Page 1
Operating, Installation and Servicing Instructions for
Indirect fi red condensing pool & spa heaters
M2709D
Models: MB20S, MB35S, MB50S
Genie
WARNING: If the information in these instructions are not followed exactly, a fi re
or explosion may result causing property damage, personal injury or death.
Do not store or use gasoline or other fl ammable 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, service
agency or the gas supplier.
Page 2
PERFORMANCE SPECIFICATIONS
GAS CATEGORY, TYPE AND SUPPLY PRESSURE II
2H3P
G20 @ 20 mbar
G31 @ 37 mbar
NATURAL GAS PROPANE
MODEL MB20S MB35S MB50S MB20S MB35S MB50S
Corgi Work Code TBA 1036909 1036910 TBA 1036913 1036914
HEAT GROSS kW 21.5 38.0 51.5 23.1 38.0 51.5
INPUT Btu/h 73,305 129,650 179,100 78,941 129,650 179,100
NET kW 19.5 34.2 46.4 21.3 35.0 47.5
Btu/h 66,392 116,700 158,300 72,842 119,400 162,000
TYPICAL EFFICIENCY % gross 92 - 94 92 - 94 92 - 94 92 - 94 92 - 94 92 - 94
% net 102 - 104 102 - 104 102 - 104 102 - 104 102 - 104 102 - 104
HEAT kW 20.0 36.9 50.0 21.5 36.9 50.0
OUTPUT Btu/h 68,175 121,870 165,170 73,415 121,870 165,170
GAS RATE (NG, Propane) m3/h 1.98 3.45 4.64 0.87 1.43 1.9
MAXIMUM RATE, CO ppm 20 - 60 120-150 80-120 35 - 70 130-160 100-130
COMBUSTION SETTINGS, NG, CO2 % 8.7 - 8.8 8.9 - 9.1 8.9 - 9.1 9.9 - 10.1 9.5 - 10.5 9.5 - 10.0
OFFSET SETTING pA -3.0 -3.0 -3.0 -3.0 -3.0 -3.0
ORIFICE mm Not required 4.4 4.4 5.2
GENERAL SPECIFICATIONS
WATER CONTENT MB20S & MB35S/MB50S 3.0 Litres / 4.0 Litres
WEIGHT (net) MB20S & MB35S/MB50S 53 kg / 55kg
DIMENSIONS, OVERALL 375 mm wide, 520 mm deep, 980 mm high
SERVICE CLEARANCE 300mm Left, Right and Above. 800 mm Infront
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 32°C (90°F) Spa 41°C (106°F)
ELECTRICAL SUPPLY 230V 50Hz, FUSED AT 5A, 130W
PROTECTION LEVEL IP44
FLUE SYSTEM 80/125 PP, to a max. Flue Equivalent Length of 20m
TECHNICAL DATA
GB, IE
Page 3
Condensing Pool Heater Genie S
TECHNICAL DATA Inside cover
User Instructions 1
INTRODUCTION 3
Heater Location 3
Gas Supply 4
Conversion 4
Flueing 4
Air Supply 4
Outdoor Heaters 4
Flue Terminal Position 5
Condensate Drain 6
Pool Pump & Pipework 6
Winterisation 6
Electricity Supply 6
INSTALLATION OF HEATER 7
Procedure 7
Outdoor Terminal 7
Flue Systems 7
Wall Terminal 7
Flue Examples 12
Roof Terminal 12
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 24/26
SERVICING 25
Routine Service 27
Changing Components 27
Spares 30
Heater Components 31
List of Figures
Page
Fig 1.0 Flue Terminal Positions 5
Fig 2.0 Hydraulic Resistance Graph 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 Orifi ce Position 13
Fig 6.2 Gas Valve Tappings 14
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 Button 16
Fig 8.2 Heat Exchanger Sight Glass 16
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 19
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 27
Fig 13.0 Electrical Components 30
Fig 14.0 Heater Components 31
Section Page
Contents
Page 4
Condensing Pool Heater Genie S
Before Start Up
Keep heater area clear and free from combustibles,
fl ammable liquids and chemicals.
Pool water must be fl owing 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
switch on the Front Panel and set the desired temperature with the Pool Temperature Knob. In a few
seconds the Heater will fi re.
Summary of Controls (Left to Right)
Pressure Gauge - This should be between 1.5 to
2.5 bar, repressurise if too low.
ON/OFF Switch - Turns the Heater On and Off .
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 fl ashes the Set
temperature.
It also resets Gas Control lockouts, GAS and OH2.
Pool Temperature Display - This normally
shows the Pool Temperature but also shows the
Setting Temperature when the Pool Temperature
Control Knob is moved. The Display is also used for
commissioning and diagnostic purposes. (Page 17)
If the display alternates the temperature with ‘SEr’ it
is recommended that the Heater is serviced. In the
mean time the heater will continue to function.
1
Genie USER’S OPERATING INSTRUCTIONS
FOR YOUR SAFETY - READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION
MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
This appliance is equipped with an ignition device
which automatically lights the burner.
BEFORE OPERATING after a prolonged time off ,
smell all around the appliance area for gas. Be
sure to smell next to the fl oor because some gas
is heavier than air and will settle on the fl oor.
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 fi re 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 qualifi ed 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 confi ned areas, extra care should be exercised
when lighting Propane heaters.
WARNING: There are no user serviceable items
in this appliance. Do not interfere with any sealed
components.
IMPORTANT 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.
On/Off Switch
Reset/Lock
Button
Temperature
Display
Pool Temperature
Control Knob
Pressure
Gauge
Page 5
Condensing Pool Heater Genie S
2
Pool Demand LED - Green
Off - There is no pool heating demand.
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.
