Factory set for Natural Gas.
Can be Converted to Propane
with parts provided.
WARNING: If the information in these instructions are not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable vapours and liquids in the vicinity
of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbour's phone. Follow the gas
supplier's instructions.
- Installation and service must be performed by a Gas Safe registered installer. A page is
included on the inside back page of this booklet for recording commissioning and
service details.
Serial No:
Genie DUAL
Operating, Installation and
Servicing Instructions for
Condensing
Pool & Spa Heaters
0087
Model:
MB36D
GB, IE, CH, ES, PT,
SI, SK & TR
M2709
TECHNICAL DATA
GENERAL SPECIFICATIONS
WATER CONTENT 4.0 Litres 0.88 gallons
WEIGHT (net) 54 kg 119 lbs
DIMENSIONS, OVERALL 375 mm wide, 520 mm deep, 1040 mm high
SERVICE CLEARANCE 300mm Left, Right and Above. 800 mm In front
CORE DRILL DIAMETER 175 mm
MINIMUM FLOW RATE 80 l/m (17.8 gpm)
MAX PRIMARY WATER PRESSURE 2½ bar (37 psi)
INTERNAL PUMP SETTING Speed 3
MAXIMUM POOL TEMP Pool 41°C (106°F)
ELECTRICAL SUPPLY 230V 50Hz, FUSED AT 3A, 130W
PROTECTION LEVEL IP44
FLUE SYSTEM 80/125 PP, to a maximum Flue Equivalent Length of 20m
PERFORMANCE SPECIFICATIONS
GAS CATEGORY, TYPE AND SUPPLY PRESSURE II
NATURAL GAS PROPANE
MODEL MB35D MB35D
Corgi Work Code 1036909 1036913
HEAT GROSS kW 38.0 38.0
INPUT Btu/h 129,650 129,650
NET kW 34.2 35.0
Btu/h 116,700 119,400
TYPICAL EFFICIENCY % gross 92 - 94 92 - 94
% net 102 - 104 102 - 104
POOL kW 35.7 35.7
OUTPUT Btu/h 121,870 121,870
HEATING kW 6 - 15.6 6 - 15.6
OUTPUT RANGE Btu/h 20,500 - 53,250 20,500 - 53,250
G20 @ 20 mbar
2H3P
G31 @ 37 mbar
GAS RATE (NG, Propane) m3/h 3.45 1.43
MAXIMUM RATE, CO 120-150 130-160
COMBUSTION SETTINGS, NG, CO
2
9.2-9.4 10.3-10.5
OFFSET SETTING pA -3.0 -3.0
ORIFICE mm Not required 4.4
Condensing Pool Heater 01/07/09
GB, IE, PT, CH, ES, PT, SI, SK, TR
Contents
Section Page
TECHNICAL DATA Inside cover
List of Figures Page
User Instructions 1
INTRODUCTION 3
Heater Location 3
Gas Supply 4
Conversion 4
Flueing 4
Air Supply 4
Outdoor Heaters 4
Condensate Drain 5
Pool Pump & Pipework 5
Winterisation 6
Hydraulic Designs 6
Electricity Supply 6
INSTALLATION OF HEATER 7
Procedure 7
Outdoor Terminal 7
Flue Systems 7
Wall Terminal 7
Flue Examples 10
Roof Terminal 12
Pool Plumbing 12
Pressure Switch 12
Gas Conversion 13
Gas Connection 13
Condensate Connection 14
Electrical Connection 14
Commissioning 16
Control Setup 17
Multiple Heater Kit 18
Wall Mounting Kit 20
FAULT FINDING 23
Operation 23
Safety Controls & Lockouts 23
Engineering Mode 23
Test Temperature Disp.Mode 23
Display Fault Codes 24/25
SERVICING 26
Routine Service 26
Changing Components 26
Spares 29
Heater Components 30
COMMISSIONING & SERVICE
HISTORY Inside back cover
Fig 1.0 Terminal Positions 4
Fig 2.0 Hydraulic Resistance Graph 5
Fig 2.1 Hydraulic Schematic 6
Fig 2.2 Heating Design Examples 6
Fig 3.0 Outdoor Terminal Fixing 7
Fig 3.1 Service Access &
Pipe Connections 8
Fig 3.2 Wall Terminal Dimensions 8
Fig 3.3 Outdoor Terminal Dimensions 9
Fig 3.4 Roof Terminal Dimensions 9
Fig 4.0 Wall Terminal Installation 10
Fig 4.1 Extended Wall Terminal
Installation 10
Fig 4.2 Extended Vertical Roof
Installation 10
Fig 4.3 Outdoor Terminal Installation 10
Fig 5.0 Pressure Switch 12
Fig 6.0 Throttle Adjustment 13
Fig 6.1 Orifice Position 13
Fig 6.2 Gas Valve Tappings 13
Fig 7.0 Condensate Disposal 15
Fig 7.1 Condensate Syphon 15
Fig 8.0 Heat Exchanger Air Vent 16
Fig 8.1 Pump Priming 16
Fig 8.2 Heat Exchanger Sight Glass 17
Fig 8.2 Heating Output setting 17
Fig 9.0 Controls 17
Fig 10.0 Multiple Heater Install 18
Fig 10.1 Multiple Heater Install 18
Fig 10.2 Multiple Heater Install 20
Fig 10.3 Wall Mounted Heater 20
Fig 10.4 Wall Mounting Dimensions 20
Fig 10.5 Wall Mounting Assembly 21
Fig 11.0 Schematic Wiring 22
Fig 12.0 Electrode gap setting 26
Fig 13.0 Electrical Components 29
Fig 14.0 Heater Components 30
Condensing Pool Heater 01/07/09
Genie
Dual
USER'S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION
MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
This appliance is equipped with an ignition device
which automatically lights the burner.
BEFORE OPERATING after a prolonged time off,
smell all around the appliance area for gas. Be
sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
* Do not try to light any appliance
* Do not touch any electric switch
* Do not use any phone in your building.
* Immediately call your gas supplier
from a neighbour's phone. Follow the
gas supplier's instructions.
* If you cannot reach your gas supplier,
call the fire service.
* Isolate the appliance with the Service
Cock inside. If this is not accessible,
isolate at the gas meter.
* Do not use this appliance if any part has been
under water. Immediately call a qualified
service engineer to inspect the appliance and
to replace any part of the control system and
any gas control which has been damaged.
CAUTION: Propane gas is heavier than air and
will settle on the ground. Since it can accumulate
in confined areas, extra care should be exercised
when lighting Propane heaters.
WARNING: There are no user servicable items in
this appliance. Do not interfere with any sealed
components.
MPORTANT INFORMATION
Incorrect water balance will cause premature
failure of this heater. Such damage is not covered
under warranty. For additional information please
see page 3 of these Instructions.
Reset/Lock
Button
Pool Temperature
Control Knob
Temperature
Before Start Up
Keep heater area clear and free from combustibles,
flammable liquids and chemicals.
Pool water must be flowing through the Heater and the
Heater pressure gauge showing between 1.5 to 2.5 bar
for it to operate.
Quick Start
Check that the Electricity and Gas Supplies are on.
Turn on the Pool Pump. Turn on the Heater with the
Pool or Heating Temperature Knob and set the
desired temperature. In a few seconds the Heater
will fire.
Summary of Controls (Left to Right)
Display
Heating Temperature
Control Knob
Pool Temperature Control Knob
16°C to 32°C (60°F to 90°F)
(Maximum is changed in Setup Mode, see Page 16)
Rotate clockwise to increase the Pool Temperature.
The Setting Temperature is shown whilst rotating
and for 3 seconds after.
To lock the required Temperature Setting see
Lock/Reset Button.
Pool Demand LED - Green
Off - There is no Pool Heating demand, pool heating
is off.
On - There is Pool Heating Demand and the Pool is
not up to temperature.
Flashing - The Pool Heating Demand is met, the
pool is up to temperature.
Pressure
Gauge
Lock/Reset Button - If it is pressed for 2 seconds
it locks the Set Temperature so the Pool Temperature Knob is inoperative. To unlock, press again for 2
seconds. When locked a short press or turning the
Temperature Knob flashes the set temperature.
It also resets Gas Control lockouts, GAS and OH2.
Condensing Pool Heater 1 01/07/09
Temperature Display -
In Pool Heating Mode.
This normally shows the Pool Temperature but also
shows the Setting Temperature when the Pool
Temperature Control Knob is moved.
In Heating Mode.
It normally shows the boiler temperature but also
shows the Setting Temperature when the Heating
Temperature Knob is adjusted.
If the display alternates a temperature with ‘SEr’ it is
recommended that the Heater is serviced, it will
continue to function.
The Display is also used for commissioning and
diagnostic purposes. (Page 16)
Heating Demand LED - GREEN
(Only in use when heating system connected)
Off - There is no Heating Demand , heating is
switched off.
On - There is a Heating Demand , heating is on but
not yet up to temperature.
Flashing - The Heating Demand is met , heating is
up to temperature.
Heating Temperature Control Knob
(Only used when heating system connected)
Off - There is no Heating Demand, heating is
switched off.
Normal - Normal setting for heating, it can be
adjusted lower if required.
