined in step 6, scribe a line on the bypass shaft and case to mark the correct adjustment position. Wire or remove the valve handle to prevent tampering. Table 9. Water Temperature Rise and Flow Rates (Measured at Return Header) THERMOMETER WITH PETE'S PLUG® Figure 25. Temperature Rise Measurement The internal bypass can be adjusted by means of a screw on the right-hand side of the header. To adjust the temperature rise to within the ranges specified in Table 9, proceed as follows: 1. If the piping system has an external bypass valve, close it. 2. Set the heater's control panel to the "OFF" position. 3. Start the filter pump. 4. After three (3) minutes, note and record the thermometer reading. This is the pool water temperature. 5. Start the heater by setting the control panel to either "POOL" or "SPA". Allow the heater to operate for five (5) minutes or more. Note and record the thermometer reading. Subtract pool water temperature from this reading. This difference is the temperature rise. Refer to Table 9. If your measured temperature rise is within the range designated for your heater, skip steps 6 through 8. 6. Locate the bypass adjustment screw on the righthand side of the header, see Figure 25. Loosen the nut so that the screw can be adjusted. A slight water leak past the nut may be expected. Turn the screw counterclockwise to decrease the temperature rise, and clockwise to increase the temperature rise as needed to achieve the ranges in Table 9. After the adjustment, tighten the nut so that no leaks occur. 7. If the temperature rise is too low and cannot be raised by means of the adjustment screw, the flow is in excess of 7.9 lpm. An external bypass will need to be installed, or if one already exists, open the external bypass valve gradually until the temperature range in Table 9 is achieved. Model Minimum Temp Rise, °F (°C) Maximum Temp Rise, °F (°C) Minimum System Flow lpm (GPM) 125 7 (4) 10 (5) 110 (30) 175 10 (6) 13 (7) 110 (30) 250 16 (9) 20 (11) 110 (30) 325 20 (11) 26 (14) 110 (30) 400 23 (13) 29 (16) 110 (30) In a system without external bypass, it may be necessary to make changes. If temperature rise is too low, a manual bypass must be installed. If temperature rise is too high, there is inadequate flow, possibly requiring a change to the piping system or a larger pump. Before proceeding with either remedy, verify proper heater operation. Low gas input results in low temperature rise and vice-versa. A problem with the heater internal bypass assembly also affects measured temperature rise. Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Section 11. Replacement Parts 11.1 Ordering Information To order or purchase parts for the Legacy Model WLRZ electronic pool and spa heater, contact your nearest Zodiac dealer or distributor. See the Zodiac web site at www.zodiac.com.au for the nearest service center. If they cannot supply you with what you need, contact Customer Service at Zodiac, Telephone 1800-688-552. NOTE To supply the correct part it is important that you state the model number, serial number and type of gas when applicable. This information is on the rating plate inside the heater. Page 37 Page 38 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® R 24 VAC FC+/IGNITER / IGNITION CONTROL CIRCUIT 13 12 IGN 240 IGN FS GY L1 L2 W/R W/BK 14 W BK Y/BK VAL BR 15 GND BL BR 11 10 W/R BL HOT SURFACE IGNITER BL G/Y GAS VALVE FLAME SENSE W/BK BL BR G/Y 6 BK 5 2 R 1 BK BK 2 12 R 11 BK FUSE 8 7 1 G/Y 220-240 VAC HEATER POWER SUPPLY WATER TEMP SENSOR BK BL WATER TEMP FAN/LOUVER UNIVERSAL CONTROLLER POWER INTERFACE BR BL PUMP COMP/IGN 24 VAC 3 GAS VALVE USER INTERFACE 9 BK O BL R HIPRESS HILIMIT GY 8 GY 7 LOPRESS FUSELINK 6 BL O TO COMBUSTION AIR LOUVER STARTER (IF USED) 5 WATER PRESS GY 4 TO PUMP STARTER CONTACTS (IF USED) Y/BK R BL REMOTE SPA POOL COM V BK O BL R POWER INTERFACE UNIVERSAL CONTROLLER USER INTERFACE 52°C LIMIT SWITCH 42°C LIMIT SWITCH Figure 26. Test Point Identification Diagram BL 152°C ROLL-OUT SWITCH (FUSIBLE LINK) WATER PRESSURE SWITCH 240°C VENT TEMPERATURE LIMIT Factory Wired 24V Factory Wired 220-240V BK - BLACK BL - BLUE BR - BROWN G/Y - GREEN WITH YELLOW TRACE GY - GRAY O - ORANGE R - RED V - VIOLET W/BK - WHITE WITH BLACK TRACE W/R - WHITE WITH RED TRACE Y/BK - YELLOW WITH BLACK TRACE Page 39 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 11.2 Parts List Model No. Order Part No. Key No. Description Burner Tray Assy, Natural 125-400 R0523601-05 48 Bypass Spring, Adjustable, Polymer All R0453901 1 Burner Tray Assy, LP 125-400 R0524601-05 49 Tailpiece w/ Union Nut (Set of 2), 2" All R0449000 2 Burner Tray, Shelf Only 125-400 R0469101-05 50 Header Gasket Assembly (Set of 16) All R0454300 3 Gas Valve, Natural All