Certikin MBC100N, MBC100NW Installation, Service & User Instructions

GC No. 47 555 02 and 47 555 17
WRc No. 95 110 46

0087

Certikin

100 & 100W Condensing

Pool Heaters

Note to the Installer: Natural gas Only

Please leave these Instructions adjacent to the meter.

Installation,

Service & User

Instructions

Model: MBC100N MBC100NW
Serial No:

1

1. USER
INSTRUCTIONS

1.1 Important Safety Notes

1.2 Connections

1.3 Quick Start

1.4 Summary of Controls

1.5 Re-Pressurising

1.6 Running the Pool Pump

1.7 Switching the Heater Off
– temporarily

1.8 Switching off for the
Winter

1.9 Maintenance

1.10 T roub le Shooting –
Failure to Start

1.11 Service

1.12 Water Quality

2. INSTALLATION

2.1 Introduction

2.2 Standards & Regulations

2.3 If Combined with a
Heating System

2.3 Standards & Regulations

2.4 Heater Controls

2.5 Gas Supply

3. FLUEING

3.1 Air Supply

3.2 Water Supply

3.3 Condensate Drain

3.4 Sealed Systems

3.5 Electricity Supply

4. INSTALLATION
WIRING

4.1 Wiring

4.2 Installation of Heater

4.3 Fixing the Heater

4.4 Terminal

4.5 Twin Pipe Assembly

4.6 Plumbing

4.7 Gas Connection

4.8 Condensate Connection

5. SPACE HEATING

5.1 System Design

5.2 Electrical Connections

6. COMMISSIONING

6.1 General Information

6.2 Procedure

6.3 Setting up the Controls

6.4 Pump Pressure Switch

6.5 Responsibility

7. FAULT FINDING

7.1 Heater Control

7.11 Control F ault Diagnostics

7.2 Ignition Faults

8. SERVICING

8.1 Heater Servicing

8.2 Changing Components

8.2.1 Control Boards

8.2.2 Gas Valv e

8.2.3 Sequence Controller

8.2.4 CVI V alve and
Full Pressure Set Up

8.2.5 Pressure Gauge

8.2.6 Pump

8.2.7 Diverter V alve

8.2.8 Safety V alve

8.2.9 Water to Water Heat
Exchanger

8.2.10 Flow Regulator and
Strainer

8.2.11 DHW T emperature Sensor

8.2.12 Removing the Case

8.2.13 Fan Assembly

8.2.14 Air Pressure Switch

8.2.15 Flue Thermostat

8.2.16 Pump Overrun
Thermostat

8.2.17 Control Sensor

8.2.18 Overheat Cut-Off Device

8.2.19 Electrode and HT Lead

8.2.20 Pilot Assembly

8.2.21 Burner

8.2.22 Main Injector

8.2.23 Combustion Chamber
Insulation

8.2.24 Primary Heat Exchanger

8.2.25 Secondary Heat
Exchanger

9. PARTS

9.1 Spares

9.2 Electrical Components

1:4 Control Panel
1:5 The Filling Loop
2:3 Typical Circuits
3:4 Alternative Methods of

Filling a Sealed System

4:1 Installation Wiring

Diagram for Heater

Controller
4:3 Fixing Positions
4:5 T win Flue P ositions
4:8 Installation Dimensions

Service Access
5:2a Model 100 Schematic

Wiring
5:2b Model 100W Schematic

Wiring
5:1 Hydraulic Schematic
6:2 a Model 100 Gas V alve
6:2 b 100W Gas V alve
6:3 Control Display in Setup

Mode
6:4:a Adjustment Knob
6:4:b Heater Installation Limits
7:1 Control Display
7:2:a Indicator Lights, Model

100 Only
7:2:b Fault Finding Operation

Sequence, 100W
7:2:c Fault Finding Hot Water

Operation, 100W
7:2:d Fault Finding P ool or

Space Heating, 100W
8:2:2 Gas V alve Model
8:2:4 CVI V alve Modureg

Operator
9:2 Electrical Components
10:1 Major Components
10:2 Example Condensate

Disposal Methods
10:3 Condensate Drain Tap

CONTENTS

FIGURES

100 Gas Condensing Pool Heater

21/10/03

1: USER INSTRUCTIONS
1:1 Important Safety Notes

T o obtain the best possib le performance and trouble
free operation from your Heater , it is important that
you read these instructions carefully . Your Pool
Heater has built-in safety features, which are
detailed in the relevant section of this manual.