(NOTE: The Heater is supplied set for Pool Priority.
It will satisfy the Pool Temperature before providing
Heating. To change the priority, see Page 16,
Commissioning Section, of these Instructions)
Pool Pump Pressure LED - YELLOW
On - If the pump is running there is insufficient
pressure, possibly due to a blocked Pool Filter. The
Heater will not run.
Lockout - Left Red LED, Display “GAS”
On - This indicates the Heater Gas Ignition Control
has locked out. Press the Lock/Reset Button to start
the Heater again. If this problem persists this should
be investigated by a Service Engineer.
Condensate - Right Red LED, Display “HI”
This indicates that the Condensate drain is blocked
and the Heater has shutdown. When the blockage is
cleared for the Heater will operate again.
Overheat - Flashing Red LED, Display “OH2”
Flashing - This indicates the Heater has overheated
and it has shutdown. Wait for the Heater to cool then
press the Lock/Reset Button to start the Heater
again. If this problem persists this should be investigated by a Service Engineer.
General Information
Water Pressure Switch
A pool water pressure switch is provided in the
heater to shut off the burners in the event that water
supply to the heater is interrupted. The water
pressure switch should be checked and adjusted for
proper operation by a qualified service person at the
time of installation, and thereafter checked at each
service.
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to
the Heater.
Water Temperature Settings
The Heater is designed to provide the maximum
amount of heat to the pool up to one degree below
the set temperature. For that last degree it reduces
the power to maximise control. For certain installation designs, if the pool is used before it is up to set
temperature, the water entering the pool from the
Heater could be warmer than the pool. This is not a
fault but part of the design. It will reduce for the final
degree up to set temperature.
Chemistry
Please see page 3 for the maximum levels and the
procedural requirements for adding chemicals
Cleaning
It is recommended that periodically the casing is
cleaned and sprayed with WD40 or similar liquid, and
any exposed threads are lightly coated in grease.
Service & Maintenance
It is recommended that the Heater is serviced every
2000 hours of operation, for normal use this is about
12 months. The control will alert when you when it
reaches this period by its display, ‘SEr’ alternating
with the temperature.
It is a mandatory requirement that any gas work
carried out must be by a registered engineer with an
appropriate accreditation.
Winterisation
Provided the Mains Electricity and Gas are connected and on, the Heater will fire to prevent it
freezing, it will use the space heating circuit for this.
If the Pool and Heater are not going to be used for
the cold winter months it is recommended that the
equipment is winterised. Contact your pool installer
for help with this.
Failure to run or winterise the Heater during a period
of freezing could cause damage to the Heater which
will not be covered by your warranty.
Pressure Gauge - This should be between 1.5 to
2.5 bar, repressurise if too low.
Condensing Pool Heater 2 01/07/09
INTRODUCTION
These Instructions cover an indirect, floor mounted,
gas fired, condensing pool and space heater which
is room sealed and fan assisted. The flue system
available is concentric, left, right, rear, and vertical,
all up to 20 metres ‘FEL’. There is also an Outdoor
Top terminal for use where the Heater is installed
out of doors. The ignition system is fully automatic.
The Heater is designed to also provide a heating
output suitable for a number of radiators or an
indirect Hot Water cylinder.
There is one model - see the Technical Data on
Inside Cover for details. The Heater can be installed in multiples to obtain a larger, combined
output.
The casing is of green and black polyester powder
coated mild steel. The Heater uses a high performance stainless steel heat exchanger and is suitable
for connection to pools using chlorinated and salt
chorinated water provided the following levels of
chemicals are maintained.
pH 7.2 to 7.8
Total Alkalinity 80 to 140 ppm
Calcium Hardness 200 to 400 ppm
Salt maximum 30000 ppm
Free Chlorine 1 to 4 ppm
Water Undertaking, any relevant requirements of the
Local Authority, and Health and Safety document No
635, “Electricity at at Work Regulations”. Detailed
recommendations are contained in the following
British Standard Codes of Practice.
Codes of Practice.
BS.6798 Installation of gas fired hot water boilers of
rated input not exceeding 70kW.
BS.5440: Part1 and Part 2. Flues (for gas appliances of rated input not exceeding 60kW).
BS 6891 Specification for installation of low pressure
gas pipework.
BS5482:1 Code of practice for domestic butane &
propane gas burning installations.
Building Regulations Part L1.
IMPORTANT. It is important that no external
control devices are directly connected to this appliance - unless covered by these ‘Installation and
Servicing Instructions’ or otherwise recommended
by the manufacturer. If in doubt, please enquire.
Any direct connection of a control device not
recommended by the manufacturer could infringe
the Gas Safety (Installation & Use) Regulations, the
above regulations and the normal appliance warranty.
Manufacturer’s notes must NOT be taken, in any
way, as overriding statutory obligations.
All chemicals must be introduced and completely
diluted into the pool water before being circulated
through a firing heater. Do not place chlorine tablets
or bromine sticks in the skimmer, high chemical
concentrations will result when the pump is not
running. Turn the Heater off when shock dosing
Chlorinators must feed downstream of the heater
and have an anti-siphoning device to prevent
chemical back-up into the heater when the pump is
shut off.
NOTE: High chemical concentrates from feeders
and chlorinators that are out of adjustment will
cause corrosion to the heat exchanger in the
heater. Such damage is not covered under the
warranty.
Gas Safety (Installation and Use)
Regulations, (as amended).
It is the law that all gas appliances are installed by a
competent person (e.g. a Gas Safe registered
operative) in accordance with the above Regulations. Failure to install appliances correctly could
lead to prosecution. It is in your own interest, and
that of safety, to ensure that the law is complied
with.
The installation of the Heater MUST also be in
accordance with the current I.E.E. Wiring Regulations, the Local Building Regulations, Building
Standards (Scotland), the Bye Laws of the Local
Condensing Pool Heater 3 01/07/09
Location of Heater
The Heater MUST be installed on a flat and level
floor or wall, capable of adequately supporting the
weight of the Heater and any ancillary equipment.
Provision is provided for the heater to be fixed to the
floor and a kit is available for wall mounting.
It is IP 44 Rated and can be installed outdoors in a
suitable position. In all cases the choice of position
should take into account the flue, the plume and
condensate drainage.
IMPORTANT NOTICE.
If the Heater is to be fitted in a timber framed building it should be fitted in accordance with the British
Gas publication ‘Guide for Gas Installations in
Timber Frame Housing’, reference DM2. If in doubt,
advice must be sought from the Local Gas Region of
British Gas.
The Heater may be installed in any room or internal
space. Particular attention is drawn to the requirements of the current I.E.E Wiring regulations and, in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland with respect to
the installation of the boiler in a room or internal
space containing a bath or shower.
Where a room sealed appliance is installed in a
room containing a bath or shower then the appliance
and any electrical switch or appliance control,
utilising mains electricity should be so situated that it
cannot be touched by a person using the bath or
shower.
Where the installation will be in an unusual location
then special procedures may be necessary and
BS6798 gives detailed guidance on this aspect.
A compartment used to enclose the Heater MUST
be designed and constructed specially for this
purpose. An existing cupboard, or compartment,
may be used provided if it is modified for the purpose. Details of essential features of cupboard
compartment design, including airing cupboard
installations are given in BS 6798.
In siting the Heater, the following limitations MUST
be observed:
1. The position selected for installation MUST allow
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
2. This position MUST also permit the provision of a
satisfactory balanced flue termination.
3. This position MUST also permit the provision of a
satisfactory connection to the condensate drain.
Terminal Position Minimum
Below window or vent 300 mm
Below gutter or pipes 75 mm
Below eaves 200 mm
Below balcony or roof 200 mm
From a window 200 mm
From vertical pipe 75 mm
From corners 300 mm
Above ground, roof or balcony 300 mm
From facing surface 600 mm
From facing terminal 1200 mm
From opening under a car port 1200 mm
Vertically from a terminal 1500 mm
Horizontally from a terminal 300 mm
Fig. 1.0
3. The Heater is supplied separate to the chosen
flue set. It can be fitted with up to 20 metres
equivalent length of Concentric flue, see the Flue
Section on page 9, 10 & 1 1 for examples and
parts selection.
IMPORTANT.
Gas Supply
An existing meter and pipework should be checked,
preferably by the Gas Supplier, to ensure that they
are adequate to deal with the rate of gas supply
required.
Supply pipes should be sized to suit the installation
and obtain a working pressure of 20 mbar (NG), 37
mbar (Propane) 29 mbar (Butane). Installation pipes
should be fitted in accordance with BS 6891.
A Natural Gas Heater must be connected to a
governed meter.
Conversion
For countries permitted to use different gasses the
appliance is supplied setup for the primary gas. It
can be converted to an alternative by the addition of
an Orifice which is supplied with the heater. See the
inside cover page for the data and Page13 for conversion instructions.
It is absolutely ESSENTIAL to ensure in practice,
that products of combustion discharging from the
terminal cannot re-enter the building, or any other
adjacent building, through ventilators, windows,
doors, other sources of natural air infiltration or
forced ventilation/air conditioning.
If this should occur, the appliance MUST be turned
OFF IMMEDIATELY and the Local Supplier consulted.
