COMMERCIAL POOL HEATERS Copper
Contents
1. 05 INSTRUCTIONS FOR OPERATION COMMERCIAL POOL HEATERS Copper Fin 11 Models 400 000 750 000 Btu hr Input This section contains specific requirements for Pool Heaters All warnings cautions notes installation and operating instructions and maintenance requirements from the general Installation and Service Manual apply to these units in addition to the following specific requirements for pool heating equipment These instructions must be followed closely to obtain maximum life and usage of your pool heater PERFORMANCE Your pool heater is a high efficiency unit which has been designed to operate scale free and trouble free for many years Particular attention should be directed to the following items 1 Correct adjustment of the pool heater s pumped bypass and valves 2 Required minimum inlet temperature to pool heater 3 Correct piping to the pool filter system with specified pipe materials and size 4 Electrical interconnection of the pool heater controls bypass pump and filter pump to ensure continuous circulation LOCATION AND VENTING Consult the Installation and Service Manual for the specific model you are installing The Installation and Service Manual is included with the basic installation package shipped with the pool heater This manual contains the specific requirements for clearances from combustible surfaces combustion and ventilation air requirements venting requirements available ven2. 3 Shut off the electrical supply to both the pool heater and setting on the switch To check operation turn on the heater the bypass pump and pump Turn the pump off and on several times to ensure 4 Drain the heat exchanger and bypass assembly proper operation of the water pressure switch on low no completely by removing threaded inspection plugs from water flow to the pool heater 7 FACTS ABOUT WATER CHEMISTRY Factors which affect pool and spa water and more importantly the efficiency of your new pool spa heater are PROPER FILTRATION PROPER CIRCULATION DISINFECTION AND OXIDATION pH CONTROL AND TOTAL ALKALINITY ALGAE CONTROL Mm BR D The water chemistry of your pool or spa changes daily due to natural evaporation of the water and the addition of chemicals Chemicals are used to sanitize and control algae growth in the pool Their addition must be carefully monitored If there is an imbalance in the pool water chemistry the minerals in the pool water will precipitate out and collect in the pool filter system and the pool heater The accumulation of minerals or scale in the pool heater due to a chemical imbalance will cause a non warrantable failure of the heat exchanger and its components pH is the most important factor maintaining proper balance in your pool spa water pH is the measurement of the acidity or alkalinity of water The chart below shows the ideal pH range and what can happen when
3. operating sensor for the digital temperature control 1s mounted in the bulb well located in the inlet piping of the bypass assembly Sensor A displays the pool water temperature Sensor B is mounted in the inlet side of the units front header Sensor B serves as a digital thermometer to monitor the temperature of the pre heated inlet water to the heat exchanger The pool heater also has 2 fixed setting limit controls a high limit and an auxiliary limit The high limit control 1s factory mounted in the outlet side of the front header NOTE REMOVE JUMPER AT Fig 17 The auxiliary pool limit must be field installed in the pool filtration return piping system Connection of the electronic pool aquastat temperature sensor and the limit controls to the 24 VAC control circuit is by wire No capillary tubes are used for the connection to the sensing bulbs The temperature sensor Sensor A for the electronic digital temperature control for pool water temperature 15 factory installed in a bulb well located in inlet piping of the bypass assembly The temperature sensor for the fixed setting auxiliary limit control must be field installed directly into the heated pool water downstream of the bypass assembly in the pool filtration system piping The limit is pre wired with 20 ft of wire If the field installed location for the auxiliary limit 15 more than 20 ft away from the pool heater simply replace the wires with a l
4. SETTING SPA AND HOT TUB SAFETY The following safety rules must be observed while operating a spa or hot tub l r Spa or hot tub water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is considered safe for a healthy adult Special caution is suggested for young children 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 Pregnant women beware Soaking in water above 102 F 39 C can cause fetal damage during the first three months of pregnancy resulting in birth of brain damaged or deformed child Pregnant women should observe the 100 F 38 C maximum rule Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa both the inlet and outlet side of the front header Use an hot tub thermostats may err in regulating water air hose to blow any remaining water from the heat temperatures by as much as 4 F 2 C exchanger tubes 5 Persons with medical history of heart disease circulatory 5 Drain the pump and related piping problems diabetes or blood pressure problems should obtain their physician s advice before using spas or hot tubs 6 Persons taking medications which induce drowsiness CHEMICAL FEEDERS such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs All chemicals must be diluted into