If it is known or suspected that a fault exists on the
Heater, it MUST NO T be used until the f ault has
been corrected by a competent engineer (see
Section 1:10, Trouble Shooting - Failure to Start)

It is essential that these instructions are strictly
followed f or saf e and economic operation. F ailure to
observe these instructions may invalidate your right
to free breakdown cover during the guarantee
period.

We recommend that you keep these instructions in
a place near your Heater for easy reference.

1:2 Connections

Your Heater should be connected to an electrical
supply complying with the Electrical Wiring Regula­tions (BS7671): as well as a gas supply complying
with BS6891; and an appropriate flue system.

AL WAYS SWITCH OFF THE ELECTRICAL
SUPPLY before removing any of the covers for
cleaning.

If any part of the Heater or its flue is modified then
the guarantee will be invalidated.

1:3 Quick Start

Check the Electricity and Gas supplies to the
Heater are on. If the Pool Pump is not controlled by
the Heater, turn it on. Turn on the Heater by turning
the Pool Temperature Control Knob clockwise to
show the required Pool temper ature, the Heater will
fire.
If the Heater fails to light see Section 1:10, T roub le
Shooting - Failure to Start)

1:4 Summary of Controls (left to right)

Heater Pressure Gauge
Normal - The needle should be in the area indicated
as * * NORMAL * * , if low , re-pressurise, see
Section 1:5
Flashing - The P ool Heating Demand is Met , the

pool is up to temperature.

Temperature is displayed after 3 seconds.

- Spa + - Setting for Spa Temperatures. Required
temperature is displayed when setting, actual Spa
T emper ature displayed after 3 seconds.

(NOTE: The Heater is delivered set to display in Fahren­heit. For a Centigrade display,

see 6:3

Commissioning Section of Installation Instructions)

Pool Temperature Mechanical Stop
Stop – This can be used to obtain a repeatab le

setting and to limit maximum pool temperature. To
set, loosen the screw , adjust as required and then
re-tighten.

Pool T emperature Display
Display - Normally shows the actual P ool Tempera-

ture, but also displa ys the Setting Temperature and
a Setting Dot lit whilst being adjusted. The display is
also used for commissioning and diagnostic pur­poses.

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 b ut
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: Supplied set for Pool Priority. It will satisfy the
Pool Temperature before supplying full Heating. To

change the priority,

see 6:3

Commissioning Section of

the Installation Instructions)

Filter LED - YELLO W
On - Pool Filter Bloc k ed - Insufficient pressure,

possibly due to a blocked pool filter. The heater will
not run.
Flashing - Clean Pool Filter - The filter ma y require
back washing. The heater will run. Can be reset by
turning the Pool Temperature knob off and back on

again.

Pool Temperature Control Knob

16°C to 41°C (60°F to 106°F)
Off - There is no P ool Heating Demand , pool
heating is off.
Pump - Runs Pool Pump only, if connected via
heater. ‘P’ is indicated on P ool T emperature Displa y .

- Pool + - Setting f or pool temperatures. Requested
temperature is displayed when setting, actual Pool

2

100 Gas Condensing Pool Heater01/06/02

Heater Overheat LED - ORANGE
On - Heater Ov erheat - This indicates that the

Heater has overheated and shut down. See Over­heat Reset instructions below.

Overheat Reset 100 Only

In the unlikely event of an Overheat it will neces­sary to obtain the assistance of a competent person
to reset the thermostat.
Turn the Mains supply off. Remov e the single fixing
screw holding the Electrical Chassis and pull it out,
hanging it on the back support. Remov e the Con­trols Cover and locate the Reset Switch on the side
of the Control Chassis. Turn it off then back on
again.
Replace all the panels in reverse order .
If the Heater repeated overheats a Service Engineer
should be called to inspect the Heater.

Overheat Reset - 100W Model Only

In the unlikely event of an Overheat it will neces­sary to obtain the assistance of a competent person
to reset the thermostat.
The procedure is detailed in Section 8:2:18
If the Heater repeated overheats a Service Engineer
should be called to inspect the Heater.

Automatic Frost Protection

The Heater will automatically run a Frost Protection
routine if the temperature falls below 3°C (37°F). The
Pool Temperature Display will show 0°C. This will
include the use of the Pool Pump if it is connected
to the Heater.

1:5 Re-Pressurising

Connect a Mains W ater supply then connect the
free end of the braided flexible hose (the Filling
Loop) (see Fig.1.5) to the incoming mains connec-
tor.

Open the Valve to the supply , then, slo wly open the
V alve on the Base P anel until the Pressure Gauge
shows 1 Bar .
Close both valves then disconnect the Filling Loop.