Air Supply
It is NOT necessary to have a purpose provided air
vent in the room or internal space in which the boiler
is installed.
Where the boiler is installed in a cupboard or
compartment no air vents are required.
However the user may wish to ensure that it is
ventilated to provide air circulation.
Outdoor Heaters
Flueing
Only flue components specified by the Manufacturer
should be used with these appliances. Detailed
recommendations for flueing are given in BS 5440:
The following notes are intended for general guidance.
1. Be aware of the plume from the flue and the
wetting effect it can have to adjacent property.
2. The flue can be taken upwards, left, right or to
the rear of the appliance, but never downwards.
Condensing Pool Heater 4 01/07/09
These Heaters are certified for outdoor installation,
when equipped with the approved terminal.
WARNING: The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet openings and into
the heater. This could cause heavy internal rusting or
damage some electrical components, and this would
void the warranty.
It is recommended that periodically the casing is
cleaned and sprayed with WD40 or similar liquid, and
any exposed threads are lightly coated in grease.
Genie Resistance
1.6
1.4
1.2
1.0
0.8
m head
0.6
0.4
0.2
0.0
0 50 100 150 200 250
l/m
Fig. 2.0
Condensate Drain
See Fig. 7.0, and 7.1
A 75mm condensate trap is provided in the Heater
and is satisfactory when connected to Soakaways,
Gullies, Rainwater Pipework and Internal Drainage
systems. All pipework and fittings in the condensate
drainage system MUST be made of plastic, unless
they carry other liquid waste. No other materials
may be used. The pipework should be insulated if
run out of doors.
The drain outlet on the boiler is :
40 mm Hunter waste pipe.
Pool Pump & Pipework
The Heater is an indirect design and uses two very
high performance heat exchangers. The pool water
passes through the Secondary, the water in the
Primary is completely separate. The Heater controls
modulate the input when approaching the set temperature for greater accuracy and economy. It is
recommended that pool pump overrun is used to
maximise the life of the Heater.
If a new pump is being fitted consult the Pressure
Loss graph (Fig 2.0) to determine its size.
The Heater is provided with both 1½” and 50mm
plastic pool connections. As built the connections are
‘From Pool’ on the left, ‘To Pool’ on the right, however these can be easily reversed.
With the exception of automatic dosing equipment,
the Heater should be plumbed as the last piece of
equipment before the pool.
It is permissable to fit an isolating valves on the
pipework on either side of the Heater but in these
circumstances it is recommended to fit a flow switch
in the Heaters Mains supply.
Condensing Pool Heater 5 01/07/09
Space Heating
It is essential that an additional expansion vessel
is sized and fitted to the enlarged system. The
one provided is 4 litres.
This appliance is designed to provide a heating
output and this can be plumbed into the flow and
return connections on the left hand side of the
Heater.
The pump in the Heater is able to provide the circulation required for all types of ‘heating’ circuit, radiators, cylinders and fan coil units. The Heater also
includes an electric 3 port valve which determines
the flow of the heated water. (See Fig 2.1)
The Heater’s control enables a priority to be selected
(See Commissioning page 17), Pool satisfied
before Heating or vice versa. The Heating temperature control on the front panel enables the maximum
flow temperature to be set.
The heating system should be installed in accordance with current good practice, three example
designs are given in Fig 2.2
The control will automatically reduce the output for
Heating to about 15% (~6kW). If this is insufficient it
can be increased in Service Mode
(See Fig 8.3 and Commissioning page 16 and
Fault Finding on page 23)
Hydraulic Schematic
Tf lim
Primary
T lim
Tf
TH flow
PRV
G
3P
External circuit
D
2 x NRV
Th pool
Water 2 Water
P
Example Heating Designs
TH exch
Rear connection
Exp V
TH pool
TH exch
TH flow
T lim
Exp V
Tf lim
PRV
Pool Sensor
Heat Exchanger Sensor
Flow Sensor
Flow Stat ~ 80C
Tf
Hi Limit Stat ~ 100C Manual Reset
Expansion Vessel
Flue High Limit ~ 100C Manual
Drain
D
Pressure Switch
P
Pressure Relief Valve
Pressure Gauge
G
3P 3 Port Valve
230609
Fig. 2.2
Expansion vessel
3 Way Valve
Pool Plus Heating and Hot Water
Heater
Heater Expansion
Vessel
4 litres
Expansion vessel
Pool Plus Heating
Winterisation
Leave the Mains Electricty and Gas Supply on and
the Heater will run its own Frost protection programme using the Space Heating circuit. This can not
be used if the heating circuit has not been completed.
If the pool is not being heated disconnect heater from
mains elecricity.
Alternatively the Heater and Heating circuit can be
drained by fitting the drain assembly in place of the
double check valve/hose connector. The Condensate
Syphon can be drained by removal of its Drain Cap.
See Fig 7.1
Heater
Heater Expansion
Vessel
4 litres
e
a
e
h
A
i
h
t
w
w
a
x
c
e
t
r
e
n
g
a
h
u
q
i
s
i
m
o
r
t
t
a
a
s
P
o
o
2
t
r
a
e
d
w
n
c
o
S
Heater
Heater Expansion
Vessel
r
e
t
r
a
l
l
4 litres
P
l
u
p
s
a
S
Fig. 2.3
The Heater operate with 230V ~ 50Hz. Single phase.
Fuse rating is 3A.
The method of connection to the mains electricity
supply MUST facilitate complete electrical isolation
of the Heater, preferably by the use of a fused
double pole switch having a 3mm (1/8in.) contact
separation in both poles and servicing only the
Heater and its controls.
The point of connection to the mains should be
readily accessible and adjacent to the Heater.
Electricity Supply
Wiring external to the appliance MUST be in accordance with the current I.E.E. Wiring Regulations and
any Local Regulations that apply .
Note. Where a Heater is installed in a room con-
taining a pool or shower, the appliance, any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be
touched.
Condensing Pool Heater 6 12/08/09
INSTALLATION OF HEATER
Space Required for Installation and Service.
Left, Right or Above 300 mm 12 in.
In Front 800 mm 40 in.
Suggested procedure:
Site to suit the pool, terminal, plume and condensate
drain limitations. The Terminal position should follow
BS 5440 and be at least 600mm away from any
opening or obstacle.
1. For an indoor installation only : Mark & Drill
Flue hole. (See Fig. 3.1 and 3.2 for dimensions)
2. Fix the Heater to the floor using the holes provided in the front channel. See page 20 for the
wall mounting details.
3. The Heater should be connected to a suitable
supply as detailed on Page 6. It is required to
provide both permanent and Switched live supplies
to the Heater, this can be achieved as follows:
Remove Front Top Panel after releasing the
retaining M5 screw under the lip.
Remove the Electrical Cover to access the
Mains connector.
Pull out the Mains connector and replace
the link wire with a Permanent and Switched
live supply. (See Fig 11.0)
4. Pipe to the 22mm gas connection. A gas isolating
valve is provided on the Heater Gas Valve.
5. Plumb to the Pool Pump and Filter.
6. Fill Primary system with water using the supplied
hose connector. The Heater is supplied with one
litre of Sentinel X100 Inhibitor in the pipework.
IMPORTANT. Remove the air from the primary
through the Air Vent on the righthand Side Panel
and the Vent on the top of the Primary Heat
Exchanger. (See Fig 8.0) by running the internal
pump in short one second bursts, venting, then
pumping, until it has all been removed. The pump
can be run by rotating the Pool Thermostat to
show ‘P’ on the display, this also energises the 3
Port Valve to include the Heating circuit. The
Mains must be connected and on.
7. Test for leaks.
8. Replace the Electrical Cover and Panels.
Assembly of the Outdoor Terminal
A specific Outdoor Top Terminal must be used for an
outdoor installation. There must be at least 600mm
clearance around the terminal and complete clearance above. The Outdoor Top Terminal is a push fit
into the Flue Adapter and locked in position with a
clamping ring. (See Fig. 3.0 & 3.3)
If lubrication is required only Centra Cerin or silicone
grease should be used.
All Other Flue Systems
The maximum Flue Equivalent Length (FEL) permitted
is 20 metres, horizontal or vertical. The component
parts have the following FELs:
Condensing Pool Heater 7 01/07/09
Fig. 3.0
1 metre of concentric flue 1.0
2 metres of concentric flue 2.0
A 45 degree concentric bend 1.1
A 90 degree concentric bend 1.5
A concentric Roof Terminal 3.3
A concentric Wall Terminal 3.9
Sum the Flue Equivalent Lengths used in the design
this must not exceed 20 metres.
All items assemble by a push fit/clamp system. If it is
required to lubricate the seals only Centra Cerin
supplied by the manufacturer or Silicone Grease
should be used. The pipes should be assembled so
the socket end is always furthest from the Heater.
Flues should be supported by brackets every metre
of run. Horizontal flues should incline back to the
Heater by 3 degrees (5mm in 100mm)
Wall Terminal
The Horizontal Wall Terminal is supplied with two
rubber wallplates, one for inside and one for the
outside. The core drill diameter required is 175mm
and should incline upwards to the outside.
Because of the incline the height of the centre of the
flue hole on the wall is determined by the distance of
the heater is from it, calculate as follows.