5. of combustible materials gasoline pool chemicals and other flammable liquids and vapors Never cover your unit lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to your pool heater CAUTION amp Under no circumstances should the equipment room ever be under a negative pressure Particular care should be taken when exhaust fans compressors air handling units etc may rob air from the heater The combustion air supply must be completely free of any chemical fumes which may be corrosive to the heater Common chemicals which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as freon trichlorethylene perchlorethylene chlorine etc Combustion air must be free of dust and fumes from chemicals used for pool spa water treatment These chemicals when burned form acids which quickly attack the copper tubes headers flue collector and heater stack The result is improper combustion and premature heater failure ELECTRICAL REQUIREMENTS The appliance is wired for 120 volt service The heater when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Codes ANSI NFPA No 70 Basic Electrical Wiring MNL7013 Electrical power circuits to pool
6. the pH increases or decreases from the ideal of 7 2 to 7 8 pH Scale HEAT EXCHANGERS DESTROYED HEAT EXCHANGERS DESTROYED CORROSION AREA LOW pH HIGH pH ALKALINE Fig 20 If the pH becomes too high it lowers the ability of chlorine to destroy bacteria and algae water can become cloudy filter elements may become blocked and scale formation will occur in the pool and heat exchanger If the pH becomes too low the water becomes acid You can have eye burn and skin irritation etching of the plaster corrosion of metal fixtures and the resulting stains on the plaster degradation of sand and gravel filters and corrosion of the copper tubes in the heat exchanger Damage to the pool heater due to improper pH is non warrantable We recommend using a four way test kit to monitor the Following levels to ensure proper operation of your pool heater Recommended Water Chemistry Test Recommended Level 7 2 7 8 1 0 5 0 PPM 80 120 PPM 175 350 PPM Correct pH Chlorine Residual Total Alkalinity Calcium Hardness Fig 21 Chlorine residual is the chlorine remaining in the pool water after it is consumed in the process of destroying bacteria algae and other oxidizable materials Total alkalinity is the measurement of the total amount of alkaline chemicals in the water Alkalinity controls pH Sodium bicarbonate is used to raise total alkalinity Calcium hardness can be raised by the addition of calcium chlor
7. the pool or spa water being circulated through the pool heater Any concentration of chlorine in the pool heater can cause damage to the unit DO NOT place chlorine tablets or bromine sticks in the TUBES skimmer High chemical concentrations will result when the pump 15 not running This pool heater is designed to operate without the accumulation of scale in the heat exchanger even in very hard Chlorinators MUST feed downstream of the heater and have water Periodic inspection of tubes should be made to be anti siphoning device to prevent chemical back up in the sure that no scale is accumulating when operating the pool heater when the pump is shut off heater in hard water areas or when pool chemistry has not been properly maintained Removable threaded inspection High chemical concentrations from plugs are provided on the front header of the heat exchanger improperly adjusted feeders and chlorinators can cause rapid If there is any doubt about proper water flow water hardness corrosion to the heat exchanger This damage is or maintenance of proper water chemistry the plugs should non warrantable removed at the end of the first 30 days of operation and the tubes inspected for scale accumulation This inspection should be repeated again at the end of 90 days of operation and then at the end of each six months of operation thereafter The pressure switch is factory preset for normal installations at de
8. the temperature set point for the pool heater s operating controls and adjust the heater bypass Ensure that the limit controls are properly installed LIGHTING AND SHUTDOWN PROCEDURE Follow the Lighting Instructions section in the Installation and Service Manual for detailed instructions to start the ignition system turn off gas to the appliance and checkout the ignition system POOL HEATER PIPING INSTALLATION Pool Heater Piping to Pool Filter System Install piping from the filter system to the pool heater as shown in the pool heater piping diagram Minimum pipe diameter to and from the installed pool heater to the filter system piping is 2 ft A valve should be installed in the filter system piping between the supply and return piping connections for the pool heater This valve can be partially closed to divert a portion of the filter system flow to the pool heater so it can be heated added to the filter system piping and returned to the pool The piping from the filter system to the pool heater may be PVC CPVC or Copper Pipe The piping from the pool heater back to the filter system will carry water with temperatures in excess of 110 F and MUST be CPVC or Copper Pipe The temperature of the heated water from the pool heater will be substantially cooled as it is mixed back into the pool water from the filter system and returned to the pool The mix of heated water and pool water from the filtration system should only be slightl