Pool Temperature Control Knob
16°C to 32°C (60°F to 90°F)
(Maximum is changed in Setup Mode, see Page 17)
Rotate clockwise to increase the pool temperature.
The setting temperature is shown whilst rotating the
control knob and when released fl ashes 3 times to
confi rm setting..
To lock the required temperature setting see
Lock/Reset button Page 1
Pool Pump Pressure
- Yellow LED, Display, Pool Temperature
On - If the pump is operating and there is insuffi cient
pressure, possibly due to a blocked pool fi lter. The
heater will not operate.
Overheat - Flashing Red LED, Display “OH2”
Flashing - This indicates the heater has overheated
and it has shutdown. Wait for the heater to cool then
press the Lock/Reset button to start the heater again.
If this problem persists this should be investigated by
a service engineer.
Overheat - Red & Yellow LED, Display “GAS”
On - This indicates the Heater Gas Ignition Control
has locked out. Press the Lock/Reset Button to start
the Heater again. If this problem persists this should
be investigated by a Service Engineer.
Condensate - Display “HI”
This indicates that the condensate drain is blocked
and the heater has shutdown. When the blockage is
cleared, the heater will operate again.
Water Pressure Switch
A water pressure switch is provided in the heater
to shut off the burner in the event that water supply
is interrupted. The water pressure switch should
be checked and adjusted for proper operation by a
qualifi ed service person at the time of installation,
and thereafter checked at each service.
Operation without water circulation may
cause rapid and severe damage to the
heater.
Water Temperature Settings
The heater is designed to provide maximum heat
output up to one degree below the set point. Power is
reduced for the last one degree to maximise control.
For some installations, if the pool is used before it is
up to set point, the water entering the pool from the
heater could be noticeably warmer than the pool.
This is not a fault but part of the design. It will reduce
for the fi nal degree up to set temperature.
CAUTION: Elevated water
temperature can be hazardous.
It is important to follow these
guidelines:
1. Spa or hot tub water temperatures should never
exceed 40°C (104°F). A temperature of 38°C
(100°F) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and drowning.
3. Pregnant Women Beware! Water over 38°C
(100°F) can be dangerous, especially during the
fi rst three months of pregnancy. Please seek
medical advice before using pools and hot tubs.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer.
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pressure
problems should obtain a doctor’s advice before
using pools or hot tubs.
6. Persons taking medications which induce drowsiness, such as tranquilizers, antihistamines, or
anticoagulant, should not use spas or hot tubs.
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 & Anti-freeze Inhibitor
As supplied the heater includes a dose of Sentinel
X500 anti-freeze/inhibitor. Subject to not being removed or diluted, the appliance is protected to -10oC.
If the primary circuit of the appliance is drained for any
reason, the correct quantity of new anti-freeze/inhibitor
must be added to give the level of protection required.
The swimming pool water is not protected against
freezing. Please contact your pool installer for guidance on how to protect this pool heater from damage
caused by frozen pool water.
Failure to follow these guidelines could cause
damage to the heater which will not be covered by
warranty.
Page 6
Condensing Pool Heater Genie S
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 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.T. Wiring Regulations, the Local Building
Regulations, Building Standards (Scotland), the Bye
Laws of the Local Water Undertaking, any relevant
requirements of the Local Authority.
Detailed recommendations are contained in the following British Standard Codes of Practice.
Codes of Practice.
BS.6798 Installation of gas fi red hot water boilers of
rated input not exceeding 70kW.
BS.5440: Part1 and Part 2. Flues (for gas appliances
of rated input not exceeding 70kW).
BS 6891 Specifi cation for installation of low pressure
gas pipework.
BS5482:1 Code of practice for domestic butane &
propane gas burning installations.
Building Regulations Part L1.
IMPORTANT.
No external control devices should be 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.
Location of Heater
The Heater MUST be installed on a fl at and level
fl oor, capable of adequately supporting the weight of
the Heater and any ancillary equipment.
Provision is provided for the heater to be fi xed to the
fl oor.
It is IP 44 Rated and can be installed out of doors in
a suitable position. In all cases the choice of position
should take into account the fl ue, the plume and the
condensate drainage.
INTRODUCTION
These Instructions cover a range of indirect, fl oor
mounted, gas fi red, condensing pool heaters which
are room sealed and fan assisted. The fl ue 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.
There are three models with diff erent outputs - see
the Technical Data on Inside Cover for details.
These models can be installed in multiples to obtain
a larger, combined output.
The casing is of green and black polyester powder
coated mild steel. The Heaters use a high performance Cupro Nickel heat exchanger and are suitable
for connection to pools using chlorinated and salt
chlorinated 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
All chemicals must be introduced and completely
diluted into the pool water before being circulated
through a fi ring heater. Do not place chlorine tablets
or bromine sticks in the skimmer, high chemical concentrations will result when the pump is not operating. 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 .
High chemical concentrates from feeders
and chlorinators that are out of adjustment
will cause corrosion to the heat exchanger
inside the appliance. Such damage is
not covered under the warranty.
3
Page 7
Condensing Pool Heater Genie S
Conversion
For countries permitted to use diff erent gases the
appliance is supplied setup for the primary gas. It
can be converted to the alternative by the addition
of an Orifi ce which is supplied with the heater. See
page the inside cover for the data and Page 12 for
conversion instructions.
Flueing
Only fl ue components specifi ed by the Manufacturer
should be used with these appliances. Detailed recommendations for fl ueing are given in BS.5440: The
following notes are intended for general guidance.
1. Be aware of the plume from the fl ue and the
wetting eff ect it can have to adjacent property.
see Flue terminal location diagram 1.0 page 5,
2. The fl ue can be taken upwards, left, right or to
the rear of the appliance, but never downwards.