1. Ensure service clearance is available.
2. Fit the 90 degree elbow to the heater and
measure from its outlet face to the wall.
3. Add 5 mm for every 100 mm distance.
Example: Distance measured = 480 mm
(5 x 480) / 100 = 25 mm
Flue centre 1065 + 25 = 1090mm
If it is required to reduce the length of the Terminal
the minimum overall length is 300mm. The Flue duct
should be cut 10mm longer than the Air duct.
Terminal Guard
The flue products from this appliance are very low
temperature so a guard is only required if the terminal is is in a position where it may be damaged. A
suitable guard is available from:
TFC Ltd. 01732 351555, Model DK6
Heater Dimensions
Pipe Connections
& Locations
403
293
134
491
409
253 (LH)
265 (RH)
374
841
1008
1048
138
200
233
Fig. 3.1
307
361
533
Service Access
Left, Right or Above 300mm
In Front 800mm
Connections
A Multi Heater Connection
B Electric & External Control (CCP01)
C CH Flow - 22mm Copper
D Gas Supply - 22mm Copper
E Safety V alve Outlet - 15mm Copper
F CH Return - 22mm Copper
G Condensate Drain - 1¼” or 40mm Hunter Plastic
H From Pool - 1½” / 50 mm Plastic Demountable Fittings
78 90
A
B
C
E
F
H
D
G
Horizontal Wall Terminal
Dimensions
°
3
1000mm
52mm
Horizontal Wall Terminal
(MBHT)
1133
Rear Flue Left/Right Flue
WT 136
188
9
3
°
°
3
9
SW
WT
Fig. 3.2
Condensing Pool Heater 8 30/03/10
1133
Outdoor Terminal
Dimensions
Outdoor Flue Terminal
(MBOT)
Clamp Assembly Screw
Vertical Roof Terminal
Dimensions
Pitched Roof
Installation
Flat Roof
Installation
550
Fig. 3.3
500
Use Seldeck Flashing
System for all Roof
Installations
500
Vertical Roof Terminal
(MBVT)
1 metre Horizontal/
Vertical Extension Pipe
(MBHVE)
45 degree bends
(MB45DB)
Fig. 3.4
Condensing Pool Heater 9 01/70/09
Flue Examples
Horizontal Wall Terminal
MB90DB
MBHT
(not shown)
Fig.4.0
Outdoor Terminal
Extended Horizontal
Wall Terminal
MB90DB
MBHVE
MBHT
(not shown)
TO OFFSET
USE MB45DB
Extended Vertical
Roof Terminal
MBVT
MBHVE
TO OFFSET
USE MB45DB
MBOT
Fig.4.3
Flue Kit Part Codes
Determine the type of Flue system you require and
choose from the list of kits available below:
Fig.4.1
Fig.4.2
Type of Flue System
Kit Code Description Outdoor Kit Horizontal Terminal Vertical Terminal
MBHT Horizontal Wall Terminal n/a Yes n/a
MBHVE 1 metre Horizontal/Vertical Extension Pipe n/a Option Option
MBVT Vertical Roof Terminal n/a n/a Yes
MBOT Outdoor Terminal Yes n/a n/a
MB45DB 45 degree bend n/a Option Option
MB90DB 90 degree bend n/a Option n/a
Condensing Pool Heater 10 01/07/09
Flue Kit Part Codes (cont.)
The Maximum Flue Equivalent Length (FEL) permitted is 20 metres, horizontal or vertical. The Flue Kits available below list the FEL for each component. Add up all the FEL’s used in your design and check that this does
not exceed 20 metres. (See page 7)
Kit Code Description FEL Photo of Kit
Flue
Equivalent
Length (m)
MBHT Horizontal Wall Terminal 3.9m
MBHVE 1 metre Horiz./Vertical Extension Pipe 1.0m
MBVT Vertical Roof Terminal 3.3m
MBOT Outdoor Terminal n/a
MB45DB 45 degree bends (pair) 1.1m
(per bend)
MB90DB 90 degree bend 1.5m
Condensing Pool Heater 11 01/07/09
Roof Terminal
The Vertical Roof Terminal should be fitted in a
minimum of 300mm clear unobstructed space. It is
not permitted to alter the construction of the Terminal, above the roof line, however the concentric
section below the roof line can be altered to suit the
installation.
It is recommended that:
1. The Installation of the flues are completed before
their connection to the Heater. This will ensure
that any debris that gets into the flues can be
cleared.
2. That bends in vertical flues are 45 degrees.
3. Flues may be reduced in length by cutting. The
inner Flue pipe should be cut so it is 5 to 10mm
longer than the outer Air duct. It will ease assembly if the cut edges are cleaned, chamfered and
greased before assembly.
Pool Plumbing
The heater requires water flow and pressure to operate
properly. It must therefore be installed downstream of
the filter and pump. A typical installation is plumbed as
follows:
Flow Rate
The Heaters have a very low resistance to the Pool
Water flow and will tolerate a wide range of flows.
The minimum recommended flow is:
80 litres/min
Pressure Switch
The Heater is protected by an adjustable water
pressure switch that has to close before the Heater
will operate.
It is very important to verify that it turns off when
the water flow is interrupted.
It has an adjustment range equivale nt to
and is factory set for most conditions but can be
altered if required:
1. With the pump on turn the knurled nut clockwise
until a click is heard.
2. Turn the nut anti-clockwise a quarter of a turn.
3. Turn the pump on and off to check the switch
operates correctly.
±1.5 metres
Fig. 5.0
1. The Pump outlet is plumbed to the inlet of the Filter.
2. The outlet side of the Filter is then plumbed to the
inlet of the Heater.
3. The outlet of the Heater is plumbed to the return line
to the pool or spa. The Pump, Filter and Heater are
plumbed in series.
If it is necessary to install a valve on the return to the
pool then it is recommended that a flow switch is
installed and interlocked with the Heater supply.
The Heater must be located so that any water leaks will
not damage the structure of the adjacent area.
There is no requirement for heat shunt connections to
the Heater, plumbing can be made in standard plastic
1½” or 50mm pipe from the supplied demountables
Use the pressure loss chart on page 5 to select a
suitable pump.
Connection to the Heater can be made from either
left to right, or right to left, it is supplied with the
‘From Pool’ connection on the left. To change, undo
the demount connection on the right, complete with
blanking plates, and swap with the connections on
the left. Ensure that the Pool Sensor is correctly
positioned in its pocket and the Pressure Switch is
connected after the change.
Condensing Pool Heater 12 01/07/09
Conversion to LPG
The Heater can be converted on site. NG to Propane, or Propane to Butane.
1. With the Gas and Electrical supply off, undo
the three screws that hold the Venturi to the
Gas Valve. (See Fig.6.0)
2. Allow the Gas valve to drop and gently hang
on its cables.
3. Fit the Conversion Orifice into the Rubber
Seal that sits in the Gas Valve. (See Fig.6.1)
4. Re-assemble the Gas Valve and Venturi.
5. Affix the new Serial Number Data
Label supplied over the existing.
6. Turn Gas on and check for leaks.
7. Fire Heater and allow to run for 5 minutes
before checking and adjusting the CO2 with
the Throttle.(See Fig 6.0 and Datatable
inside cover)
8. Replace the Sealing Cover over the Throttle.
LPG to NG Conversion
The method is as detailed above except the Orifice
is removed and the Venturi and Gas Valve reassembled with just the Rubber Seal between them. A new
Serial Number Data Label should be obtained from
the manufacturer and affixed over the existing.
Throttle
Adjustment
Fig. 6.0
Gas Connection
The 22mm copper gas connection provided can be
positioned to exit the Heater from either the left or
the right. A minimum of 20mb. (NG), 37mb (propane)
28 mbar (butane) must be available at the Heater
inlet, with the Heater and other connected appliances firing. Check for gas tightness (B.S. 6891:
1988) in pipework to boiler using a manometer.(See
Fig. 6.2) Gas and combustion soundness within the
Heater should be checked using sense of smell and
leak detection fluid. Check the maximum rate and
combustion are to specification.
See Table 6.0 and Datatable Inside Cover.
Rating Table (1040 Btu/ft³) (38.8 MJ/m³)
kW gross Btu/h sec/ft³ m³/2 mins
7.5 25590 145 0.023
12.5 42650 87 0.039
20 68240 55 0.062
34.6 108055 31.5 0.107
52 177420 21 0.161
Orifice in position
Inlet pressure
tapping
Offset
connection
Fig. 6.1
Fig. 6.2
Table 6.0
Condensing Pool Heater 13 01/07/09
Condensate Connection
The direction of the plastic condensate drain pipe
connection can be altered from the factory position
on the left, to the right.
Remove the blanking plate from the right hand
side (See Fig. 3.1)
Loosen the two screws holding the Trap
bracket and swivel the trap through 90 degrees.
Secure the bracket and fit the supplied 40 mm
pipe.
Example installations are shown in Fig 7.0.
Fit blanking plate to the left hand side.
(See Fig 7.1)
Where possible an internal termination of the condensate discharge pipework should be used.
If this is not possible external pipes should be kept
as short as possible and insulated.
Where fitted in pipework that includes another trap or
a pump, for example the filter backwash pipework to
drain, an Air Break should be fitted between the
Heater and that pipework.