9. the threads on the limit to prevent leaks and install the limit into the threaded opening in the pipe Install the limit control and tighten to seal Do not over tighten the brass limit into the threaded opening the PVC pipe Over tightening the limit can damage the limit and or strip the threads cut into the plastic pipe Wire the limit into the pool heater control circuit as shown in the wiring diagram for your model If additional wire length is needed use 18 GA wire for distances up to 30 ft For longer distances size the wire per the following chart Use weatherproof connections for outdoor installation Wire Gauge Maximum Allowable Length This pool heater 15 high efficiency unit which requires special pumped bypass on the heater for proper operation This bypass assembly and the required pump are pre installed on heater as shipped from the factory piping to connect to the filter system to the pool heater 15 made directly to the bypass piping on the pool heater The pump supplied on the pool heater bypass has a sealed motor suitable for outdoor installations All electrical wiring to the pump must comply with local code requirements Installed Bypass Assembly Side View Bypass Installed on Models CP0401 thru CP0751 Assembly Components Exploded View ELECTRICAL INSTALLATION OF THE CIRCULATOR PUMP MOTOR 1 The circulator pump must run simultaneously with the filtration system pu
10. 8 F during the week Lower setting to a range that can be easily achieved in one day s operation of the pool heater COMMERCIAL POOL HEATER PIPING DETAIL SINGLE HEATER INSTALLATIONS Fig 22 3 PVC FROM ALTERS de 110 F LIMIT Fig 23 COMMERCIAL POOL HEATER PIPING DETAIL MULTIPLE HEATER INSTALLATIONS Fig 26 ot CFSP 05 10 5 02 PRINTED IN U S A
11. YSTEM 1 Verify proper installation of the pool heater temperature controls and the installation of the 110 F auxiliary limit in the mixed discharge water from the filter piping to the pool 2 Clean the filter 3 Start the filter pump Be sure all air is out of all lines including pressure connection Ensure that the pool heater is not air bound by manually opening the temperature and pressure relief valve Leave the valve open until a steady flow of water is observed at the discharge from the valve Close the valve and complete filling the system 4 Ensure that a manual bypass valve is installed in the filter system and installed between the pipe connection supplying water to the pool heater and the return from the pool heater to the filter system Adjustment of this valve will divert a portion of the water flow from the filter system to the pool heater for heating NOILA Backwash the filter when the GPM filtration rates are too low to meet local codes or state code A high temperature rise across the pool heater is also an indication of low flow in the filter system Sustained low flow to the pool heater will result in cycling of the heater on the limit controls and possible opening of the relief valve WARNING A Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance CONTROL SETTINGS See the specific requirements of each model for instructions to adjust
12. ck level The adjustment knob 15 set at 5 psi The switch scale deposit of paper thickness is normal Heavier will stop operation of the pool heater on low water flow DO deposits should be cleaned out with a brush or reamer If NOT adjust the pressure switch unless the pool heater is scale deposits are found in tubes THE CAUSE MUST located more than 4 ft above or below the deck level BE FOUND AND CORRECTED Inspect the tubes on a regular interval to ensure that the cause for the scaling has been corrected PRESSURE SWITCH ADJUSTMENT The probable cause for scaling is improper water chemistry Water Pressure Switch Check the following possible causes 1 High pH 2 Improper adjustment of the heater bypass valves 3 Inadequate pump flow Ea i ADJUSTMENT Always be sure the pool heater bypass pump is in good KNOB operating condition and runs continuously when pool heater 1s in operation PREVENTION OF FREEZING Heat exchangers headers pumps or bypass assemblies damaged by freezing are not covered by warranty If the pool heating equipment is subject to freezing temperatures the following precautions must be observed WINTERIZING The adjustment knob will increase the switch pressure setting when turned clockwise and decrease the pressure setting 1 Shut off gas supply when turned counter clockwise Check operation of the 2 Shut off the water supply pressure switch whenever an adjustment is made to the