3. The Heater is supplied separate to the chosen
fl ue set. It can be fi tted with up to 20 metres
equivalent length of Concentric fl ue, see pages
8 - 11 for fl ue examples and parts selection.
4
IMPORTANT
If the Heater is to be fi tted in a timber framed building it should be fi tted 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.T. 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 installation will be in an unusual location then
special procedures may be necessary and BS.6798
gives detailed guidance on this aspect.
A compartment used to enclose the Heater MUST
be designed and constructed specially for this
purpose. An existing cupboard, or compartment,
may be used provided it is modifi ed 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 fl ue termination.
3. This position MUST also permit the provision of a
satisfactory connection to the condensate drain.
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 installation
and obtain a working pressure of 20 mbar (NG), 37
mbar (Propane) 29 mbar (Butane). Installation pipes
should be fi tted in accordance with BS.6891.
A Natural Gas Heater must be connected to a governed meter.
ESSENTIAL
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 infi ltration 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
These Heaters are certifi ed 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.
Page 8
Condensing Pool Heater Genie S
Minimum Distance mm
A Directly below an opening, air brick, opening window etc. 300
B Above an opening, air brick, opening window etc. 300
C Horizontally to an opening, air brick, opening window etc. 300
D Below a gutter or sanitary pipework 75
E Below the eaves 200
F Below a balcony or carport roof 200
G From vertical drain or soil pipework 150
H From an internal or external corner 300
I Above ground, roof or balcony level 300
J From a surface or a boundary line facing a terminal 600
K From a terminal facing a terminal (Horizontal fl ue) 1200
K From a terminal facing a terminal (Vertical fl ue) 600
L From a opening in a carport (e.g. door, windows) into the building 1200
M Vertically from a terminal on the same wall 1500
N Horizontally from a terminal on the same wall 300
R From an adjacent wall to fl ue (Vertical only) 300
S From an adjacent opening window (vertical only) 1000
T Adjacent to windows or openings on pitched and fl at roofs 600
U Below windows or opening on pitched roofs 2000
Fig. 1.0
5
Flue terminal positions
Page 9
Condensing Pool Heater Genie S
Winterisation
Turn off the Mains electricity and Gas Supply.
As supplied the Heater includes one litre of Sentinel
X500 Inhibitor/Anti-freeze, this is suffi cient to protect
the Heater down to -10°C. It is recommended that
this is maintained and so should be replenished if
there is a loss of primary water. See Fig 14.0
Draining the Heater can be achieved by fi tting 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
Electricity Supply
Wiring external to the appliance MUST be in accordance with the current I.E.T. Wiring Regulations and
any Local Regulations that apply.
The Heater is supplied with a plug and lead for 230V
~ 50Hz. Single phase. Fuse rating is 5A.
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.
Where a Heater is installed in a room
containing a pool or shower, the appliance,
any electrical switch or appliance control
utilising mains electricity should be so
situated that it cannot be touched.
6
Condensate Drain
See Fig. 7.0, and 7.1
A 75mm condensate trap is provided on the Heater
and is satisfactory when connected to Soakaways,
Gullies, Rainwater Pipework and Internal Drainage
systems. All pipework and fi ttings 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 & Pipe work
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 Heaters 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 fi tted 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 permissible to fi t an isolating valves on the pipework on either side of the Heater. In these circumstances it is recommended to fi t a fl ow switch in the
Heaters Mains supply.
Fig. 2.0
Page 10
Condensing Pool Heater Genie S
Space required for installation and
servicing:
Left, right and above 300mm
Front 800mm
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 fl oor using the holes pro-
vided in the front channel.
3. The Heater is provided with an Electrical Plug and
lead. This can be connected to a suitable supply
as detailed on Page 5. If it is required to separately time the operating of 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 Mains lead and link wire with a
Permanent and Switched live supply.
See Fig 11.0
4. Pipe to the 22mm gas connection. A gas isolating
valve is provided on the Heater Gas Valve.
5. Plumb to the Pool Pump and Filter.
6. Fill Primary system with water using the supplied
hose connector. The Heater is supplied with one
litre of Sentinel X500 Inhibitor/ Anti-Freeze in the
pipework.
7. IMPORTANT. Remove the air from the primary
through the Air Vent on the right-hand Side Panel
and the Vent on the top of the Primary Heat Exchanger. (See Fig 8.0) by operating the internal
pump in short one second bursts, venting, then
pumping, until it has all been removed. There is
a special button (See Fig. 8.1) for operating the
pump on its own, under the chassis on the pressure gauge side. To operate the Mains must be
connected and on.
8. Test for leaks.
9. Replace the Electrical Cover and Panels.
Assembly of the Outdoor Terminal
A specifi c 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 fi t
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.
7
All Other Flue Systems
The maximum Flue Equivalent Length (FEL) permitted is 20 metres, horizontal or vertical. The component parts have the following FELs:
1 metre of concentric fl ue 1.0
2 metres of concentric fl ue 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 of the Flue Equivalent Lengths used in
the design this must not exceed 20 metres.
All items assemble by a push fi t/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 fl ues should incline back to the Heater by
3 degrees (5mm in 100mm)
Wall Terminal
The Horizontal Wall Terminal is supplied with two
rubber wall plates, 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
fl ue hole on the wall is determined by the distance of
the heater 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.