ON

bar

0 4

2

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100

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1:6 Running the Pool Pump

If this option has been installed the Heater can run
the Pool Pump on its o wn. Turn the Pool Tempera­ture Control Knob to ‘Pump’, just ne xt to Off .

1:7 Switching the Heater Off -

temporarily

The Heater may be stopped by turning the Pool
T emperature Control Knob and/or the Heating
T emperature Control Knob to OFF on Control P anel.

1:8 Switching off for the Winter

T urn both T emper ature Control Knobs to Off.
If the built in Frost Protection is required do not
isolate the Heater from its electrical supply .
If the Heater is to be shut off for the Winter, it is
advisable to have it thoroughly serviced when first
shut down. Thorough cleaning will minimise corro­sion during the idle period.

1:9 Maintenance

For normal cleaning of the outside casing, simply
wipe with a dry cloth. To remove stubborn marks
and stains, wipe with a damp cloth and finish off
with a dry cloth. DO NO T use abrasive cleaning
materials. A spr a y of WD40 or similar will also help
to protect it.
The Heater must be serviced every year by a
qualified service engineer.

1:10 Trouble Shooting - Failure to Start

If the Heater fails to start, adopt the following
procedure:-

1. Check that the P ool pump is operating and that
the Filter lamp is not illuminated.

2. Check that the Heater Control Thermostat is set
high enough to be “ON” and that the Pool De­mand lamp is on.

Fig 1:4

3

100 Gas Condensing Pool Heater 20/10/03

Fig 1:5

3. Check whether the Heater Overheat light on the
control fascia is glowing, if so it indicates an
overheat situation. (See Section 1:4) If the
Heater repeatedly overheats a Service Engineer
should be called to inspect the Heater.

1:11 Service

T o ensure efficient and reliable oper ation of the Heater
it is essential that the Heater is serviced every year.
The Manufacturer recommends this is prior to start­ing the Heater each season.

1:12 Water Quality

Chemical imbalance can cause severe damage to
your Heater and associated equipment.
Maintain the pool water pH between 7.4 and 7.6 and
ensure that the free chlorine levels are within the
range recommended by the chemicals manufacturer
for your size of pool.
Check the Filter regularly and keep the pool free of
debris such as leaves and grass cuttings.

4

100 Gas Condensing Pool Heater20/10/03

Filling Loop

First Valv e

Second V alve

100

Filling Loop

Second V alve

100W

2 INSTALLATION
2:1 Introduction

This Manual covers Operation, Installation, Com­missioning and Maintenance of the 100 and 100plus
Condensing Pool Heater .
The Pool Heater is :-

• Designed for heating pools and Spas by utilising

an internal water to water heat exchanger .

• Incorporates its own sealed system

components; pressure vessel, filling loop, safety
valve, and pressure gauge.

• Can also be used for space heating.

• The 100 Plus also provides Instantaneous Hot

W ater.

• Supplied with a manual reset limit thermostat.

• Suitable for new installations and for replacing

existing Heaters.

• Includes an internal automatic bypass to

accomodate all likely Space Heating designs.

These Instructions are for a Gas Fired, Condensing
Pool Heater which are room sealed and f an assisted
on the flue side. The flue system available is Twin
Pipe, horizontal total combined length of 22 metres
or vertical, up to a total length of 30 metres. The
ignition system is fully automatic. The 100 plus
incorporates electronic gas modulation.

The Heater casing is of polyester powder coated
enamelled zinc coated steel.

Includes all the components required for a sealed
system including a pump and is designed for the
connection of an optional Heating or Hot W ater
system.

It includes a pump overrun device and an automatic
bypass valve.

There is no requirement for a scale reducer to be fit­ted to the cold water mains supply to the 100 Plus.

The Heater contains integral frost protection, the
Heater will fire if the temperature within it ap­proaches 4 to 5 degrees Centigrade. It will do this
even when turned to Off, and can only be inhibited
by removing the P ermanent Live supply to the
Heater.

Adequate arrangements for completely draining the
system, by provision of drain cocks MUST be
provided.

2:2 Standards & Regulations
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 CORGI registered
operative) in accordance with the above Regula­tions. F ailure 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 Water Undertaking, any
relevant requirements of the Local A uthority , and
Health and Safety document No 635, “Electricity 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 Heaters
of rated input not exceeding 70kW .
BS.5449:1 Forced circulation hot water systems
(small bore and microbore domestic central heating
systems).
BS.5546 Installation of gas hot water supplies for
domestic purpose (2nd Family Gases).
BS.5440: P art1. Flues (f or gas appliances of rated
input not exceeding 60kW).
BS 6891 Specification for installation of low pres­sure gas pipework.
BS 7074:1 Application, selection and installation of
expansion vessels and ancillary equipment for
sealed water systems.
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 NO T be tak en, in any
way, as overriding statutory obligations.