R0523100 51* Bypass Hardware, Gaskets All R0453800 3 Gas Valve, LP All R0524400 52 Heat Exchanger Tube Assy, Copper 125-400 R0490101-05 4 Anti-Rotation Bracket All R0469700 53 Plug, Sensor All R0456800 5 Hot Surface Igniter All R0457501 6 Flame Sensor Rod All R0458601 54 Combustion Chamber Panels 125-400 R0494901-05 R0469800 55 Igniter Box Assy 125-400 R0484000 Key No. Description 1 Burner, Main All Order Part No. Water System (Continued) Main Gas Assembly 7 Model No. Firebox Components Jacket Components 8 Burner Manifold 125-400 R0485801-05 9 Manifold Assy, Natural Gas 125-400 R0523201-05 56 Door with Latch 125-400 R0470901-05 9 Manifold Assy, LP 125-400 R0524501-05 57 Latch Assembly All R0334900 10* Gas Conversion, Natural to LPG All R0523300 58 Grommet, Sealing, 2" All R0460300 11* Orifice Set (41), Natural 125-325 R0523400 59 Button Plug, 7/8" All R0491100 11* Orifice Set (40), Natural 400 R0528200 60 Rear Panel Assy 125-400 R0482301-05 11* Orifice Set LP (53), LPG All R0469500 61 Side Panel, Right All R0482400 62 In/Out Cover Panel, Top All R0482500 Electrical System 12 Universal Controller w/ Bezel All R0515200 63 In/Out Cover Panel, Bottom All R0482600 13 Universal Control User Interface All R3008800 64 Side Panel, Left All R0482700 14 Universal Control Power Interface All R0470200 65 Return Side Cover, Top All R0482800 15 Transformer All R0486100 66 Return Side Cover, Bottom All R0482900 16 Temperature Sensor All R0456500 67 Heat Shield 125-400 R0483101-05 17 Gasket, Temperature Sensor All R0456600 68 Heat Deflector Guard, Front 125-400 R0483201-05 18 Nut, Sensor Retainer All R0523900 69 Rear Partition 125-400 R0483401-05 19 Pressure Switch Assembly (2 PSI) All R0455400 70 Heat Deflector Guard, Rear 125-400 R0483501-05 20 Pressure Switch, 2 PSI All R0013200 71 Controller Mounting Panel 125-400 R0483901-05 21* Pressure Switch, 1-10 PSI All R0015500 72 Weather Stripping All R0491000 22 Water Pressure Switch Tubing All R0483600 73 Grommet 7/8" All R0492800 22* Water Pressure Switch Tubing, Long All R0483601 Optional Components 23 High-Limit Switch Assembly All R0514000 74* Noncombustible Base 125-400 R0471001-05 24* High-Limit Switch Set All R0514100 75* Press Relief Valve Kit,75 PSI, Polymer All R0336100 25 High-Limit Switch, 42°C (Manual Reset) All R0514200 76* Temp Rise Measurement Kit All R0336000 R0514300 NOTES: 1. All hardware sets contain all pieces necessary for assembly, including gaskets. 26 High-Limit Switch, 52°C All 27 Ignition Control All R0486200 28 Roll-Out (Fusible Link) Assembly, 152°C All R0012200 29 Roll-Out (Fusible Link) Bracket All R0337200 30* Australia Wire Harnesses Set All R0513500 31 Top Enclosure 125-400 R0470301-05 Vent System 32 Vent Cover 125-400 R0470401-05 33 Rainshield (Partition) 125-400 R0478201-05 34 Flue Collector Assembly 125-400 R0470501-05 35 Outdoor Vent Cap 125-400 R0491601-05 36 Indoor Draft Hood 125-400 R0499601-05 37 Adapter Plate 125-400 R0478301-05 38* Clip All R0500200 39 Vent Temp Limit Assembly All R0534800 40 Vent Temp Limit Switch, 240°C All R0524300 R0470800 Water System 41 Inlet/Outlet Header Assy, Polymer 125-400 42 Return Header Assy, Polymer All R0454201 43* Header Hardware Set, Polymer All R0454500 44 Heat Exchanger Assembly, Complete 125-400 R0514401-05 45 Heat Exchanger Drain Plugs (2), Polymer All R0446000 46 3" Coupling Nut Kit w/ O-ring All R0454000 47 Bypass Assembly, Polymer 125-400 R0453701 2. Gaskets and hardware are included in all kits that involve the removal of a gasket as part of the procedure to replace a part. * PARTS NOT SHOWN ON KEY VIEW ** MANIFOLD KIT INCLUDES INSTALLED ORIFICES BUT DOES NOT INCLUDE GAS VALVE Page 40 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 11.3 General Exploded View 32 35 36 31 37 33 34 66 65 64 42 40 20 44 59 39 19 61 22 54 41 54 59 54 29 28 69 70 55 57 71 70 67 4 13 12 1 72 62 56 68 63 73 61 Page 41 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® 11.4 Detailed Exploded View 27 15 13 14 7 9 3 2 55 5 8 45 6 52 47 50 48 17 41 46 49 45 18 16 25 26 24 53 Page 42 Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Legacy™ Model WLRZ Pool/Spa Heater Installation and Operation Manual ® Page 43 ® ® ZODIAC CUSTOMER SERVICE CENTRE Zodiac Group Australia 219 Woodpark Rd, Smithfield, NSW 2164 Australia Tel: 1800 688 552 Fax: 1300 781 688 Email: [email protected] www.zodiac.com.au H0338200 Rev E Due to constant developments and improvements, specifications may change without notice. Improper use could affect performance and void warranty. © 2012 Copyright Zodiac Pool Systems, Inc. Zodiac® is a registered trademark of Zodiac International, S.A.S.U., used under license. All other trademarks used herein are the property of their respective owners.