Fig. 3.0
INSTALLATION OF HEATER
Page 11
Condensing Pool Heater Genie S
Heater Dimensions
Pipe Connections
& Locations
8
Fig. 3.1
Dimensions
Model A B C
Genie 20 / 35 138mm 226mm 361mm
Genie 50 170mm 258mm 425mm
D
E
Connections
D Multi Heater Connection
E Electric & External Control (CCP01)
F Gas Supply - 22mm Copper
G Safety Valve Outlet - 15mm Copper
H Condensate Drain - 1¼” or 40mm Hunter Plastic
I From Pool - 1½” / 50 mm Plastic Demountable Fittings
Fig. 3.2
Service Access
Left, Right or Above 300mm
In Front 800mm
Rear Flue Left/Right Flue
Horizontal Wall Terminal
Dimensions
Horizontal Wall Terminal
(MBHT)
F
G
H
I
374
78
90
134
A
B
307
C
533
SW
WT
WT 136
188
1000mm
Page 12
Condensing Pool Heater Genie S
Outdoor Terminal
Dimensions
9
Fig. 3.3
Outdoor Flue Terminal
(MBOT)
Fig. 3.4
Clamp Assembly Screw
Pitched Roof Installation
Vertical Roof Terminal
Dimensions
Flat Roof
Installation
Use Seldeck Flashing
System for all Roof
Installations
Vertical Roof Terminal
(MBVT)
1 metre Horizontal/
Vertical Extension Pipe
(MBHVE)
45 degree bends
(MB45DB)
Page 13
Condensing Pool Heater Genie S
10
Flue Examples
Flue Kit Part Codes
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
Outdoor Terminal
Extended Horizontal
Wall Terminal
Extended Vertical
Roof Terminal
Horizontal Wall Terminal
MBOT
MB90DB
MBHVE
MBHT
(not shown)
TO OFFSET
USE MB45DB
MB90DB
MBHT
(not shown)
MBVT
MBHVE
TO OFFSET
USE MB45DB
Fig.4.3
Fig.4.0
Fig.4.1
Fig.4.2
Determine the type of Flue system you require and
choose from the list of kits available below:
Page 14
Condensing Pool Heater Genie S
11
Flue Kit Part Codes (cont.)
Kit Code Description FEL Photo of Kit
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
MB90DB 90 degree bend 1.5m
Flue
Equivalent
Length (m)
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)
(per bend)
Page 15
Condensing Pool Heater Genie S
12
Terminal Guard
The fl ue products from this appliance are very
low temperature so a guard is only required if the
terminal is in a position where it may be damaged.
A suitable guard is available from:
TFC Ltd. 01732 351555, Model DK6
Roof Terminal
The Vertical Roof Terminal should be fi tted 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 fl ues are completed
before their connection to the Heater. This will
ensure that any debris that gets into the fl ues
can be cleared.
2. That bends in vertical fl ues 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.
Plumbing
The heater requires water fl ow and pressure to operate properly. It must therefore be installed downstream of the fi lter and pump. A typical installation is
plumbed as follows:
1. The Pump outlet is plumbed to the inlet of the Filter.
2. The outlet side of the Filter is then plumbed to the
inlet of the Heater.
3. The outlet of the Heater is plumbed to the return
line to the pool or spa. The Pump, Filter and Heater
are plumbed in series.
If it is necessary to install a valve on the return to
the pool then it is recommended that a fl ow switch
is installed and interlocked with the Heater supply.
The Heater must be located so that any water leaks
will not damage the structure of adjacent area. The
heat shunt connections of the Heater, can be made
in standard plastic 1½” or 50mm pipe supplied demountable.
Use the pressure loss chart on page 6 to specify 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
Fig. 5.0
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 after the change.
Flow Rate
The Heaters have a very low resistance to the
Pool Water fl ow and will tolerate a wide range of
fl ows.
The minimum recommended fl ow 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 fl ow is interrupted.
It has an adjustment range equivalent to ±1.5 metres. The switch is factory set for most conditions
but can be altered if required:
1. With the pump on turn the knurled nut clock-
wise 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.
Page 16
Condensing Pool Heater Genie S
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 away from the venturi.
3. Fit the conversion orifi ce into the rubber seal that
sits in the gas valve. (See Fig.6.1)
4. Re-assemble the gas valve and venturi.
5. Affi x the new LPG serial number data label supplied over the existing.
6. Turn gas on and check for leaks.
7. If converting an MB50S initially turn the throttle
adjustment screw four turns anti-clockwise
8. Operate heater and if necessary turn the throttle
screw anit-clockwise another turn until ignition is
achieved.
9. Allow fi ve minutes for the heater to warm up before checking and adjusting the CO2. Adjust using
the throttle screw to the values on the data plate.
10. Replace the dust cover over the throttle, when
adjustment is complete.
LPG to NG Conversion
The method is as detailed above except the steps are
reversed (if converting an MB50S remember to initially turn the throttle screw fi ve turns clockwise before
operating the heater).
The orifi ce is removed and the venturi and gas valve
reassembled with just the rubber seal between them.
A new serial number data plate should be obtained
from the manufacturer and affi xed over the existing.
Gas Connection
The 22mm copper gas connection provided can be
positioned to exit the Heater from either the left or the
right. A minimum of 20mb. (NG), 37mb (propane) 28
mbar (butane) must be available at the Heater inlet,
with the Heater and other connected appliances fi ring.
NB: If the gas valve test point is used there is a
2-2.5 mbar drop for the Genie 50 at full rate.
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
fl uid. Check the maximum rate and combustion are to
specifi cation.
See Table 6.0 and Data table Inside Cover.
Rating Table (38.8Mj/m3)
13
kW
gross
Btu/h sec/ft
3
m3/2 mins
7.5 25,590 145 0.023
12.5 42,650 87 0.039
20 68,240 55 0.062
34.6 108,055 31.5 0.107
52 177,420 21 0.161
Table 6.0
Inlet pressure
tapping
Off set
connection
Fig. 6.0
Fig. 6.2
Throttle
Adjustment
Fig. 6.1
Orifi ce in position
Page 17
Condensing Pool Heater Genie S
14
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 fi t 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 fi tted in pipework that includes another trap
or a pump, for example the fi lter backwash pipework
to drain, an Air Break should be fi tted 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-fl ow 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 help prevent the condense liquid 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 fl ue and check it emerges at the
drain. This will also fi ll 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.T. 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 5A fused isolating switch with a
contact separation of 3mm minimum on both poles.