Avoid connecting to a kitchen sink trap as the solids
and fats in the drain will cause a blockage.
It is permissible to connect to an external gully or
rain water hopper provided they connect to a combined system.
The condensate should not be run into a ‘grey water’
recycle system.
If the condensate pipe is connected to a stack it
should join not less than 450 mm above the foot of
the stack. In addition it should be positioned so there
no chance of cross-flow to another connection.
Installation pipework must be in 40 mm Hunter
plastic pipe to a suitable drain location with a gradient of 2.5° (45mm/ metre run) minimum. If connected
to another drainage trap, an air break is required
between the Heater drain and that trap. (See Fig.7.0
& 7.1). External runs, should, if possible, be insulated to defer problems from freezing.
Check during commissioning that there is a leak free
working connection from the Heater to the drain. The
simplest way to do this is to carefully pour some
water into the boiler flue and check it emerges at the
drain. This will also fill the trap ready for operation.
Electrical Connections
WARNING: The appliance MUST be earthed.
All wiring for the Heater and system controls MUST
conform to I.E.E. Wiring Regulations, and work
should be tested using a suitable meter, for Earth
Continuity, Polarity, Short Circuit and Resistance to
Earth.
The Heater supply must be through a common
isolator, a double pole 3A fused isolating switch with
a contact separation of 3mm minimum on both
poles.
The cable used should be no less than 0.75mm
BS.6500 PVC, 3 core, and fixed ensuring the Earth
connection is longer than the Live and Neutral.
Access to the Heater connections is made by the
removal of the Front Top Panel and the Electrical
Chassis cover, two screws.
The simplest and most flexible control scheme is to
use a Certikin CCP01 Control Unit. This provides an
electrical safety trip and timer with outputs for the
Heater, lights and an auxilary voltage free output. It
is pre-wired and tested and provided in a standard
IP55 plastic control box.
The Heater’s internal wiring is shown in Fig.11.0.
Connections are as follows :-
4 Way Terminal Supply Connection
Earth
N Mains Neutral
Ls Pool Demand
L Permanent Live
3 Way Terminal
L Heating Demand
It is recommended that this product is supplied with
a permanent live as both the combustion fan and
internal pump require to run after the switched live is
removed.
For systems using an external programmer, the
electrical wiring should follow the relevant control
manufacturer’s recommendations, with the switched
lives from the controls returning to Ls in the 4 and L
in the 3 way push-fit connector.
2
to
The “Guide to the Condensing Boiler Assesment
Procedure for Dwellings” can be refered to, see
http://www.planningportal.gov.uk/england/profession-
It is possible to connect several Heaters together
using the Multiple Heater Kit. Details for the parts
and installation of this kit are given on Page 18.
als/en/1115314255842.html
Condensing Pool Heater 14 01/07/09
Example Condensate Disposal Methods
Note: Do not reduce the pipe size below the 40mm provided.
Soakaway
200mm Land Drain
Filled with Lime
Insulate against
freezing
Fig.7.0
chippings 400mm
deep
1:20 Fall ( 2.5 Degrees )
Stack Attachment
Strap-On
Boss
Soil Pipe or
Drain
Condensate Syphon (75 mm)
Condensate
Drain from
Heater
Connect To
Waste
(Option to
exit Heater
left or right)
Condensate Pressure
Switch Pipe
Connection
Removable Plate
(Use to close off
unused Waste exit
on panels)
Drain Cap, (behind
vessel) can be
removed for
Winterisation
Fig.7.1
Condensing Pool Heater 15 01/07/09
Commissioning
General
IMPORTANT The heater primary contains Sentinel X100 inhibitor. The minimum water should be
released during filling to maintain its concentration.
The elimination of air from the heat exchanger is
essential to maximise the life of the Heater.
It is strongly recommended that the Heater is first run
with the GAS OFF until the air has been purged.
If air has not been released then there is a possiblity
of the Heater overheating and triggering one of its
safety thermostats. An Air Vent is provided on the
top of the Heat Exchanger (See Fig 8.0) to assist its
removal. It is opened and closed by rotating the front
connector. A second is a standard radiator vent in
the righthand Side Panel.
The internal pump can be run by using the Pool
Thermostat in the ‘P’ position. (See Fig 8.1) to aid
de-aerating, this also opens the 3 Port Valve to
utilise the heating system. If this is not yet plumbed
and the connections have been sealed, temporarily
remove the brown wire to the 3 Port V alve at its 6 way
terminal strip on the Electrical Chassis. Reconnect
when re-commissioning with the heating circuit.
It requires that the Mains in connected and that there
is a live on Pool demand, the Pool Pump need not be.
The boiler is factory set for Natural Gas, fitted with
automatic ignition and will start when the gas cock is
open, mains is connected and the Pressure Switch is
activated by the pool pump. (for greater detail about
the internal controls see the Maintenance section,
Fault Diagnosis)
LPG models require to be modified as described on
page 13.
It is recommended that the condensate trap is full of
water before firing.
If the Heater fails to light the gas it will shutdown
and try again. It will repeat this a total of 5 times and
then lock out. This will show as the Red LED lit and
‘GAS’ on the display. Press the Lock/Reset button
to start another 5 attempts.
It is possible with the front door off to see when the
burner is lit through the sight glass. (See Fig. 8.2)
After the burner has been lit for a few minutes the
gas rate and combustion should be checked, see
the Technical Data on Inside Cover for details.
The Heater is factory set and should not require
adjustment. When the Heater has been running for
at least 10 minutes check all joints, gas and water,
for leaks, and correct where necessary.
When running satisfactorily, complete the commissioning details on the inside back page of these
instructions.
Commissioning - Pool
The Heater Control is factory set to display in Fahrenheit and work to a maximum temperature of 90°F
(32°C). If a Centigrade display or higher temperature
106°F (41°C) maximum is required, this can be
changed in the User Setup Mode. (See Page 17)
Fig. 8.0
Fig. 8.1
Note: The boiler is fitted with a syphon trap that includes a blocked drain detection device. This is to safeguard the boiler from a blockage or the possible freezing of the condensate pipework in extreme weather.
Should this happen the control will lockout and the
display will show ‘HI’, as in “condensate level is high”.
See the Fault Finding section for more details.
This will have to be corrected before the Heater will run.
The user should be made aware of this feature and,
that in the event of blocked or frozen condensate
pipework, the boiler will automatically stop functioning.
It will start again as soon as the blockage has cleared.
Finally, instruct the user on Heaters operation and controls.
Commissioning - Heating
First commission the Heater for Pool use.
As supplied the Heater is set to provide its minimum
output to heating, about 6 kW. This can be increased
but not decreased.
To increase access the controls Service Mode (See
Page 23) and alter the Heating Input Maximum
from its starting point of 0% to the required level.
(See Fig 8.3). It is not recommended that this is
increased above 50% as the Heater operates as
either as a Pool Heater or a Heating boilers, but not
both at the same time.
The priority of Pool or Heating, which is satisfied
first, can be set in Service Mode (See Page 23).
A four minute anti-short cycling delay operates on
the Heating thermostat, it can be reset to zero by
altering the Heating Temperature Control Knob.
Condensing Pool Heater 16 12/08/09
Heating Output
60
50
40
30
%
20
10
0
5 7 9 1113151719
Output kW
Fig. 8.2
User Setup Mode
Pressure
Gauge
Lock/Reset
Button
Temperature
Display
Heating Temperature
Control Knob
Pool Temperature
Control Knob
User Setup Mode Setting Factory Setting Alternative Display Indicator
Fig. 9.0
Fig. 8.3
1 Display units ° F = Fahrenheit ° C = Centigrade ° F or ° C
2 Maximum temperature 32 °C (90 °F) 41 °C ( 106 °F) PL or SPA
3 Priority Pool first Heating first P or H
4 Software Version e.g 017
Switch on with the panel switch whilst pressing the Lock/Reset button then release. The control is now in
Setup Mode.
The control can now be altered by rotating the Pool Temperature Control Knob to a certain position and then
pressing the Lock/Reset button, then switching off. (See Fig. 9.0)
Example:
To change from Fahrenheit to Centigrade:
Turn Panel Switch OFF then back ON whilst pressing the Lock/Reset button.
Turn the Pool Temperature Control Knob until the display shows ‘F’.
Press the Lock/Reset button once and the display will show ‘C’.
Switch the Panel Switch OFF then back ON again.
The Control will now display in Centigrade.
Condensing Pool Heater 17 01/07/09
Multiple Heater Kit
Overview
It is possible to connect together several Heaters
and by doing so obtain a larger output with an
economical and a fail-safe design. The Multiple
Heater Kit enables 2 or more Heaters to be connected to obtain the necessary Load Sharing,
automatically. This works by one Heater being a
Master and the others being Slaves. The Master is
set for the required pool temperature and it then
controls as many of the Heaters as necessary to
obtain the temperature. It also equalises the running
time of every Heater so they all do the same amount
of work. If there is a mix of Heater models, the Genie
Dual should be the master.
Kit Part Codes:
2 Heaters: MBMIK2
3 Heaters: MBMIK3
4 Heaters: MBMIK4
5 Heaters: MBMIK5
6 Heaters: MBMIK6
7 Heaters: MBMIK7
8 Heaters: MBMIK8
Installation Instructions
Disconnect the Heater from the Mains then
remove the Top Panel and the Electrical Chassis
Cover.
