XL-3 Oil-Fired Pool Heater
Contents
1. Lift from bottom of Storage tank to Total Tubing Length Allowed fuel unit 3 8 dia 1 2 dia 0 ft 0 0m 68 ft 20 7m 100 ft 30 5m 2 ft 0 6m 63 ft 1 9 2m 100 ft 0 5m 4 ft 1 2m 58 ft 17 7m 100 ft 30 5m 6 ft 1 8m 53 ft 16 2 m 100 ft 30 5m 8 ft 2 4m 48 ft 14 6m 100 ft 30 5m 10 ft 3 0m 42 ft 12 8m 100 ft 30 5m 12 ft 3 7m 37 ft 11 3m 100 ft 30 5m 14 ft 4 3m 32 ft 9 8m 100 ft 30 5m 16 ft 4 9m 27 ft 8 3m 100 ft 30 5m 18 ft 5 5m 22 ft 6 7m 88 ft 26 8m Table 1 Fuel Line Sizes Figure 10 One Pipe and Two Pipe Systems Laars Check apale Metal pipe aoe to act as heat sink P i Plastic Pipe N To Pool Figure 11 Oil Filter Installation using an Allen wrench Check the instructions attached to the fuel pump for proper fuel connections Compression fittings are not recommended See Table 1 for correct fuel line sizes NEVER USE TUBING SMALLER THAN 3 8 1cm Water Pik Technologies provides an oil filter with the XL 3 heater Install this filter using the fittings provided for convenient servicing of the oil burner and filter see Fig 11 Post a notice near the heater stating filter service frequency Provide an approved high quality shutoff valve at the oil supply tank 2F Water Piping 2F 1 Water Connections Connect the inlet and outlet piping to the2. Model DP Oil Fired Heater Page 9 The bypass valve is properly adjusted Remove the handle on the valve or place a warning tag DO NOT TOUCH THIS VALVE Install a check valve and heat sink pipe in the heater inlet if any part of the piping or filter system uses plastic materials see Fig 15 2G Pressure Relief Valve A pressure relief valve is not furnished with the heater except in Canada Check local building and plumbing codes to determine if a pressure relief valve is required A 75 psi rated relief valve is recommended for protection of the filter system if there is a shut off valve installed between the heater and the pool see Fig 14 If a pressure relief valve is not required leave the standard 3 4 brass plug in place Pressure Relief Valve Figure 14 Pressure Relief Valve 2H Automatic Chlorinators A concentration of chlorine in the heater can be very destructive Heater damage caused by high concentrations of chlorine for any reason is not covered by the warranty IMPORTANT 1 Provide the automatic chlorinator with an anti siphoning device to prevent chlorine siphoning into the heater after the pump shuts off 2 Wire the electric chlorinator so it cannot operate unless the filter pump is running If the chlorinator has an independent clock control synchronize the filter pump and chlorinator clocks so the chlorinator only operates during the filter cycle 3 If the chl
3. Method for installing threaded pipe with copper sleeve For non threaded S pipe or tube discard copper a sleeve A Figure 12 Water Connections Figure 13 Thermometer Placement universal flange couplings on the heater as shown below The inlet and outlet ports on the heater are clearly marked with arrows on top of the control cover The flanged couplings accept either threaded iron pipe 1 1 2 NPT unthreaded 1 1 4 iron pipe or 1 1 2 copper tubing see Fig 12 Connect the pool heater between the pump and filter and the pool or spa If the system flow rate exceeds 60 gpm 228 lpm install a manual bypass valve between the heater inlet and outlet see Fig 15 If the flow rate is below 60 gpm 228 Ipm the automatic built in bypass valve will maintain the proper flow through the heater If a manual bypass is required adjust it using the following procedure 1 Clean the filter 2 Install a thermometer in the 1 2 NPT threaded opening in the front header casting as shown in Fig 13 3 Close the manual bypass valve 4 Turn the heater switch to OFF and run the filter pump Record the temperature 5 Turn the heater switch to ON and turn the thermostat high enough to call for heat 6 Gradually open the manual bypass valve until the thermometer reads 11 to 14 F 6 1 to 7 8 C for the DP 2000 or 16 to 20 F 8 9 to 11 1 C for the DP 3000 above the temperature recorded in Step 4
4. Brass Plug 3 4 1 All P0027000 Burner Head 3000 N0007700 36 Drain Valve Extension All P0059900 Delavan Nozzle 2 25 3000 N0007500 37 Drain Plug 1 4 3 All P0026800 Delavan Nozzle 1 65 2000 N0007600 38 By Pass Assembly All R0020600 Primary Control All R0140300 39 By Pass Valve Rod All S0074300 Honeywell Cad Cell All N0006100 40 By Pass Valve Disc All S0074200 By Pass Plug All N0007000 41 By Pass Valve Rod Retainer All S0008700 By Pass Plug All N0007100 42 By Pass Valve Spring 2000 0061300 1 8 Burner Head Plug All P0026100 42 By Pass Valve Spring 3000 0061300 1 4 Burner Head Plug All P0026800 43 Flange amp Gasket Assembly All R0031900 44 Flange 1 1 2 All 10309200 OPTIONAL EQUIPMENT 45 Flange Gasket 1 1 2 All S0053100 64 Pressure Relief Valve 3 4 NPT 75 PSI All R0040400 46 Flange Sleeve 1 1 2 All S0028000 Chimney Cap 9 Not Shown All D0014900 47 Flange Bolt All F0031700 48 Gasket All S0065300 For more information Telephone Main 415 382 8220 Order Fax 800 526 3928 Customer Service Ext 245 Warranty Service Ext 260 Literature Requests Ext 237 Pool Systems Address 21 Pimentel Ct Novato CA 94949 Mailing Address P O Box 6101 Novato CA 94948 6101 Web Address http www jandy com International 480 S Service Rd West Oakville Ontario Canada L6K 2H4 905 844 8233 voice 905 844 2635 fax Model DP Oil Fired Heater Page 19 H0223500A Laars Oil Fired Warranty Limited Warranty Thi