The cable used should be no less than 0.75mm
2
to
BS.6500 PVC, 3 core, and fi xed 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 fl exible 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
SL Switched Live
L Permanent Live
A factory installed link has been fi tted between SL
and L which should be removed if the Heater is to
have its own switched supply.
For systems using an external programmer, the
electrical wiring should follow the relevant control
manufacturer’s recommendations, with the switched
live from the controls returning to SL in the 4 way
push-fi t connector.
It is possible to connect several Heaters together
using the Multiple Heater Kit. Details for the parts
and installation of this kit are given on Page 18.
Page 18
Condensing Pool Heater Genie S
Example Condensate Disposal Methods
Condensate
Drain from
Heater
Condensate Pressure
Switch Pipe
Connection
Connect To
Waste
(Option to
exit Heater
left or right)
Drain Cap, (behind vessel)
can be removed for
Winterisation
Condensate Syphon (75 mm)
15
Fig.7.1
Removable Plate
(Use to close off
unused Waste exit
on panels)
1:20 Fall ( 2.5 Degrees )
Strap-On
Boss
200mm Land Drain
Filled with Lime
chippings 400mm
deep
Insulate against
freezing
Note: Do not reduce the pipe size below the 40mm provided.
Fig.7.0
Soakaway
Stack Attachment
Soil Pipe or
Drain
Page 19
Condensing Pool Heater Genie S
16
Fig. 8.2
Commissioning
IMPORTANT The heater primary circuit
contains Sentinel X500 inhibitor/anti-freeze.
The minimum water should be released
during fi lling 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 fi rst operated with the
GAS OFF until the air has been purged.
If air has not been released then there is a possibility 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 vent is a standard radiator vent in the righthand Side Panel.
A button has been provided to just operate the internal
pump (See Fig 8.1) to aid de-aerating. Mains connection to heater required. See Page 6 for more details.
Commissioning Procedure
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, enter User Setup Mode.
(See Page 17)
The boiler is factory set for Natural Gas and fi tted 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 modifi ed as
described on page 12.
Fig. 8.0
It is recommended that the condensate trap is full of
water before fi ring. 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 locks 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 Tech-
nical Data on Inside Cover for details.
The heater is factory set and should not require adjustment. When the heater has been operating for at least
10 minutes check all joints, gas and water, for leaks, and
correct where necessary.
When operating satisfactorily, complete the commissioning details on the inside back page of these instructions.
The boiler is fi tted 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 pipe work 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 operate.
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.
Fig. 8.1
Button
Page 20
Condensing Pool Heater Genie S
17
User Setup Mode
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.
Lock/Reset
Button
On / Off
Switch
Temperature
Display
Pool Temperature
Control Knob
Fig. 9.0
User Setup Mode Setting Factory Setting Alternative Display Indicator
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 Software Version e.g 020
Pressure
Gauge
Page 21
Condensing Pool Heater Genie S
Kit Part Codes:
2 Heaters: MBMIK2
3 Heaters: MBMIK3
4 Heaters: MBMIK4
5 Heaters: MBMIK5
6 Heaters: MBMIK6
7 Heaters: MBMIK7
8 Heaters: MBMIK8
Multiple Heater Kit
Adapter PCB
Connectors
Photo 2
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 operating 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.
18
Fig. 10.0
Installation Instructions
Disconnect the Heater from the Mains then
remove the Top Panel and the Electrical Chassis
Cover.
Remove Pool Thermostat Control Knob
Remove Pool Thermostat Board by removing
retaining plate and carefully slide out until fully
accessible. (Fig. 10.0)
Carefully fi t the Adapter PCB in the space behind
the Pool Temp. Display on the Board (Fig. 10.0)
ensuring that the six pins on the Board pass
through the underside of the Adapter PCB
and, that the plastic locking pillars snap into
place. Refi t Pool Thermostat Board and Knob.
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 fi rst and last
Heater in the ‘chain’ will use the Terminator Plugs
to fi ll their 2 unused sockets. There are 2 diff er
ent coloured Terminators, they can go in either
the fi rst 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 six 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.
Interconnection Cables
Fig. 10.1
Fig. 10.1
Page 22
Condensing Pool Heater Genie S
Operation
• Turn on all the Heaters with their Pool Temperature Controls.
• The Master will show temperatures and the
Slaves will show “---”.
• Set the required temperature on the Master and
provided there is an electrical demand at the
Master’s Pool Demand connection, the Heaters will operate.
Features
• A Master is the only Heater with a Pool Sensor
connected, move the sensor and the Master
changes.
• If the Master Pool Temperature Control is
turned off , none of the Heaters will operate.
• If a Slave’s Pool Temperature Control is turned
off it will not operate. The Master will know and
alter its control accordingly.
• If a safety device on the Master operates it will
not operate 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
operate again.
• If a safety device on any of the Slaves oper-
19
• 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 display of dashes, this indicates it not correctly connected to the Master, check the Interconnection cable plugs are fully home.
• Replace the panels.
Fig. 10.2
ates that Slave will not operate.
• If a Slave has Flow fault which its Pressure
Switch detects the burner will stop immediately
and the Filter LED will light. It will no longer be
available to the group. It will then check every
3 minutes or so to see if the problem has been
corrected, the Filter LED be lit. It will put itself
back in the group if fl ow is satisfactory.
• The Master display can be altered in Setup
Mode like a single Heater. (see Page 17)
• Unlike a single Heater, there is no modulation
of individual burners.
Displays
• The Master display is just like a single Heater.