Remove Pool Thermostat Control Knobs
Remove Thermostat Board by removing its
electrical connectors then the retaining plate and
carefully slide out until fully accessible.(Fig. 10.0)
Carefully fit the Adapter PCB in the space beside
the Pool Temperature Potentiometer on the
Board (Fig. 10.0) ensuring that the six pins on the
Board pass through the underside of the Adapter
PCB and, that the plastic locking pillars snap into
place. Refit Thermostat Board and Knobs.
Repeat steps 1) and 2) for all the Heaters.
Using the supplied cables, pass them through the
upper rear panel grommet and daisy chain the
Heater Adapter PCBs together . The first and last
Heater in the ‘chain’ will use the Terminator Plugs
to fill their 2 unused sockets. There are 2 different
coloured Terminators, they can go in either the
first or last Heater. NB. Ensure the connectors
are fully home (Fig. 10.1)
Choose which Heater is to be the Master and
then make the rest Slaves by disconnecting their
Pool Temp Sensors. Remove the leads to the
Pool Temp Sensor from the four way terminal
strip on the electrical chassis and tie back in a
safe place. (Fig. 10.2)
Any external electrical control should only be
connected to the Master, Pool Demand.
Remove any Pool Demand links from the Slaves.
Adapter PCB
Interconnection Cables
Fig. 10.0
Connectors
Fig. 10.1
Interconnection Cable
T erminator Plug
(on first & last heater only)
Fig. 10.1
Fig. 10.1
Photo 2
Condensing Pool Heater 18 17/08/09
Turn on the Mains, then switch on all the
Heaters. After a short self-test the Master
should show the actual temperature, and the
Slaves three dashes “---”. If a Slave continues
to show a moving display of dashes this indi
cates it not correctly connected to the Master,
check the Interconnection cable plugs are fully
home.
Replace the panels.
Operation
Turn on all the Heaters with their Pool Tempera
ture Controls.
The Master will show temperatures and the Slaves
“---”.
Set the required temperature on the Master and
provided there is an electrical demand at the
Master’s Pool Demand connection, the Heaters
will run.
If a safety device on the Master operates it will
not run but will continue to control the Slaves.
If the Master Control fails the ‘system’ will fail.
Change the Master to a Slave and one of the
Slaves to a master to enable the system to run
again.
If a safety device on any of the Slaves operates
that Slave will not operate.
If a Slave has Flow fault which its Pressure
Switch detects the burner will stop immediately
and the Yellow LED will light. It will no longer be
available to the group. It will then check every 3
minutes or so to see if the problem has been
corrected, the Yellow LED will flash. It will put
itself back in the group if flow is satisfactory .
The Master display can be altered in Setup
Mode like a single Heater. (see Page 16)
Unlike a single Heater, there is no modulation
of individual burners.
Features
A Master is the only Heater with a Pool Sensor
connected, move the sensor and the Master
moves.
If the Master Pool T emperature Control is
turned off, none of the Heaters will run.
If a Slave’s Pool T emperature Control is turned
off it will not operate. The Master will know and
alter its control accordingly .
Displays
The Master display is just like a single Heater.
A Slave will display “---” when working as part of
the group. It will show all the fault conditions of a
single Heater except “P/oc”, the Pool Sensor
Open Circuit fault. If this is displayed it indicates
a interconnection problem, check the cables and
connectors.
The Pool Demand LEDs work as a Single Heater.
On when running, Off when off, and Flashing if
not needed by the Master.
The warning LEDs work for all in a group, as per
a single Heater.
Pool Temp Sensor wires
Fig. 10.2
Condensing Pool Heater 19 01/07/09
Wall Mounting Kit
Overview
The Genie Dual 36 can be wall hung using the Wall
Mounting Kit.
Kit Part Code: MBWMK35/50
Instructions
Select a suitable wall and position to mount the
Heater. (Note the Heater weighs 54kg.)
Screw the Top Wall Mounting Bracket level to the
wall. (Fig 10.4)
Attach the Top Handle Bracket to the rear of the
Heater by using the three M4 screws supplied.
(Fig 10.5)
Attach the Bottom Wall Mounting Bracket to the
rear of the Heater by using the existing three
screws that fix the base to rear panel.(Fig 10.5)
Hang the Heater on Top Wall Mounting Bracket
locating it on the two 5mm studs.
With the Heater now in position drill and screw
the Bottom Wall Mounting Bracket to the wall.
See (Fig 10.4)
Fig. 10.3
DRILL HOLES AFTER
HEATER HAS BEEN
WALL HUNG
HEATER
OUTLINE
170
HORIZONTAL
WALL
TERMINAL
CORE DRILL
POSITION
5MM STUD (2 PLC'S)
46
80
TOP WALL
MOUNTING
BRACKET
BOTTOM WALL
MOUNTING
BRACKET (FITTED TO
HEATER BEFORE
WALL HUNG)
1008
HEATER CABINET HEIGHT
HEATER CABINET WIDTH
376
476
Fig. 10.4
REQUIRED CLEARANCE
FLOOR
Condensing Pool Heater 20 01/07/09
TOP HANDLE BRACKET
M4 SCREWS
SUPPLIED (3 PLC'S)
LOCATING STUDS
(2 PLC'S)
TOP WALL
MOUNTING BRACKET
REMOVE DEMOUNTABLE
POOL FITTINGS FOR BETTER
DRILL ACCESS
Fig. 10.5
GOLD SCREWS SUPPLIED (3 PLC'S)
BOTTOM WALL MOUNTING BRAKET
Condensing Pool Heater 21 01/07/09
Schematic Wiring
MODULATION -ve
MODULATION +ve
IGNITION
CONTROL
LOCKOUT ALARM
FAN -ve
HI LIMIT
FAN +ve
RESET -ve
FAN PWM
HI LIMIT
RESET +ve
FAN TACHO
FAN 230v
HEAT DEMAND
N
N
L
X12.16
X12.14
X12.13
X12.12
X12.11
X12.10
X12.8
X12.5
X12.4
X12.3
X12.2
X12.1
X1.10
X1.9
X1.8
X1.7
X1.5
X1.3
X1.2
X1.1
Bk
Bk
Gy
G
Y
Or
P
R
V
B
B
Br
GyBk
G
W
Flue
Water
Hi Limit
Gy
910 ohms
Hi Limit
1%
Control Stat
FAN
V
Bk
Or
P
E
N
Gy
E
B
N
R
Br
KEY
Bk
Black
Blue
B
Brown
Br
Grey
Gr
Or
Orange
Pink
P
Red
R
Violet
V
White
W
Y
Yellow
G
Green
100609
Heater pump
3 Port Valve
Heating demand
Permanent Live
BrBkG/Y
BGy
>>>
>
N
E
Pool demand
>
Factory Fitted Link
Remove when seperate
switched live supplied
Condensate
Level Switch
NC
G
W
R
P
Gy
Bk
B
Br
R
G
Y
Bk
P
Gy/Bk
LKOUT
BURNER
NC
3P VLV
HTR PMP
HTG DMD
PL DMD
N
NC
L
315 mA
RESET
MODULATION
COMB' SENSOR
COND' HI
PRESSURE
+
PL SENSOR
+
-
NC
R/B
Or
V
Pressure Switch
B' SENSOR
SENSOR RTN
Gy
Flow sensor
V
Or
Pool sensor
P
Combustion sensor
Fig.11.0
Condensing Pool Heater 22 01/07/09
FAULT FINDING
WARNING: BEFORE COMMENCING OR COMPLETING ANY ELECTRICAL WORK ON THE APPLIANCE,
IT IS RECOMMENDED THAT THE BASIC SAFETY CHECKS FOR EARTH CONTINUITY, SHORT CIRCUIT,
POLARITY AND RESISTANCE TO EARTH ARE MADE. ALL WORK CARRIED OUT SHOULD FOLLOW
GUIDELINES LAID DOWN BY THE I.E.E.
Operation
The Heater requires Mains on both the Live (L) and
Switched Live connections to be able to run. It requires
a Permanent Live supply for the correct operation of
the Fan and Pump.
T o enable Pool Heating the Heater must have a Mains
supply , Gas, Pool Pump pressure sufficient to activate
the Pressure Switch, all safety switches closed and a
pool temperature below the set point. For Space Heating the Pool Pump need not be running.
If all the above are correct then the Gas Ignition Control starts the Ignition sequence:
1. The Fan and internal Pump runs as a pre-purge of
the Heat Exchanger. For heating the 3 Port Valve
is also energised.
2. After a few seconds a spark is created at the electrode and the burner is lit.
3. The burner flame is sensed and the spark is re
moved.
4. The Fan speed is then changed to the required
speed according to the demand.
5. If the burner fails to light the spark will stop and
the Fan and internal Pump will run on as a postpurge of the Heat Exchanger.
6. The ignition sequence will be repeated up to five
times, then the control will lockout and will require
a reset to start again.
7. On Heating only there is a 4 minute anti-short
cycling mode. This can be reset by moving the
Heating T emperature Control Knob.