5. ROOF WINDOW OR GRILL G LIVING AREA OF HOUSE Figure 5 Connection Locations Figure 7 Incorrect Installation Page 6 Laars 1 4 inch 6 cm rise per foot run minimum aL Ls Pool heater Pi Nd Inner Pool stack heater heater furnace PROPER LOCATIONS OF BAROMETRIC DRAFT CONTROLS Chimney Incorrect locations 2 Always use a Y connector to join 2 vents Correct location If two appliances are connected to the same breeching each appliance requires its own Barometric Draft Control Figure 8 Venting Indoor Installation the room containing the heater must have its own combustion and ventilation openings as described below see Fig 8 Vent the XL 3 to a permanent chimney or through the roof with an approved stack when it is installed indoors You must install a barometric draft control between the heater and the stack with a minimum 13 clearance between the chimney connector and any combustible surface Observe NFPA Standard No 31 and all national and local ordinances Run the vent pipe as directly as possible with minimum turns Never use a vent smaller than 9 23cm On lateral runs maintain a minimum pitch of 1 4 6cm per linear foot If a chimney is used the total equivalent straight length of flue piping between the heater and the chimney should not exceed 75 of the vertical height of the chimney above the flue pipe connec
6. be maintained on standby temperature operate the filter pump until the water temperature reaches 70 F 21 C If the pool is going to be used for swimming bring the water up to swimming temperature before replacing the Page 12 Laars time clock stops When the water reaches the temperature level on the thermostat the heater will turn off automatically but the filter pump will continue to run for about 20 minutes 3C Winter Shutdown The heater could be seriously damaged by freezing temperatures if it is not properly drained To shut the heater down for the winter turn off all electrical power to the heater Remove both drain cocks or plugs see Fig 18 Grease the threads on both the plugs and the holes and store them in a safe place during the freezing weather It will also be necessary to remove one end of the pressure switch siphon loop refer to Fig 3 1 Remove the siphon loop cover on the right side of the heater 2 Remove the compression nut attaching the siphon loop tube near the front of the heater 3 The siphon loop should drain Figure 18 Heater Drains NOTE The XL 3 heater is not designed for continuous use to combat freezing temperatures Keep the temperature at a minimum 70 F 21 C or shut the heater down completely Operating the heater for long periods at or near freezing water temperature can seriously damage the heater and may create a dangerous condition by foulin
7. mishandling Water Pik Technologies carefully manufactures inspects and packages the heater before delivering it to the freight carrier Immediately file any claim for damage against the freight carrier 2B Assembly and Location Only use the XL 3 heater with pools filled with potable water Using the heater with mineral water salt water sea water or other non potable water will void the warranty The installation must comply with all local building and safety codes Typically install the heater on a noncombustible surface Under Standard NFPA No 31 it is permissible to install the heater on a combustible surface when the installation complies with the requirements of the American Insurance Association These requirements specify that the surface under the heater must be hollow masonry not less than 4 thick covered with at least 24 gauge sheet metal The masonry must be laid with ends unsealed and joints matched to provide a free circulation of air through the masonry Maintain the minimum clearances to combustible surfaces as specified in Sections 2C and 2D of this manual The heater must be level The XL 3 is shipped with the inner stack packaged on top of the control panel door in the box with the heater The inner stack must be assembled and installed before mounting the vent cap or vent Side View DP 2000 2212 DP 3000 2634 Front View Figure 1 XL 2 Oil Fired Heater Page 4 Laar
8. 0400801 18 High Limit Switch Harness All R0057700 63 Fire Box Cover 2 3000 10400802 19 High Limit Switch Cover All 10401100 20 Switch Cover All E0078300 OIL BURNER PARTS amp COMPONENTS Not Shown 21 ON OFF Switch All E0078200 Air Tube Screw All F0004300 22 Oil Burner Harness All R0057600 Pilot Bracket Screw All F0031300 23 Connector Elbow 90 All P0059800 End Air Shutter All N0000200 Bulk Air Band All N0000300 WATER SYSTEMS Air Tube Gasket All N0000800 24 Heat Exchanger Assembly Complete 2000 10927101 Motor 1 7 H P 3450 RPM All N0001000 24 Heat Exchanger Assembly Complete 3000 10927102 Blower Wheel 4 1 4 x 3 7 16 All N0001400 25 Heat Exchanger 2000 10927001 Flexible Coupling All N0001500 25 Heat Exchanger 3000 10927002 Fuel Unit Two Stage All R0140100 26 Inlet Outlet Header All 10403700 Pump Outlet Fitting All N0002000 27 End Cap 1 2 tap All 10403900 Connector Tube Assembly All N0002200 28 End Cap No tap All 10406100 Ignition Transformer All R0140200 29 End Cap 1 4 tap All 10403800 Contact Spring Terminals All N0002600 30 Tee Baffle 5 2000 10926901 Air Tube Combination All N0002900 30 Tee Baffle 5 3000 10926902 Nozzle Line Electrode Assembly All N0003100 31 End Baffle 2 2000 10387702 Electrode Clamp All N0003500 31 End Baffle 2 3000 10387703 Electrode Rod amp Tip All N0004000 32 Tube Gaskets 12 All S0063400 Burner Head amp Screws All N0004500 34 Grommet 2 Required All S0098800 Burner Head 2000 N0004700 35
9. H0223500 Installation Operation and Service Instructions Installation Operation and Service Manual for the XL 3 Oil Fired Pool Heater Models DP2000 and DP3000 FOR YOUR SAFETY This product must be installed and serviced by a professional service technician qualified in pool heater installation and maintenance Improper installation and or operation could create carbon monoxide gas in flue gases which could cause serious injury property damage or death Improper installation and or operation will void the warranty AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or gas supplier Laars Laars SECTION 1 General Information 1A Warranty ineen aE 3 SECTION 2 Assembly amp Installation 2A Shipping Damage eeseeeeesseeeeeeeeereeereee 3 2B Assembly and Location 3 2C Outdoor Insta