• A Slave will display “---” when working as part of
the group. It will show all the fault conditions of
a single Heater except “P/oc”, the Pool Sensor
Open Circuit fault. If this is displayed it indicates
an interconnection problem, check the cables
and connectors.
• The Pool Demand LEDs work as a Single Heat
er. On when operating, 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
Page 23
Condensing Pool Heater Genie S
Wall Mounting Kit
Overview
The Genie models 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 53kg).
• 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 3 M4 screws supplied
(Fig 10.5).
• Attach the Bottom Wall Mounting Bracket to the
rear of the Heater by using the existing 3 gold
screws that fi x 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)
20
Fig. 10.4
Fig. 10.3
476
376
HEATER
OUTLINE
TOP WALL
MOUNTING
BRACKET
HORIZONTAL
WALL
TERMINAL
CORE DRILL
POSITION
BOTTOM WALL
MOUNTING
BRACKET (FITTED TO
HEATER BEFORE
WALL HUNG)
FLOOR
DRILL HOLES AFTER
HEATER HAS BEEN
WALL HUNG
5MM STUD (2 PLC'S)
HEATER CABINET WIDTH
Page 24
Condensing Pool Heater Genie S
21
Fig. 10.5
BOTTOM WALL MOUNTING BRAKET
REMOVE DEMOUNTABLE
POOL FITTINGS FOR BETTER
DRILL ACCESS
TOP WALL
MOUNTING BRACKET
LOCATING STUDS
(2 PLC'S)
GOLD SCREWS SUPPLIED (3 PLC'S)
M4 SCREWS
SUPPLIED (3 PLC'S)
TOP HANDLE BRACKET
Page 25
Condensing Pool Heater Genie S
Fig.11.0
22
Schematic Wiring
Page 26
Condensing Pool Heater Genie S
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.T.
Operation
The Heater requires mains on both the Live (L) and switched live (SL) connection to be able to operate. It is
delivered with a link between them which can be removed if a separate heater switched live is going to be used.
To operate, the heater must have a mains supply, gas supply, pool pump pressure suffi cient to activate the
pressure switch, all safety switches closed and a pool temperature below the set point.
If all the above are correct then the gas ignition control starts the ignition sequence:
1. The fan and internal pump operates as a pre-purge of the heat exchanger.
2. After a few seconds a spark is created at the electrode and the burner is lit.
3. The burner fl ame is sensed and the spark is removed.
4. The Fan speed is then changed to the required speed according to the modulation curve.
5. If it fails to light the burner the spark will stop and the fan and internal pump will operate on as a post-purge
of the heat exchanger.
6. The ignition sequence will be repeated up to fi ve times, then the control will lockout and will require a reset
to start again.
Safety Controls & Lockouts
The pool thermostat control indicates the actual and set temperature of the pool and also displays all the lockouts. The next pages detail the fault conditions, the indicators, the display and the actions required.
User Setup Mode
Turn off on the panel switch. Turn on with the panel switch whilst pressing the Lock/Reset Button.
The controls are 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 thermostat
potentiometer. To zero or change them, press the Reset/Lock button
To exit, turn the Panel Switch off then back on again.
23
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 fl ash rapidly.
4. Heat Exchanger Combustion Temperature. The Red LED will fl ash 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.
FAULT FINDING
Service Mode Setting Factory Setting Reset press Display Indicator
1 Pressure Log Number of Operations Resets to zero Yellow LED ON
2 Unused Red LED ON
3 Combustion Gas Log Number of Operations Resets to zero Count, Red LED fl ashing
4 Gas Lockout Log Number of Operations Resets to zero Count, Red & Yellow LED ON
5 Condensate Blocked Log Number of Operations Resets to zero Count, Front Red PCB LED ON
6 Unused Rear Red PCB LED ON
7 Hours run 0 Resets to zero 156 =1560 hrs, both PCB LEDs on
8 Pool Temperature Off set 0.5 C (0.9 F) Steps of 0.5C (0.9F) -3.0 to 3.0 (-5.4 to 5.4)
9 Display td0 td1 td0 / td1
Page 27
Condensing Pool Heater Genie S
Fault Codes
24
LOCK / RESET
GREEN
YELLOW
RED
LED1
RED
RED
LED2
Operating, raising pool temperature to 28°C
Up to temperature, 28°C
Insuffi cient water pressure. Filter?, Blockage?
‘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 Stat tripped.
Investigate cause. Reset on Flue Stat
OFF, no mains supply or failed power supply
Flashing
‘HI’ Condensate level high. Blocked? Clear
obstruction and allow control to auto reset .
‘SEr’ alternating with pool temperature. Service
required, working hours has reached setpoint.
Page 28
Condensing Pool Heater Genie S
Fault Codes
25
LOCK / RESET
GREEN
YELLOW
RED
LED1
RED
RED
LED2
‘P’ alternating with ‘oc’ = Pool sensor open circuit OR No net-
work detected if a Master in a multiple heater installation
‘P’ alternating with ‘cc’ = Pool sensor short circuit
For all of the above. Turn off , correct problem and turn back
on again and the display and operation will be normal.
Page 29
Condensing Pool Heater Genie S
Replace CVBC on
gas valve. Check for
bent pins. Fault will
self clear
Is wiring and con-
nections between
CVBC and fan OK?
YES
Is gas being re-
leased by the gas
valve?
Check
wiring /
Replace gas
valve
Suspect CVBC
to be at fault
Replace Gas
valve. Fault will self
clear
Is CVBC seated
on gas valve
c o r r e c t l y ?
Is continuity of gas
valve coils OK?
V1 = 2.8k
V2 =1.6k
Are there any
faults in the wir-
ing or connec-
tors?