13. h the inlet and outlet temperatures should equalize ADJUSTMENT OF THE AUXILIARY CONTROLS AND THE SET POINT OF THE ELECTRONIC POOL HEATER CONTROLS Start the adjustment with the heaters bypass discharge valve half closed and the bypass valve full open The pool heater s internal adjustable high limit should be preset at 200 F as a redundant high limit control The pool heater also has a 200 F fixed setting high limit installed in the discharge side of the units front header The field installed auxiliary limit control has a fixed setting of 110 F to limit the maximum discharge water temperature to the system The units electronic digital temperature control serves as the pool heater aquastat and should be should be set at the desired pool temperature setting usually 80 F to 85 F not exceeding the maximum temperature allowed by applicable codes Carefully read the Installation and Operation Instructions supplied with the unit if it 1s necessary to change the factory pre set pool temperature of 85 F Start the heater and observe the inlet temperature Adjust the balancing valve in the bypass discharge by slowly closing it until the inlet temperature achieves 140 F If the temperature to the heater exceeds 140 F slowly close the valve in the bypass until 140 F is maintained Operate the pool heater until the desired water temperature in the pool is achieved Observe all components for proper operation DO NOT CHANGE THIS
14. he digital temperature control must be programmed to the desired temperature set point for the pool water The digital temperature control is pre set from the factory for a pool temperature of 85 F If the set point for the desired pool temperature is to be changed from the factory setting all stages of the digital temperature control MUST be programmed to the same set point Staged burner operation is achieved by the setting of the differentials in the digital temperature control Models CP401 and 501 have a two stage digital temperature control Models CP651 CP751 have a three stage digital temperature control The differentials for each stage are factory pre programmed at the following settings stage 1 2 F stage 2 3 F stage 3 5 af equipped and stage 4 7 if equipped DO NOT CHANGE THE PRE SET DIFFERENTIAL SETTINGS Wide differences the set points or differential on the multiple stages will result in sweat and condensate formation on the units copper heat exchanger This can result in operational problems and a Non Warrantable failure of the pool heater A different temperature set point for the desired pool water temperature may be reprogrammed into the digital temperature control See the detailed instructions in the attached Installation and Operation Instructions to program the digital temperature control Water temperatures are indicated by the Sensor A or B indication in the digital display Sensor A which is the
15. heater must be installed with a ground fault circuit interrupter Follow local codes for installation of this device 1 wiring between the unit and field installed devices shall be made of type T wire 63 F 35 C rise 2 Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The pump must run continuously when heater is ON 4 Do not install any switch which can disconnect pump without disconnecting heater 5 Check heater controls and pump voltage 6 Do not energize heater or pump until system is full of water Serious damage may result 7 wiring must be accordance with all local state or federal codes 8 Provide circulating pump with proper overload protection 9 Where magnetic starter is used for pump wire auxiliary contacts in starter in series with heater control circuit PLACING THE POOL HEATER IN OPERATION PRE START CHECK LIST Before attempting to start the pool heater verify that the following items have been checked 1 Verify proper location and installation of the pool heater 2 Check gas piping and ensure line 15 purged of all air 3 Ensure that the pool is properly filled Do not operate pool heater if improperly filled 4 Check to ensure that all water connections are tight 5 Relief valve has been piped to a suitable floor drain 6 Combustion air openings are not obstructed in any way STARTING THE FILTER S
16. ide and lowered by the addition of Tri sodium Phosphate or its equivalent The corrosive level of pool water can also be measured by the Langlier Saturation Index This index is calculated by a formula which uses operating temperatures total alkalinity pH calcium hardness and total dissolved solids The optimum Saturation Index value is zero A negative value indicates a corrosive condition Your pool spa dealer can provide additional data and equipment to make this measurement if a problem exists ENERGY SAVING RECOMMENDATIONS 1 Keep the pool spa covered when not in use This will cut heating cost reduce water evaporation conserve chemicals and reduce load on the filtering system 2 Reduce pool thermostat to 78 F or lower reduce spa temperature to 100 F 3 Use an accurate pool spa thermometer to monitor water temperature 4 Mark the proper temperature settings on your pool spa thermostats and discourage further adjustments 5 Use a time clock to start filter pump no earlier than 6 a m during pool spa season This is the time when nightly heat loss stabilizes 6 Turn the pool spa heater off and drain during long periods when the pool will not be used winter vacations etc 7 Follow regular program of preventative maintenance for your heater each new swimming season Check heat exchanger controls burners and operation of the unit 8 For pools used only on weekends the thermostat may be set lower than 7