10. L Figure 16 Wiring Diagram 60 Hz Model Attach a ground wire to the green lug in the switch box as shown in the wiring diagram A separate lug is on the exterior of the heater for a system bonding conductor as required by Article 680 of the National Electric Code ANSI C1 1975 The XL 3 is factory wired for a time clock 2J Time Clock Installation A time clock which will automatically turn the pool system OFF and ON provides convenience and safety and is more economical If a time clock is installed it is recommended that it include a Fireman Switch The Fireman Switch will shut down the heater about 20 minutes before the filter pump shuts down This allows the water flow to carry away residual heat in the firebox without damage to the heater or other parts of the system Field install high temperature wires 150 C from the Fireman Switch Run the wires to the heater through the knockout on the right side of the heater body Connect them to the two wires joined with a wirenut in the control compartment The wirenut has a tag on it carrying wiring instructions Position the field installed wires away from the inner panel 2K Special Pressure Switch A special pressure switch is required if the XL 3 is installed more than 3 feet below the surface of the pool Consult a Laars representative or contact the factory IMPORTANT Before starting the heater on a new installation relieve all air from the system by running
11. NY am Laars HEATERS waterpik Technologies Inc 6000 Condor Drive Moorpark CA USA 93021 707 776 8200 FAX 707 763 7785 480 S Service Road West Oakville Ontario Canada L6K 2H4 905 844 8233 FAX 905 844 2635 Litho in U S A Water Pik Technologies 0103
12. Shut Off 4E 4 Setting the Correct Fuel Air Mixture 4E 5 Regular Maintenance c cceeeeeeereeeees SECTION 5 Service Information 5A Control and Cad Cell Tests ceeee 5B Control amp Cad Cell Trouble Shooting Guide ceeeeees SECTION 6 Parts List for Model DP Oil Fired Heater 6A Parts LSE oeiras a ETA Model DP Oil Fired Heater Page 3 SECTION 1 General Information NOTICE TO INSTALLER Deliver all documents that come with the heater to the pool owner These include the Owner s Information and Operating Manual and this Installation Manual For your safety do not store gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance Use only 2 fuel oil or 2 diesel fuel Heavier fuels will not operate satisfactorily and their use will void the warranty NOTE Read the Owner s Information Manual before starting this installation and before starting up the heater the first time 1A Warranty The XL 3 pool heater is sold with a limited warranty Details are specified on the back page of this manual Make warranty claims to an authorized Laars representative or to the factory Claims must include the serial number and model of the heater installation date and name of the installer SECTION 2 Assembly amp Installation 2A Shipping Damage After unpacking the heater check for visible damage from shipment
13. T NO No Description No PART NO FUEL SYSTEMS FIRE BOX amp JACKET COMPONENTS 1 Oil Burner Assembly 2000 L0060000 49 Burner Tube Gasket All N0006600 1 Oil Burner Assembly 3000 L0060100 50 Burner Support Bracket All 10392000 2 Oil Filter Not Shown All P0065100 51 Burner Compartment Door 2000 10412203 3 Oil Filter Cartridge Not Shown All P0065500 51 Burner Compartment Door 3000 10412204 4 3 8 Oil Line Pump to Filter All 10430402 52 Fire Box Plug All T0020700 53 Fire Box Cover Plate All 10425800 ELECTRICAL SYSTEM 54 Gap Spacer Return All 10401000 5 Thermostat All R0318800 55 Flue Collector Assemby All 10406301 6 Thermostat Knob All R0010700 55 Flue Collector Assemby All 10406302 7 Thermostat Dial All H0048400 56 Flue Top Assembly 2000 10405001 8 Thermostat Cover All 10388300 56 Flue Top Assembly 3000 10405002 9 Thermostat Back All 10368000 57 Inner Stack All 10390000 10 Thermostat Base Plate All 10362000 58 Flue Collector Shield 2000 10404501 11 Pressure Switch 1 10 PSI All R0045400 58 Flue Collector Shield 3000 10405002 12 Siphon Loop Cover All 10403400 59 Vent Blade 10 All 10319300 13 Siphon Loop Assembly All R0057800 60 Gap Spacer In Out All 10400900 14 High Limit Switch Assembly All R0023200 61 Hold Down Clip All 10401200 15 High Limit Switch 135 F All R0022700 62 Fire Box 2000 710020500 16 High Limit Switch 150 F All R0012700 62 Fire Box 3000 1T0020600 17 High Limit Switch Harness 115V All R0057500 63 Fire Box Cover 2 2000 1
14. ading could be a sign of a dirty oil filter Replace the burner nozzle with the nozzle called out on the heater rating plate and go to step 10 Replace nozzles once a year as part of the annual cleaning and inspection service Check the C02 Of the flue gases The reading should be between 11 5 to 12 5 If the reading is different go to Section D 4E 3 Oil Burner Will Not Shut Off Remove one of the thermostat leads from the primary control If the oil burner shuts off the problem is in the heater control circuit The circuit includes the pressure switch high limit safety switch thermostat and wire harness Check for worn insulation on the wire harness which could cause a short Check operation of the thermostat and pressure switch 4E 4 Setting the Correct Fuel Air Mixture Page 16 Laars e 7 16 above 5 32 GAP Ol ELECTRODE NOZZLE ELECTRODE ADJUSTMENTS NOTE ELECTRODE POSITION AHEAD OF NOZZLE Figure 21 Electrode Adjustment Measure the C02 If it measures less than 11 5 decrease the air supply If it measures higher than 12 5 increase the air supply When the fuel air setting is correct there will be zero smoke If there are still traces of smoke after adjusting the fuel air mixture slowly increase the air supply until the smoke disappears Use the proper instruments to measure both the smoke and C02 1 Too Much Air low C02 Too much air de