Rectify fault. Fault
will self clear
Suspect CVBC
to be at fault
Replace CVBC
NB - A fault involving the Gas valve circuit will
occur even if there is no heating demand. Reset
appliance when there is no heat demand to iden-
tify a fault of this nature. Once corrected, there is
no need to use the reset button, as the fault will
self clear.
Have either
the Flue gas or
Water fl ow tem-
peratures been
exceeded?
With main power
off push the red
reset buttons on
the Flue and Flow
limit devices.
Investigate cause
of overheating.
Are overheat
limit devices
working cor-
rectly?
Check limit
devices are not
open circuit.
Replace faulty limit
devices.
Are connec-
tors and wiring
between the
CVBC and limit
devices OK?
Replace faulty wiring
as necessary
Ensure wiring at
the connections
to the CVBC are
in good condition.
Suspect CVBC
to be at fault
Replace CVBC
Fan runs throughout Fan does not run
Does appliance reach
ignition stage (can you
hear the spark)?
Is appliance earth-
ing, the condition and
connection of electrode
and lead OK?
Replace faulty parts
Replace CVBC
Replace fan
NB - A fault involving the high limit circuit will occur even if
there is no heating demand. Reset appliance when there is no
heat demand to identify a fault of this nature. Once corrected,
the reset button will need to be pushed, as this fault will not self
clear.
NB - A fault involving the fan circuit or ignition circuit can
only occur if there is a heat demand. Once corrected, the
reset button will need to be pushed, as this fault will not self
clear.
NB - A fault in the ionisation circuit will be identifyable when
the ignition cycle is repeated 5 times.
26
Page 30
Condensing Pool Heater Genie S
SERVICING
Routine Service
To ensure continued effi cient 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
2,000 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. Check condition of ignition spark and sensing
probe.
3. Check boiler pipework joints for leaks.
4. Check the Air duct and Flue seals.
5. Check condensate syphon and pipework for leaks.
6. Check the Gas Rate.
7. Check the combustion CO and CO2.
8. Reset the Service Hours counter in the control.
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 Electricity 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:
• Remove Door and Front Top Panel
• Disconnect Gas cock fl ange form Valve.
• Unplug Fan electrical connectors.
• Remove Air tube from Flue Adapter.
• Undo cover over Ignition Control connections
and remove the two connectors.
• Pull off the Earth Lead connection on the Valve
and Heat Exchanger.
• Undo the four nuts holding the Heat Exchanger
front and withdraw.
• Assembly is the reverse.
• Reset the Service Hours Counter. (See Service
Mode, page 23)
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. (See Fig 12.0)
• Assembly is the reverse, ensure the gasket
is correctly placed.
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 fl exible
Air Duct to the Venturi.
Gas Rate & Combustion
See the Data table on Page 1 for the correct values.
A Combustion sample point is provided on the front
of the Flue Adapter. (See Fig.14.1)
Changing Components
There is only one fuse, the remainder
of the controls are not repairable and
if not operating must be replaced.
In all cases, before work commences turn off the
Mains Electricity and Gas Supply.
The following items can be replaced:
• Fuse, 24V supply.
• Transformer.
• Pool Thermostat.
• Condensate Pressure Switch.
• Relay.
• Pool Temperature Sensor.
• Heat Exchanger Flow Sensor.
• Water Pressure Switch.
• Control Thermostat.
• Overheat Thermostat.
27
Fig 12.0
Page 31
Condensing Pool Heater Genie S
• Heat Exchanger Combustion Temperature
Sensor
• Flue Thermostat
• Ignition Control
• Gas Valve
• Fan
• Pump
• Expansion Vessel
• Heat Exchanger
• Secondary Heat Exchanger.
On the Electrical Chassis
To access these items fi rst remove the Front Top
Panel and then the Chassis Cover.
Fuse (See Fig. 13.0)
There is one in line 3A fuse on the 24V supply
between the Transformer and the Pool Thermostat.
The Fuse Holder bayonets apart to allow its replacement.
Transformer (See Fig. 13.0)
The Transformer includes its own, internal thermal
fuse on the primary. If this has gone open circuit the
cause should be established before replacing the
Transformer.
• Disconnect from the terminal strip and fuse
holder.
• Undo the two screws holding it to the chassis
and replace.
Pool Thermostat (See Fig. 13.0)
• Pull off the pool thermostat Knob.
• Release rear retainer by undoing the wing nut.
• Pull off all the PCB connectors.
• Slide out the thermostat.
• Replacement is the reverse.
Condensate Pressure Switch
(See Fig. 13.0)
• Undo the single fi xing 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
Relay
(See Fig. 13.0)
• Pull off the three electrical connectors and transfer to the new relay.
• Undo the two fi xing nuts and secure new relay in
position.
Heater Components
The remainder of the parts can be accessed
through the front.
28
Heat Exchanger Flow Sensor
This is located on the front connection to the heat exchanger. (See Fig.14.4)
• Un-clip the sensor from the connection.
• Transfer the push on electrical connectors to the
replacement and clip back on.
Heat Exchanger Pool Sensor
This is located in a pocket in the ‘From Pool’ side of the
Secondary Heat Exchanger. (See Fig.14.6)
• Pull out the retaining slipper, and pull out sensor.
• Disconnect from the six way terminal strip on the
electrical chassis.
• Replacement is the reverse.
Water Pressure Switch
This is located on the Inlet 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.
Control Thermostat
This is located on the outlet connection of the heat exchanger. (See Fig.14.4)
• Un-clip 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.
• Replacement is the reverse.
Ensure the O ring seal is fi tted correctly to the
replacement before fi tting
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.
• Release the two electrical connectors by pressing
the latch and pulling apart.
• Pull the ignition control away from the gas valve.
• Replacement is the reverse.
Gas Valve (See Fig.14.3)
• Remove the ignition control, see above.
• Release the gas cock by undoing the four shoulder bolts holding it to the Gas Valve.