17. mp This will prevent damage to the heat exchanger when the filtration pump 15 out of service 2 The circulator pump may be wired for 120 208 or 240 volt electrical service CAUTION A THE HEATER MUST BE INSTALLED ON A 120 VOLT CIRCUIT OR DAMAGE TO THE HEATER CONTROLS WILL OCCUR 3 120 volt supply Wires 1 3 amp 8 connect to the hot Wires 2 4 amp 5 connect to the neutral 208 or 240 volt supply Wires 2 3 amp 8 Wire nut together Wire 1 connect to L1 Hot Wires 4 amp 5 connect to L2 Hot Note To reverse rotation switch wires 5 amp 8 respectively 4 Ensure that grounding and bonding conform to applicable electrical codes POOL MODELS 401 501 CP651 CP751 INSTALLATION OF TEMPERATURE CONTROLS AND BYPASS LOOP ADJUSTMENT NICE Following these instructions will permit the system circulating loop to operate at the desired temperature regardless of the higher pool heater water temperatures Location of Temperature Sensors in Pool Heater Piping for Models CP401 CP501 CP651 CP751 110 HI LIMIT HLC2503 MOUNTED IN MAIN POOL PIPING FIELD INSTALLED 25 COIL OF 18 GA WIRE 200 HI LIMIT HLC2501 MOUNTED IN HEADER OUTLET SIDE Inner Control Panel for Models CP 401 thru CP 751 INSTALLATION OF THE SENSING BULBS FOR TEMPERATURE CONTROL Models CP401 CP751 use the units internal electronic digital temperature control as the pool aquastat T
18. onger wire of the proper gauge If additional wire length 15 needed when extending the factory wiring to the auxiliary limit use 18 GA wire for distances up to 30 ft For longer distances size the wire per the chart in the Auxiliary Mixed Water Limit Control Section Use weatherproof connections for outdoor installation The auxiliary limit must be a minimum of 3 ft from the point where the heater bypass piping plumbs into the pool filtration return piping This ensures that the limit will sense a proper mixed water temperature Placing the auxiliary limit to close to the heater piping connections can result in nuisance tripping of the auxiliary limit The sensor for the auxiliary limit control is identified with a tag labeled 110 High Limit Pool Controls Wiring Diagram for Models CP401 CP501 CP651 amp CP751 110 HI LIMIT HLC2503 MOUNTED IN MAIN POOL PIPING FIELD INSTALLED 25 COIL OF 18 GA WIRE BL OR BL BK BL OR BL BK BL OR BL BK X RIWI R2W2 R3W3 TERMINAL BLOCK PRE START CHECK LIST 1 Clean the filter before attempting to adjust the water flow 2 The reading from Sensor B on the digital temperature control corresponds with the temperature of the water entering the pool heater Sensor A reads the pool water temperature The bypass pump must run continuously when the filter system is operating With the pump operating and the pool heater turned off bot
19. ting options and gas supply requirements WARNING LP propane gas 15 heavier than air and will remain at floor level if there is a leak Basements crawl spaces alcoves and areas below ground level will serve as pockets for accumulation of leaking gas Before lighting sniff at floor level IF YOU SMELL GAS follow instructions on page 1 of users information manual Shut off gas at LP tank outside of building DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED LP gas cylinders shall be located outdoors and away from the pool structure in accordance with the latest edition of the Standard for the Storage and Handling of Liquified Petroleum Gases ANSI NFPA 58 and applicable local codes This heater must be installed at least 5 feet from the inside wall of a pool unless separated from the pool by a solid fence wall or other permanent solid barrier WARNING A A pool heater installed in under or directly attached to the pool or spa structure must have a manual main gas shutoff valve located outside the pool structure When a pool heater is installed within the pool structure the structure shall be designed such that in the event of a fuel gas leak the leaking gas is vented to the exterior of the pool Structure To minimize the possibility of serious personal injury fire damage to your pool heater or improper operation never violate the following safety rules 1 Always keep the area around your pool heater free
20. y warmer than the pool water before the connections from the pool heater AUXILIARY MIXED WATER LIMIT CONTROL Mixed Water Auxiliary Limit Control High Limit Tag THIS 110 HIGH LIMIT MUST BE MOUNTED IN THE SYSTEM PIPING DOWNSTREAM OF THE HEATER IN THE MIXED WATER RETURNING TO THE IF ADDITIONAL WIRE LENGTH IS NEEDED USE 18 GA WIRE AND WEATHERPROOF CONNECTIONS FOR OUTDOOR INSTALLATION LBL2083 REV A Ensure that the auxiliary 110 F mixed water limit control supplied with the pool heater is installed in the filter system piping a minimum of three feet downstream from the point where the heated water from the pool heater is added to the filtration system piping The limit may be mounted in a 3 8 NPT tapped fitting installed in the filtration system piping or it may be installed directly into a tapped opening in the PVC filter system piping Turn off the filter system pump when installing the auxiliary limit in the filtration system piping A tapped opening can be added to the PVC pipe by first drilling a 9 16 pilot hole in the PVC pipe at least three feet down stream of the point where the heated water from the pool heater is added to the filter piping The drilled pilot hole can now be carefully threaded with a 3 8 NPT taper tap After the pipe threads have been cut into the PVC pipe wall the limit can be inserted into the tapped opening Apply a small amount of a high quality silicone sealant to
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