15. al ON 9 Are there any loose wires or terminals 10 Is the pool filter clean and is the pump operating properly 4D Operating Sequence When every part of the system is working properly the heater will go through the following sequence 1 When the filter pump builds up enough pressure in the piping the contacts in the heater pressure switch close 2 The heater thermostat calls for heat completing the circuit between the two thermostat terminals on the primary control of the oil burner 3 The primary safety control on the oil burner goes through a self test sequence One of the steps in the sequence is to check out the cadmium cell flame detector If the cad cell senses light the Prima ontrol Transformer ye Figure 20 Cad Cella and Primary Control burner will not fire If everything checks out the burner motor and ignition transformer are powered On 60Hz models the ignition transformer operates during the entire burner operation 4 If the cad cell does not sense a good flame within 30 seconds the primary control de energizes the motor and ignition transformer This turns off the heater It can be manually restarted by pushing the reset button after waiting about one minute 5 During the period when the filter pump is running which is set by the time clock the thermostat will turn the burner on and off as required to maintain the water temperature set on the thermostat 6 I
16. bove 2 Partly plugged 8 Loosen one cad cell terminal screw on the nozzle primary control Move the resistor wire slightly Cad cell dirty to temporarily break contact When the burner Cad cell misaligned starts quickly tighten the terminal screw Defective cell Ohmmeter pointer below 3 Not enough 9 Check combustion to make sure there is flame If combustion air there is no flame open the thermostat jumper and Cad cell sees too stop the test much light Adjust alignment 10 The ohmmeter pointer should go to zero If the pointer stops between 2 and 3 that s okay Step 11 11 After three minutes remove one 2 000 ohm Primary won t lock out Defective primary resistor wire from the primary control The primary should lock out on safety within 25 SEPI seconds Ohmmeter pointer below 50 Stray light in burner housing 12 After the primary locks out the ohmmeter pointer Defective cad cell should move to near the 50 mark on the scale Step 14 13 Wait three minutes then perform the following p a Burner won t start Open circuit in steps in the right order a Remove the 2 000 ohm resistor from the Dirty thermostat primary control contacts b Remove the jumper wire from the primary Defective thermostat control thermostat terminals thermostat wiring Step 14 Page 18 Laars SECTION 6 Parts List for Model DP Oil Fired Heater Key Model ORDER Key Model ORDER No Description No PAR
17. creases the efficiency of the heater and causes overheating of the jacket by pressurizing the firebox Too much air can also cause poor ignition and a pulsating flame If the C02 reading is below 11 5 reduce the air adjustment openings on the burner Not Enough Air high C02 Not enough air is much easier to detect The flame is dark yellow and the heater will smoke Generally the C02 reading will be above 12 when not enough air is provided Lacking proper instruments a temporary fuel air adjustment can be made Close the end shutter and then slowly close the air bank until the heater starts to smoke Slowly open the end shutter until the smoke completely disappears The fuel air mixture will be close to the correct setting 4E 5 Regular Maintenance At least once during the pool heating season or every six months remove accumulated soot from the heat exchanger Remove the top of the heater and lift out the flue collector Remove the T baffles the retaining wire does not have to be replaced Brush the soot and ash from the spacing between the fins using a brush across the top Clean the underside through the inspection hole Use a bottle brush to clean the spacing between the tubes Remove all of the ash and soot that has fallen to the bottom of the heater with a vacuum cleaner Model DP Oil Fired Heater Page 17 2 Replace the oil nozzle once a season see the oil c Attach the cad cell wires to the primary bur
18. e pool water reaches a temperature of approximately 70 F 21 C there may be condensate on the heat exchanger This will stop after the water reaches the right temperature NOTE The firebox in the heater is made from the best high temperature material available Starches have been added to this material during the molding process When the heater is first fired the starches oxidize producing noticeable smoke This will stop after about an hour of operation If the heater is installed in an enclosed area keep all doors and windows open during the first two hours of operation After a long shutdown there may be some smoke like emissions from the heater when it is first fired This condition will only last a few minutes 3B Setting the Time Clock The most economical and trouble free way of operating a pool heater and filter system is to include a time clock in the system for automatic cycling Adjust the stops on the time clock to provide a single filter cycle every 24 hours The ON cycle should be at least 12 hours to allow the filter system to properly clean the pool Set the ON cycle at least 4 to 6 hours before the pool is to be used During cold spells the heater may have to be on longer to maintain the proper pool temperature Remove all stops on the time clock during these periods IMPORTANT Run the heater continuously during the initial warm up period by removing all time clock stops If the pool temperature is going to
19. f atime clock is used the contacts in the Fireman switch open about 20 minutes before the pool filter cycle is completed This shuts off the oil burner The oil burner cannot be restarted during this period The filter pump continues to run for another 20 minutes transferring any heat stored in the firebox to the pool 4E Troubleshooting NOTE These troubleshooting procedures require connections to electrical terminals and jumper wires to check operation To avoid electrical shock turn off electric power before servicing line voltage controls Never leave a jumper wire in place to fix a heater This would bypass safety and operating controls 4E 1 Burner will not start motor and transformer do not come on Model DP Oil Fired Heater Is there power to the heater Have you checked the reset buttons on the motor and primary control Place a jumper wire across the two terminals on the cad cell If the burner starts the problem is in the heater control circuit This circuit consists of the pressure switch high limit control safety switch thermostat time clock switch if one is installed or the wire harness Check the wire harness for any loose wires or worn insulation Then jumper each control until the problem is located Press the reset button on the primary control If the unit does not start go to step 5 If the unit starts turn off the power and check the following items that can lock out the primary control a Dirt