Safety Controls & Lockouts
The Thermostat Controls indicates the actual and set
temperature of the pool or the heater and also displays
all the lockouts. The next pages detail the fault conditions, the indicators, the display and the corrective actions required.
User Setup Mode
Turn off the Mains supply. Turn on with the Panel
Switch whilst pressing the Lock/Reset Button.
The Control is now in User Setup Mode. See Page 17
for details.
Service Mode
This is a special mode used to set the operation of the
Control and to investigate fault conditions, it is entered
from User Setup Mode.
Rotate Pool Thermostat knob fully clockwise to
show the software version number.
Press the Lock/Reset Button for 3 seconds. The
control is now in Service Mode.
It is now possible to change some of the Control’s
parameters. To show them, rotate the Pool Ther
mostat Potentiometer. To zero or change them,
press the Reset/Lock button
To exit, turn the Panel Switch off then back on again.
Service Mode Setting Factory Setting Reset press Display Indicator
1 Pressure Log Number of Operations Resets to zero Yellow LED ON
2 Combustion Gas Log Number of Operations Resets to zero Count, Right Red LED flashing
3 Gas Lockout Log Number of Operations Resets to zero Count, Left Red ON
4 Condensate Blocked Log Number of Operations Resets to zero Count, Right Red LED ON
5 Hours run 0 Press resets to zero
156 =1560 hrs, All LEDs ON
6 Heating Input Maximum 0 % Alter with Htg control 0 to 100, Green Htg LED ON
7 Pool Temperature Offset 0.5 C (0.9 F) Steps of 0.5C (0.9F) -3.0 to 3.0 (-5.4 to 5.4)
8 Display td0 td1 td0 / td1
Test Temperature Display Mode 1 (td1).
Temperatures are displayed to 0.1 degree resolution, not the normal 1 degree. The display will now show each
sensor temperature and cycle around them for each press of the Lock/Reset button.
1. Pool Temperature as normally displayed. The Green LED will be alight.
2. Pool Temperature is displayed to 0.1 degrees. The Green LED will be alight.
3. Heat Exchanger Flow Temperature. The Yellow LED will flash rapidly.
4. Heat Exchanger Combustion Temperature. The left Red LED will flash rapidly.
Rotating the potentiometer will change the set temperature. Pressing and holding the button whilst one of the
temperatures is displayed will ‘lock/unlock’ it on the display for continuous observation.
Condensing Pool Heater 23 01/07/09
Fault Codes
Flashing
EXPLANATION
RED
RED
YELLOW
GREEN
FRONT PANEL
OFF, no mains supply or failed power supply
Running, raising pool temperature to 28°C
Up to temperature, 28°C
Insufficient water pressure. Filter?, Blockage?
‘SEr’ alternating with pool temperature. Service
required, working hours has reached setpoint.
‘OH2’ Flue gas over temperature. Allow to
cool then investigate in Engineering Mode.
Reset with Button
‘GAS’ Gas Control Lockout. Unable to light burner , reset with Button.
OR Flue or Water Stat tripped, reset on stat OR Fan resistor open
cicuit, investigate cause. OR Valve Coils faulty , replace valve.
‘HI’ Condensate level high. Blocked? Clear
obstruction and allow control to auto reset .
DISPLAY
LOCK / RESET
Condensing Pool Heater 24 20/10/10
Fault Codes
EXPLANATION
‘P’ alternating with ‘oc’ = Pool sensor open circuit OR No
RED
RED
YELLOW
GREEN
FRONT PANEL
DISPLAY
‘F’ alternating with ‘cc’ = Heat Exchanger Flow sensor short circuit
‘F’ alternating with ‘oc’ = Heat Exchanger Flow sensor open circuit
‘P’ alternating with ‘cc’ = Pool sensor short circuit
network detected if a Master in a multiple heater installation
‘H’ alternating with ‘cc’ = Heat Exchanger Combustion sensor short circuit
‘H’ alternating with ‘oc’ = Heat Exchanger Combustion sensor open circuit
‘Err’ alternating with ‘4’ = Pool potentiometer open circuit
‘Err’ alternating with ‘7’ = Heating potentiometer short circuit
‘Err’ alternating with ‘5’ = Pool potentiometer short circuit
‘Err’ alternating with ‘6’ = Heating potentiometer open circuit
For all of the above. Turn off, correct problem and turn back
on again and the display and operation will be normal.
LOCK / RESET
Condensing Pool Heater 25 01/07/09
SERVICING
Health and Safety Statement :
This Heater contains no asbestos.
Routine Service
To ensure continued efficient operation of the
appliance it is recommended that it is checked and
serviced at regular intervals.
The frequency of servicing will depend upon the
particular installation and usage but in general every
2000 hours of operation should be the maximum.
It is law that any service work should be carried out
by Registered personnel.
1. Clean burner and combustion chamber.
2. Replace the Heat Exchanger silicone door seal
every 4000 hours.
3. Check condition of ignition spark and sensing
probe.
4. Check boiler pipework joints for leaks.
5. Check the Air duct and Flue seals.
6. Check condensate syphon and pipework for leaks.
7. Check the Gas Rate.
8. Check the combustion CO and CO2.
9. Reset the Service Hours counter in the control.
(See Service Mode, page 22)
Follow the procedures given in Changing Components
for parts removal in addition to the following notes.
In all cases, before work commences turn off the
Mains Electrictity and Gas Supply.
Burner & Combustion Chamber
To view the burner and the inside of the Heat Exchanger it is suggested you remove the front of the
Heat Exchanger complete with the Fan and Gas
Valve:
Fig 12.0
Pipework
IMPORTANT. The Heat Exchanger connections are
made using O rings and should not be strained in
any direction. Any strain will result in damage to the
Heat Exchanger and will not be covered by the
warranty.
Condensate Syphon
The lower bowl of the Syphon can be unscrewed,
examined and cleaned.
Air Duct & Flue Seals
A visual inspection should establish there are no
leaks around any of the seals, including the flexible
Air Duct to the Venturi.
Gas Rate & Combustion
See the Datatable on inside cover for the correct
values.
A Combustion sample point is provided on the front
of the Flue Adapter. (See Fig.14.1)
Changing Components
Remove Door and Front Top Panel
Disconnect Gascock flange from Valve.
Unplug Fan electrical connectors.
Remove Air tube from Flue Adapter.
Undo cover over Ignition Control connections
and remove the two connectors.
Pull off the Earth Lead connection on the
Valve and Heat Exchanger.
Undo the four nuts holding the Heat Exchanger
front and withdraw.
Replace the silicone door seal every 4000 hours.
Assembly is the reverse.
Spark & Sense Electrode
Turn off the Heater.
Pull off the HT Lead.
Undo the two screws retaining the electrode
assembly and carefully withdraw.
The spark gap should be 3.0 mm ± 0.5.
THERE IS ONE FUSE, THE REMAINDER OF THE
CONTROLS ARE NOT REP AIRABLE AND IF NOT
WORKING MUST BE REPLACED.
In all cases, before work commences turn off the
Mains Electricity and Gas Supply.
The following items can be replaced:
Fuse 315 mA, on Thermostat PCB.
Pool Thermostat.
Condensate Pressure Switch.
Pool Temperature Sensor.
Heat Exchanger Flow Sensor.
Water Pressure Switch.
Control Thermostat.
Overheat Thermostat.
Heat Exchanger Combustion Temperature
Sensor.
Flue Thermostat
(See Fig 12.0 for checking fixture)
Condensing Pool Heater 26 01/07/09
Ignition Control.
Gas V alve.
Fan.
Pump.
Expansion V essel
3 Port V alve Head and Motor
Heat Exchanger .
Secondary Heat Exchanger .
On the Electrical Chassis
T o access these items first remove the Front Top
Panel and then the Chassis Cover.
Pool Thermostat (See Fig. 13.0)
Pull off the Thermostat Knobs.
Release the Rear Retainer by undoing the two
screws.
Pull off all the PCB connectors.
Slide out the Thermostat.
Replacement is the reverse.
Condensate Pressure Switch
(See Fig. 13.0)
Undo the single fixing screw .
Pull off the two electrical connectors and transfer
to the new Switch. They connect to the ‘C’ and
‘NC’ connections.
Replacement is the reverse
Heater Components
The remainder of the parts can be accessed
through the front.
Heat Exchanger Flow Sensor
This is located on the front connection to the Heat
Exchanger . (See Fig.14.4)
Unclip the sensor from the connection.
Transfer the push on electrical connectors to the
replacement and clip back on.
Control Thermostat
This is located on the front connection of the Heat
Exchanger . (See Fig.14.4)
Unclip the sensor from the connection.
Transfer the push on electrical connectors to the
replacement and clip back on.
Overheat Thermostat (manual reset)
This is located on the front connection of the Heat
Exchanger . (See Fig.14.4)
Unclip the sensor from the connection.
Transfer the push on electrical connectors to the
replacement and clip back on.
Heat Exchanger Combustion
Temperature Sensor
This is located on the top of the Heat Exchanger, on
the right hand side. (See Fig.14.1)
Release the electrical connector by pressing the
latch and pulling up.
Twist the Sensor a quarter turn clockwise and
withdraw.