Page 32
Condensing Pool Heater Genie S
29
• Remove the Off set tube from the Gas Valve and
unscrew the Off set Connector and transfer to the
new Gas Valve.
• Release the Gas Valve from the Venturi by undoing
three screws. (See Fig.14.3)
IMPORTANT: Ensure the rubber seal
(and orifi ce if propane) is transferred
from the old Valve and placed between
the Venturi and Gas Valve before
assembly.
• Replacement is the reverse.
• Fire up the Heater and check for gas leaks.
• After fi ve minutes check the rate and combustion
is correct to the Data table. (inside cover). Adjust
using the throttle on the Gas Valve, (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 up the Heater and check for gas leaks.
• After fi ve minutes check the rate and combustion is
correct. (see inside cover). Adjust using the throttle
on the Gas Valve if required. (See Fig.14.3).
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.
IMPORTANT : It is essential that all the
air is removed from the heat exchanger
before the heater is fi red. Operating the
heater which contains air inside may
damage the heat exchanger and
invalidate the warranty.
Expansion Vessel (See Fig.14.0)
• Remove the single screw holding the retaining strap.
• Release the fl exible hose connection to the Vessel
and remove it.
• Replacement is the reverse.
Heat Exchanger (See Fig.14.0)
• Remove the Expansion Vessel
• Remove the spacer below the Secondary Heat
Exchanger by removing the two screws and pulling forward.
• Release both the Heat Exchanger Demountable
connections. (See Fig.14.5)
• Undo the screws holding the panels around the
Demountable connections. (See Fig.14.5)
• Lower the pipework away from the Heat Exchanger.
• Remove the Front Top Panel and disconnect the
Flue Thermostat connections.
• Pull the Air Duct and Flue up and away from the
Heater Flue Adapter.
• Disconnect the Heat Exchanger Combustion
Sensor by pressing the latch and pulling off .
• Remove the four screws holding the Rear Top
Panel.
• Lift the Rear Top Panel with the Flue Adapter
clear of the Heat Exchanger.
• Remove the Fan, Gas Valve and Ignition Controller.
• The Heat Exchanger is now only retained by the
two side brackets and releasing the four front
screws will enable it to be pulled forward. Before
releasing ensure there is support available.
• Replacement is the reverse.
IMPORTANT : In order to maintain
suffi cient frost protection levels it is
recommended that after a drain down
the heater is re-fi lled with a suitable
anti-freeze. The manufacturer
recommends Sentinal X500.
Secondary Heat Exchanger (See Fig.14.0)
• Drain the pool side suffi ciently 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 drain cock
provided. Ensure an air vent is open to fully release the water.
• Remove the Pool Sensor from the Secondary
Heat Exchanger.
• Remove the Expansion Vessel.
• Remove the two fi xing screws holding the Spacer
below the Secondary.
• 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 fi xing the Secondary
Heat Exchanger to its mounting plate.
• Replacement is the reverse.
Page 33
Condensing Pool Heater Genie S
Spares
Item Mfg’ Part Number Supplier Part No
Primary Heat Exchanger (Genie 20 & Genie 35) M2136 SPMBG001
Primary Heat Exchanger (Genie 50) M2139 SPMBG002
Secondary Heat Exchanger M2745 SPMBG053
Propane Orifi ce (Genie 20 & Genie 35) M2150 SPMBG014
Propane Orifi ce (Genie 50) M2151 SPMBG015
Fan M2138 SPMBG003
Gas Valve M2140 SPMBG004
Ignition Control (Genie 20) M7182 SPMBGM7182
Ignition Control (Genie 35 & Genie 50) M2141 SPMBG005
Pool Thermostat PCB M2746 SPMBG057
Relay M2688 SPMBG054
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 (PRE SERIAL No:1546013120) M2683 SPMBG056
Genie Pump (POST SERIAL No:1546013120) M7966 SPMBG095
Expansion Vessel M3369 SPCOH103
Fig. 13.0
Pool Thermostat
Retainer
Transformer
Condensate
Pressure Switch
30
Electrical Components
Relay
Page 34
Condensing Pool Heater Genie S
Fig.14.6
Heater Components
31
Fig.14.0
Fig.14.1
Fig.14.4
Fig.14.3
Fig.14.2
Flue Thermostat
Heat Exchanger
Combustion
Temp Sensor
Fan Electrical
Connectors
Fan
Venturi
Fan Fixing Nuts
Ignition
Control
Gas Cock
Shoulder
Bolts
Off set
Tube
Venturi
Heat Exchanger
Flow Sensor
Heat Exchanger
Control Thermostat
Demountable Pool
Connections
Fig.14.5
Condensate
Pressure
Switch
Flue Adapter
Gas Valve
HT Lead
Spark & Sense
Electrode
Condensate
Syphon
Combustion
Sample Point
Air Tube
Throttle
Hi-Limit Thermostat
Condensate Pipe
Safety Valve
Outlet
Expansion
Vessel
Secondary
Heat
Exchanger
Drain & Fill point
with NR & Isolation
valve
Safety Valve
Pool
sensor
Water Pressure
Switch
Pump
Air Vent
Page 35
INSTALLATION & SERVICE HISTORY
Date
Cleaned ?
Pressure
CO
CO2
Service History
Commissioning
Installer No Date:
Working pressure mbar
CO ppm CO2 %
Instructed User in operation? Yes/No
Circle appropriate:
Date
Cleaned ?
Pressure
CO
CO2
Date
Cleaned ?
Pressure
CO
CO2
Condensing Pool Heater 04/12/13
Model Gas
Genie 20 Genie 35 Genie 50 NG LPG
Page 36
Station Lane
Industrial Estate
Witney
Oxon.
Tel. 01993 778855
Fax. 01993 703407
April 2016
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