20. g the external heat exchanger passages causing incomplete combustion 3D Periodic Maintenance Oil the oil burner motor every six months Use SAE 30 non detergent motor oil in both holes Check the following items at least twice yearly Wiring Safety Controls Oil Piping Oil Filter Combustion Heat Exchanger for sooting Product Specifications DP 2000 DP 3000 BTU hr 230 000 315 000 Fuel Consumption 1 65 GPH 2 25 GPH Shipping Weight 285 lbs 315 Ibs Electrical Dom 115 VAC 60Hz 1 Ph Pump Press Dom 100 psi SECTION 4 Maintenance 4A Trouble Shooting Problems which may come up with the pool heater operation or performance will require a trained professional technician There are a few preliminary symptoms the pool owner should check before calling a technician Oil Burner Does Not Fire 1 Is the pool temperature control set high enough to call for heat 2 Is the pool heater switch ON Are all circuit fuses and remote switches ON Is the pool filter clean 4 Is there enough fuel in the tank Is the fuel valve turned ON If the answer to all of these questions is yes try the manual overload reset switches on the burner motor and primary control If burner does not fire turn the heater switch OFF then ON and try the reset switches again If the burner still refuses to fire call the service technician Model DP Oil Fired Heater Page 13 Heater Does Not Maintain the Desired Water Tem
21. llation cceeeeceeeeeeeeeneeeeees 5 2D Indoor Installation ccccccceccesessteeeeeeeeesees 5 2D Venting seccecccceeceessnttaveeeestdsicteecsaniaaltceecanannand 5 2D 2 Clearances 00 sees eeeeccceeeestteeeeeeeeeeteeeeeesenaaes 6 2D 3 Combustion Air Supply 0 eeeeeeceeteeeeees 6 2E Oil PIPING iior nomian 6 2F Water PIPING essasi 8 2F 1 Water Connections 0 ccccceceeeceeeesteeeteees 8 2G Pressure Relief Valve ennenen 9 2H Automatic Chlorinators 0 cccceeeeeeeeees 9 2l Electrical Wiring cececeeseeeeeeeeeeneeeeeeeenaes 9 2J Time Clock Installation ccceeeeeeeees 10 2K Special Pressure Switch a e 10 SECTION 3 Operating Instructions 3A Start Up Procedure ccceeeeeeeeeeeeeneees 10 3B Setting the Time Clock s s s 11 3C Winter Shutdown ccceeeeeeeeseeeeteeeeeeees 12 3D Periodic Maintenance eeen 12 TABLE OF CONTENTS SECTION 4 Maintenance 4A Trouble Shooting ccecceeeeeceeeeeeteeeeeeees 4B Cleaning the Heat Exchanger s 4C Trouble Shooting Guide ceceeeeees 4D Operating Sequence ceeeteeeeetteeteeeees 4E Trouble Shooting cceccceeeeceeeeeeeeeeeeeees 4E 1 Burner will not start motor and transformer do not Come ON sesse 4E 2 Burner Tries to Start but the Primary Control 10 Shuts Off either motor or transformer or both come ONn eee 4E 3 Oil Burner Will Not
22. nd A and the end air shutter B should be partially open It is factory set for both indoor and outdoor installations but check it again after completing the installation by measuring the C0 It should be 12 C02 with zero smoke Set a barometric draft control to give 02 to 03 W C draft below the draft control when the heater is installed indoors 5 When the heater is attached to a two pipe system the fuel pump will automatically vent air out of the fuel lines If there is a lot of air the primary control may shut the burner down before all the air has been purged If this happens wait 2 minutes then press the reset button on the primary control Repeat this procedure until all the air has been vented and the unit fires properly Figure 17 Initial Air Adjustment see NOTE below If a one pipe system is used it must be thoroughly purged of air using the vent plug on the oil pump IMPORTANT If there is no ignition after three reset attempts stop Check for accumulated oil in the firebox Remove all unburned oil with dry rags before continuing the restart procedure If there is no oil accumulated try three more re sets If there is still no ignition have a qualified oil service technician bleed the fuel line and check for ignition problems When the heater does fire oil which is in the firebox will cause considerable smoke as it burns off 6 Set the thermostat to the desired temperature Until th
23. ne or two pipe system All units are Factory set for one pipe systems To convert a unit to a two pipe system Page 14 Laars a bypass plug must be installed in the fuel pump The plug is supplied with the oil burner There is a decal located on the fuel pump showing where the bypass plug goes If a fuel unit is set up for a two pipe system but is actually connected to a one pipe system the pressure in the fuel pump builds up to over 300 psi when the burner turns on This will cause the motor to bind and stop running or ruin the pump seals or both 2 Anoil filter must be installed on the inlet line A very small amount of dirt in the oil can plug the nozzle A properly sized oil filter is shipped with the heater see Fig 11 Is there oil in the storage tank 4 Are all of the shut off valves on the oil lines open 5 Are the fuel lines adequately sized according to the table on page 5 6 Are there any leaks in the fuel line A very small leak can cause the fuel pump to suck air into the system resulting in failure to operate or a pulsating noisy fire 7 Is the unit properly grounded electrically This is extremely important Use of PVC piping in the pool filter system prevents grounding through the piping 8 Ifatime clock is installed is there power to the timer Is the timer motor working There is usually a visual motor check opening on the timer mechanism Is the switch located below the timer di