IMPORTANT Ensure the O ring seal is fitted correctly
to the replacement before fitting.
Replacement is the reverse.
Flue Thermostat (manual reset)
This is located on the Flue Adapter. (See Fig.14.1).
Pull off the electrical connectors.
Slide out from under the clip.
Replacement is the reverse.
Ignition Control (See Fig.14.3)
Undo the single screw holding the Ignition Control
cover.
Release the two electrical connectors by pressing
the latch and pulling apart.
Pull the Ignition Control away from the Gas V alve.
Replacement is the reverse.
Heat Exchanger Pool Sensor
This is located in a pocket in the ‘From Pool’ side of
the secondaryheat exchanger. (See Fig.14.6)
Pull out the retaining slipper , and pull out sensor .
Disconnect from the four way terminal strip on the
Electrical Chassis.
Replacement is the reverse.
Water Pressure Switch
This is located on the From Pool connection to the
Secondary Heat Exchanger and its removal will
require the draining or isolation of the Pool water in
the Heater. (See Fig.14.6)
Pull off the Electrical Connectors
Unscrew from the Secondary Heat Exchanger .
Replacement is the reverse.
If the Water Pressure Switch needs adjustment See
Page 12 for details.
Condensing Pool Heater 27 20/10/10
Gas Valve (See Fig.14.3)
Remove the Ignition Control, see above.
Release the Gascock by undoing the four shoul-
der bolts holding it to the Gas V alve.
Remove the Offset tube from the Gas V alve and
unscrew the Offset Connector and transfer to the
new Gas Valve.
NB Coil resistances, 2.8k and 1.6k ohms.
Release the Gas V alve from the Venturi by
undoing three screws. (See Fig.14.3)
IMPORTANT Ensure the rubber seal (and orifice if
Propane) is transfered from the old V alve and placed
between the V enturi and Gas Valve before assembly.
Replacement is the reverse.
Fire the Heater and check for gas leaks.
After five minutes check the rate and combustion
is correct to the Datatable. (inside cover). Adjust
using the throttle on the Gas V alve,
(See Fig. 14.3).
Fan (See Fig.14.2)
Remove the two electrical connectors on the Fan.
Remove the two screws holding the Venturi to the
Fan.
Undo the four nuts holding the Fan to the Heat
Exchanger and withdraw. (See Fig.14.2)
Transfer the Venturi gasket to the new fan.
Replacement is the reverse.
Venturi (See Fig.14.2)
Remove the Ignition Control and Gas Valve, see
above.
Pull off the Air Tube (See Fig.14.3)
Undo the two screws holding the Venturi to the
Fan and remove.
Ensure the gasket is transferred to the new
venturi or positioned on the Fan before positioning the replacement.
Replacement is the reverse.
Fire the Heater and check for gas leaks.
After five minutes check the rate and combustion
is correct to the Datatable. (inside cover). Adjust
using the throttle on the Gas Valve if required.
(See Fig.14.3).
3 Port Valve- Motorised Head
(See Fig.14.0)
Remove the Top Panel and Chassis cover.
Release the 3 wires supplying the 3 Port Valve
from the 6 way terminal strip on the Chassis.
Remove the Motor from the Valve.
Replacement is the reverse.
IMPORTANT. The following components require
the draining of the primary. It is recommended
that it is re-filled with Sentinel X100 Inhibitor and
it is essential that all the air is removed from the
Heat Exchanger before the Heater is fired. Running the Heater with air still in it will damage the
Heat Exchanger and invalidate the warranty.
3 Port Valve- Motorised Body
(See Fig.14.0)
Drain the primary waterside of the Heater.
Remove the Top Panel and Chassis cover.
Remove the Motorised Head from the Valve.
Release its pipe conections.
Remove the Expansion Vessel.
Remove the single screw retaining the Second-
ary Heat Exchanger mounting plate and slide out.
Remove the Valve.
Replacement is the reverse.
Heat Exchanger (See Fig.14.0)
Remove the Expansion Vessel
Undo the screws holding the panels around the
Pool Demountable connections. (See Fig.14.5)
Remove the spacer below the Secondary Heat
Exchanger by removing the single screw and
pulling forward.
Release both the Heat Exchanger Demountable
connections. (See Fig.14.5)
Lower the pipework away from the Heat Ex-
changer.
Remove the Front T op Panel and disconnect the
Flue Thermostat connections.
Pull the Air Duct and Flue up and away from the
Heater Flue Adapter.
Disconnect the Heat Exchanger Combustion
Sensor by pressing the latch and pulling off.
Remove the four screws holding the Rear Top
Panel.
Lift the Rear Top Panel with the Flue Adapter
clear of the Heat Exchanger.
Remove the Fan, Gas Valve and Ignition Control-
ler.
The Heat Exchanger is now only retained by the
two side brackets and releasing the four front
screws will enable it to be pulled forward. Before
releasing ensure there is support available.
Replacement is the reverse.
Pump (See Fig.14.0)
Drain the primary waterside of the Heater.
Disconnect the Pump mains lead from the six way
connector in the Electrical Chassis.
Undo the two water connections of the pump and
remove.
Transfer the mains lead to the new Pump.
Replacement is the reverse.
Secondary Heat Exchanger (See Fig.14.0)
Drain the pool side sufficiently so that the
Heaters Pool Connections can be released.
Remove the case Retaining Plates around the
Heater’s Pool Connections.
Drain the primary system with the draincock
provided. Ensure an air vent is open to fully
release the water.
Remove the Pool Sensor from the Secondary
Heat Exchanger.
Expansion Vessel (See Fig.14.0)
Remove the single screw holding the retaining
strap.
Release the flexible hose connection to the Vessel
and remove it
Replacement is the reverse.
Remove the Expansion Vessel.
Remove the single fixing screw holding the
Spacer below the Mounting Plate.
Pull out forwards the Spacer and remove.
Undo the primary Compression connections on
the Secondary Heat Exchanger and allow it to
drop off its connections and remove.
Remove the four screws fixing the Secondary
Heat Exchanger to its mounting plate.
Replacement is the reverse.
Condensing Pool Heater 28 01/07/09
Spares
Item Mfg’ Part Number Supplier Part No
Primary Heat Exchanger (Genie36) M2136 SPMBG001
Secondary Heat Exchanger M2745 SPMBG053
Propane Orifice (Genie 36) M2150 SPMBG014
Fan M2138 SPMBG003
Gas Valve M2140 SPMBG004
Ignition Control M2892 SPMBG063
Pool Thermostat PCB M2894 SPMBG064
Pressure Gauge M4240 SPCOH2/003
Water Pressure Switch 651284 SPCOH2/014
HT Lead M2142 SPMBG006
Condensate Syphon M2143 SPMBG007
Condensate Pressure Switch M2144 SPMBG008
Spark & Sense Electrode M2146 SPMBG010
Flue Thermostat M2875 SPMBG060
Control Thermostat M2667 SPMBG055
High Limit Water Thermostat M0868 SPMBC009
Pool Temperature Sensor M2798 SPCOH2/002
Ht Exchanger Flow Sensor M2149 SPMBG013
Genie Pump M2683 SPMBG056
3 Port Valve M4531 SPMBC058
Heat Exchanger Silicone Door Seal M2995
Expansion Vessel M3369 SPCOH103
Electrical Components
Condensate
Pressure Switch
Pressure Gauge
Pool Thermostat PCB
Retainer
Pool Thermostat PCB
Fig. 13.0
Condensing Pool Heater 29 28/04/10
Heater Components
Combustion
Sample Point
Flue Adapter
Flue Thermostat
Fig.14.1
Pump
Condensate
Pressure
Switch
Air Vent
Heat
Exchanger
Spark & Sense
Electrode
Fig.14.2
Heat Exchanger
Combustion
Temp Sensor
Fan
Fixing
Nuts
Fan
Venturi
Fan Electrical
Connectors
Fig.14.0
Safety Valve
Outlet
CH Return
Secondary
Heat
Exchanger
CH Flow
Condensate
Pipe
Demountable
Pool
Connections
Gas
Expansion
Vessel
Drain & Fill point
with NR & Isolation
valve
Gas Cock
Shoulder
Bolts
Pool
sensor
Condensate
Syphon
Fig.14.3
Air Tube
Venturi
Throttle
Offset
Tube
Gas Valve
HT Lead
Ignition
Control
Fig.14.4
Hi-Limit
Thermostat
Heat Exchanger
Flow Sensor
Fig.14.6
Fig.14.5
Condensing Pool Heater 30 01/07/09
Water Pressure
Switch
Safety Valve
Control
Thermostat
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Condensing Pool Heater 31 01/07/09
INSTALLATION & SERVICE HISTORY
Tick appropriate:
Model Gas
Genie 36 Dual NG LPG
Commissioning
Installer Registration No Date:
Working pressure mbar
CO ppm CO2%
Instructed User in operation? Yes/No
Service History
Date
Cleaned ?
Pressure
CO
CO2
Date
Cleaned ?
Pressure
CO
CO2
Date
Cleaned ?
Pressure
CO
CO2
Condensing Pool Heater 01/07/09
01/07/09
St ation Lane
Industrial Estate
Witney
Oxon.
Tel. 01993 778855
Fax. 01993 703407
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