24. ner Manual control 3 Oil the burner motor every three months Use de Aa h DE RE DOS AD WIE SHO ENG primary non detergent 40 motor oil at both oil holes control i e Push the primary control reset button 4 Replace the in line oil filter cartridge once a year f Set the ohmmeter range to 100 MA when it is not going to be used SECTION 5 14 Turn the heater thermostat all the way to the Service Information right The burner should start Reset the thermostat to the appropriate temperature 5A Control and Cad Cell Tests 5B Control amp Cad Cell IMPORTANT In the following test procedures Trouble Shooting Guide 1 The 2 000 ohm resistor checks the calibration and performance of the primary safety control ta Possible Cause tep 2 2 The ohm meter checks cad cell operation only Burren nine all hoaime Defective primary Test Instructions control 1 Remove two thermostat wires from the primary Step 8 control No combustion No power to the 2 Push reset buttons on burner motor and primary pnmary control KA switch turned 3 Remove two cad cell wires from primary control Defective limit switch 4 Connect ohmmeter leads to cad cell wires Bad wits connection 5 Set ohmmeter range to 1 KW Bad burner motor No power from fuse 6 Connect resistor wires to cad cell terminals on the box Step 2 primary control Defective primary 7 Place a jumper wire on the thermostat terminals Step 10 eet cone Ohmmeter pointer a
25. oop cover 5 located on the right side of the heater under the In Out header 7 Remove both gap spacers 6 8 Disconnect the siphon loop on the header 7 Remove both drain cocks 8 one at each end of the heat exchanger Model DP Oil Fired Heater Page 5 9 Lift off both heat exchanger baffles 10 Carefully remove the insulation at each corner of the heat exchanger it will be re used Remove the four hold down screws 10 11 Unplug the electrical connector at the switch box inside the control compartment At the other end of the conduit loosen the brass compression fitting one or two turns Rotate the conduit ____assembly and lay it on top of the FOR YOUR SAFETY It is recommended that two people perform the next step 12 Lift out and rotate the heat exchanger Make sure the insulation strips stay in position under the header bars 13 Put the screws through the hold down clips at each corner of the heat exchanger Put the insulation back in the corners 14 Rotate the conduit assembly and attach it to the switch box Tighten the compression nut on the other end 15 Replace the heat exchanger baffles and the flue collector assembly 16 Install the drain cocks and pipe plug according to the illustration see Fig 5 17 Straighten the siphon loop tubing and connect it to the header where the drain plug was removed 18 Replace the gap spacers siphon loop cover and rubber plug
26. oors communicating with outside air must have specified openings see Fig 9 There must be no Model DP Oil Fired Heater Page 7 Vent Terminated t 24 0 6m Above Any Object Within 10 j 10 Ft 3 05 hs 2 Ft 0 6 m 1 4 Inch 0 63 cm Minimum Pitch per Foot of Horizontal per Foot of i Horizontal Outlet Air Duct Pipe Pipe Barometric Barometric Draft Adequate Dratt Adequate Control Air Supply Controli Air Supply to Room to Room Top and Top and Bottom Bottom aN Sides 12 All Sides intet Air Duct m Vent Terminated at Least 10 Ft 3 05 m Listed Vent 24 10 6 m an Cap Above Any Object mT Listed Vent ithi Ca Within 10 SEDEM p Storm Collar at fi Storm Collar m n D a AA Roof Jack 1 4 inch 0 63 cm Mimimum Pitch 30 48 cm ee i ES Figure 9 Combustion Air Indoor Installation openings communicating with living areas 2E Oil Piping All XL 3 heaters are equipped with two stage fuel units Water Pik Technologies recommends a two pipe system with a supply line and a return line between the heater and the tank see Fig 10 When using a two pipe system install the bypass plug in the fuel unit The plug is shipped in the small plastic bag attached to the oil burner The location for the plug is shown on the decal on the end of the fuel unit Remove the large hex head fitting and insert the plug
27. orinator is equipped with its own pump install it so that it introduces the gas or solution downstream from the heater and at a lower position than the heater outlet 2l Electrical Wiring Wire the XL 3 heater in accordance with the National Electric Code and all applicable local codes The power supply must be 11 5V 60Hz single phase with voltage maintained between 104V and 126V have a double pole ON OFF switch see Fig 16 17 Run all field supplied wires in conduit to the knockout at the bottom of the ON OFF switch box From From Main Skimmer Drain Backwashing Vaive N Filter CS q D Balancing Vaives Ge G i J l To Waste a ssc lt lt Check Valve Manual bypass is used only when filtration rate normally exceeds 60 gattons perminute Re nS i R poA A Ee Out E Thermometer For Testing Temperature Rise Metal pipe to act as l heat sink p EN Plastic Pipe N To Pool Figure 15 Water Piping Page 10 Laars oo z TEMPERATUR ELECTRODES ONTA piy JOA IGNITION TRANSFORMER hal HI LIMIT e FIREMANS SWITCH TAG F gA PRIMARY RESET BUTTON R BK HI LIMIT PRESSURE SWITCH pa L ONOFF SWITCH Lel POWER SUPPLY 115 60Hz 1 GROUND DP2000 DP3000 OILFIRED POOLHEATER LEGEND JK Black White Orange Yellow Red Blue Green WIRE NLT a Y 3 3 3 J
28. perature 1 Is the temperature control set high enough 2 Is the filter cycle setting on the time clock long enough to permit the heater to raise the temperature 3 Is the heater the right size for the pool See the Installation instructions If these conditions are satisfactory the heat exchanger could be fouled or the heater controls may not be functioning properly Call a service technician Burner Operates But There is Smoke or Pulsating Combustion This is usually caused by improper combustion adjustment fouled heat exchanger or a fuel supply problem Calla service technician Pool Water Overheating Turn the heater switch OFF and call a service technician 4B Cleaning the Heating Exchanger A caution Black carbon soot on a dirty heat exchanger can under certain circumstances be ignited by a random spark or open flame To prevent this from happening dampen the soot deposits with a wet brush or fine water spray before servicing or cleaning the heat exchanger Clean the heat exchanger annually preferably at the end of the swimming season Clean as follows Inspection Hole Insulator Hand Hold Plug Cover Plate Figure 19 Inspection Hole Location 1 Remove the heater top assembly and flue collector 2 Remove the inspection hole cover see Fig 19 3 Use an ordinary kitchen brush to brush across the top of the heat exchanger between the tube fins 4 Use a bo
29. s Concrete Block Sheet Metal Cover Min Thickness 24 Gauge Galvanized Figure 2 Non Combustible Platform Figure 3 Heat Exchanger Reversal Figure 4 Inner Stack pipe To assemble the inner stack remove the tape and small envelope from the sheet metal coil Expand the coil until the holes on each end are aligned Use the two screws supplied in the small envelope to secure the ends together Install the inner stack 7 18cm diameter on the collar of the flue collector before attaching the vent cap outdoor installation or vent pipe indoor installation as shown in Fig 4 The XL 3 can be installed with the water connections on either side Water Pik Technologies ships the heater with the water connections on the right side but changing the connections to the left side could simplify the installation or improve access for service and maintenance Make the change before locating and connecting the heater Follow these step by step instructions and Figure 3 to reverse the heat exchanger 1 Remove the control compartment door 2 Remove the chimney cap assembly or barometric draft control if one is installed and the inner stack 1 3 Remove the eight screws securing the top assembly 2 and lift off 4 Bend back retaining tabs and lift out the wire guard 3 Take off the four V baffles 2 each side Lift out the flue collector assembly 4 Remove the siphon l
30. s Laars product is backed by this warranty to assure your complete satisfaction 1 Oil burner controls heat exchanger tubes and firebox are warranted against defects in materials and workmanship for one 1 year from date of purchase 2 All other parts are warranted against defects in materials and workmanship for five 5 years from date of purchase The above warranty applies only if the installation and operating instructions applicable to the model pur chased are expressly and completely followed These instructions are furnished with the unit and are also available by writing the Laars factory The liability of Water Pik Technologies shall not exceed the repair or replacement of defective parts and shall not include transportation to or from factory field labor and consequential or incidental damages Ship inoperative parts or complete heater with Serial Number and purchase date transportation prepaid directly to address below attention Customer Service This warranty gives you specific legal rights You may also have other rights which vary from state to state and by province some do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you NOTE Heat exchanger must be cleaned and examined once each season Operating heater with sooted heat exchanger invalidates warranty See Operating and Servicing Manual REGISTERED COMPA
31. s and grommets 19 Install the T baffles on the gap spacers to match the screw holes in the top assembly 20 Replace the wire guard Bend the tabs to secure it in place 21 Attach the top assembly Install the inner stack Wall or Fence _ 6 15 cm Min Water Conn 6 15 cm Min 24 Minimum Access for Service and Maintenance Figure 6 Minimum Clearances Outdoor Installation 22 Install the chimney cap assembly or barometric draft control if one was removed 2C Outdoor Installation Install the Laars XL 3 heater in the open or in an enclosure without a roof The chimney cap supplied with the heater must be installed The danger of fire requires a minimum clearance from combustible surfaces or shrubbery of 6 inches 15cm see Fig 6 The flue products must be dispersed in the outside air and fresh air available for proper combustion Do not install the heater under eaves where roof drainage could fall directly on the heater It is possible that prevailing winds could cause a downdraft Therefore keep the side of the heater at least 3 feet 91 cm from the face of any wall or fence 2D Indoor Installation 2D 1 Venting If the heater is installed in an occupied building Left Side Connections Right Side Connections PI Syphon Drain Drain ug Loop Plug Plug ae E g 1 H edt fa a 9 Drain Drain Plug Plug Plug Loop PATIO
32. the filter pump for at least 15 minutes SECTION 3 Operating Instructions 3A Start up Procedure In a new installation always run the filter pump with the heater turned off long enough to completely clean the pool water This will remove any residue left from construction Clean the filter before starting the heater Before starting the oil burner check the wiring to make sure there are no loose connections Check all fuel line connections for tightness Open the fuel shutoff valves at the heater and the tank AXcaution Do not try to light the burner if excessive oil has accumulated in the firebox or when the heater is full of vapors A QUALIFIED SERVICE TECHNICIAN Model DP Oil Fired Heater Page 11 SHOULD START THE OIL BURNER Check the operation of the burner Make sure of the proper air adjustment Check the flame pattern and temperature The air shutter is factory set for 12 C0 but verify this after installation 1 Start the filter pump Let it run for about five minutes to free any trapped air 2 Set the thermostat well above the pool water temperature 3 Turn the heater switch ON If the burner motor does not start right away reset the manual overload switches on the motor and primary control If the motor runs but the burner fails to light it may be necessary to bleed air from the fuel line See Step 5 4 Check the initial air adjustment see Fig 17 Normally the bulk air ba
33. tion The chimney should be at least 9 23cm diameter Maintain adequate clearances between the vent pipe and combustible materials Check local codes and the vent manufacturer s instructions for proper clearances The 7 18cm dia inner stack must be in place Any change in the amount of draft in the combustion chamber can affect the flame characteristics An approved barometric draft control must be used on all indoor installations to maintain a clean and consistent flame When the system is properly adjusted the pressure in the stack below the draft control will be approximately minus 03 W C If this draft pressure cannot be achieved the chimney is too short or too small Take corrective action Avoid locating the chimney termination in a location susceptible to down draft conditions or near ventilation inlets to the building 2D 2 Clearances Provide the following minimum clearances from combustible surfaces Water Inlet Outlet side 24 61cm Other side and rear 6 15cm Front Control compartment 24 61cm Chimney connector 13 33cm 2D 3 Combustion Air Supply Do not install the heater in a room that does not have enough air supply to support combustion There must be two openings to outside air provided each opening must have a free area equal to 80 sq in 516 1 sq cm It is good practice to put one opening near the floor and the other near the ceiling When installing the heater in an interior room all d
34. tion transformer and make sure the motor rotates freely If it does not rotate freely replace the motor If the motor is internally binding replace the motor Open the inspection port and use a mirror to check combustion If there is no ignition before the primary control shuts the burner down go to step 6 If the burner does ignite with a good flame go to step 5 If the burner tries to ignite but the flame is intermittent go to step 8 Check the cad cell and primary control Lift up the ignition transformer and put tape over the front of the cad cell the burner will not start unless the cad cell senses no light Disconnect the black lead going to the motor Press the primary control reset button Use an insulated screwdriver to touch the metal blade to one spring contact on the transformer and about 3 8 away from the other spring contact If there is good spark between the blade and the spring go to the next step If there is no spark replace the transformer Remove the electrode nozzle assembly and inspect the high voltage sections for fouling cracked insulators or burnt electrodes Replace any defective parts If the flame is poor quality or intermittent use a pressure gauge to check the nozzle pressure If the pressure is below 100 psi but steady reset it to 100 psi and go to step 9 If the pressure is not steady use the attached Sundstrand Field Service bulletin to check out the fuel unit An unsteady pressure re
35. ttle brush to brush down between the tube fins toward the firebox The ash can be softened for easier removal by lightly dampening with a wet brush Do not let water get in the firebox 5 Reach through the inspection hole and brush across the bottom of the tube fins using the kitchen brush 6 Remove all dirt and soot from the firebox by inserting a vacuum cleaner nozzle through the inspection hole 7 Replace the flue collector and top assembly 8 For more thorough cleaning remove the heat exchanger completely and wash it with a garden hose A Caution Be careful to avoid damaging the firebox material when cleaning the heat exchanger or inspecting the heater Keep water out of the firebox Be sure to replace the gasket inspection plug and retainer when the cleaning or inspection is complete C Trouble Shooting Guide Introduction A qualified oil burner technician should service his equipment Frequently this service is available hrough the fuel oil supplier Acaution Some of these procedures involve exposing the line voltage circuit There is considerable danger of electric shock The XL 3 is an oil fired pool heater designed to burn No 2 fuel oil or No 2 diesel fuel Do not use other fuels The burner assembly comes standard with a two stage pump This allows the heater to be installed a relatively long distance from the fuel tank Initial Checks 1 Is the oil burner connected to a o
36. y or defective cad cell see Page 4 b Defective primary control see Page 4 c Oil level in tank too low or water in the tank d Poor combustion caused by Fouled nozzle Fuel line air leaks Improper nozzle pressure pressure should be 100 psi Improper air setting see part D Press the reset button on the motor If the unit does not start go to step 5 If the unit starts shut off power and check the blower wheel and flexible coupling between the motor and the fuel pump Make sure the blower wheel and fuel unit are not binding Make sure the return fuel line is not restricted Remove one cad cell wire from the primary control If the burner starts replace the cad cell Turn off electric power to the heater Short out the high limit switch in the high voltage circuit If the burner starts when power is restored the switch is faulty Turn off electric power and inspect the wiring below the primary control and the ignition transformer Make sure there are no loose connections If the wiring is okay and the blower wheel rotates freely replace the primary control 4E 2 Burner Tries to Start but the Primary Control 10 Shuts Off either motor or transformer or both come on Is the burner motor turning If yes go to next step Press the reset buttons on the motor and primary control If the motor does not start but 10 Page 15 transformer is providing spark at the electrodes go to step 3 Lift the igni
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