Location of Heater

The Heater MUST be installed vertical and securely
fixed .

The Heater is not suitable for an external

installation

5

100 Gas Condensing Pool Heater 05/02/03

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 f or Gas Installations
in Timber F rame Housing’, ref erence 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 Heater 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 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 f ollowing limitations MUST
be observed:

1.

The position selected for installation MUST allow
adequate space for servicing in front of the Heater
and for air circulation around the Heater .

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.

2:3 If Combined With A Heating System

The Controls provide a water temperature control for
use with a heating system, the Heating Demand Knob.
It requires an switched live from the Heating controls
to be connected to Heating Demand, as shown in the
Wiring Diagram and a pipe circuit to be connected to
the two rear tappings of the Heater in place of the Air
V ent and Drain.
It is essential that the size of the expansion vessel
in the Heater is sufficient for the proposed system
Depending upon the Priority set

(See commissioning Section 6:1)

the Pool or The

Heating will be brought up to temperature first.
Typical circuits are as

Fig 2:3.

2:4 Heater Controls

This Heater uses a control specifically designed for
it and it has the following features:

A highly accurate Pool Thermostat , 16°C to 41°C
(60°F to 106°F)
A Heater Thermostat. Fixed f or P ool, 84°C, variab le
for Heating 60 - 82°C.
A Frost Thermostat which runs the Internal and Pool
Pump at 3°C or below but then fires the Heater
alone if the temperature has not risen sufficiently.
A Return Thermostat operating an internal bypass
for condensation reduction.

Fig 2:3

Heater

Pump

Pump

Zone Valve

Non return valve

Pump

Non return valve

Second water 2 water

heat exchanger

with Aquastat or similar

Pool Plus Heating and Hot Water

Pool Plus Heating

Pool Plus Spa

3 Way Valve

Expansion vessel

Expansion vessel

Heater Expansion

Vessel

4 litres

Heater

Heater Expansion

Vessel

4 litres

Heater

Heater Expansion

Vessel

4 litres

NB: Extra Expansion Vessel only required for very large systems. See Section 3:4

6

100 Gas Condensing Pool Heater01/06/02

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 f acing surf ace 600 mm
From f acing terminal 1200 mm
From opening under a car port 1200 mm
V ertically from a terminal 1500 mm
Horizontally from a terminal 300 mm

An Over T emperature Thermostat (Overheat).
Internal Pump control with run on.
Pool Pump control with run on and out-of-season

exercise. (Requires external contactor)

Pool Temperature and Setting display . Engineer

selectable °C or °F.

User Indicators for P ool, Heating, Overheat, and

Service.
Engineer indicators of all switched outputs for
simple diagnosis.
Priority selection of Pool or Heating, engineer

selectable.
Memory of: Filter occurrences.
Sensor failure detection and indication.
Control self checking with fault indication.

For more detail see the

Commissioning (6:1) an

Fault Finding (7:1) sections

.

2:5 Gas Supply

The Local Gas Region should be consulted, at the
installation planning stage, in order to establish the
availability of an adequate supply of gas.

An existing service pipe must NOT be used without
prior consultation with the Local Gas Region, or by
a local Gas region contractor. An e xisting meter
should be checked preferably by the Gas region, to
ensure that the meter is adequate to deal with the
rate of gas supply required.
Installation pipes should be fitted in accordance
with BS.6891
Do NOT use pipes of a smaller size than the Heater
inlet gas connection.

3 FLUEING

Detailed recommendations for flueing are given in
BS.5440: 1. The f ollowing notes are intended for
general guidance.

1.

Be aware of the plume from the flue and the
wetting effect it has to adjacent property.

2.

The flue can be taken upwards, left, right or to
the rear of the appliance.

3.

The Heater is supplied with a Twin Pipe flue
suitable for terminating on an outside wall 1
metre away. More complex and length y flues
are possible, please consult the Flue Application
Guide for designs and the components.

4.

The Heater MUST be installed so that the
terminal is exposed to external air.

5.

It is important that the terminal allows the free
passage of air across it at all times.

T ab le 1.

IMPORTANT.

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 IMMEDIA TELY and the Local Gas
Region consulted.

6.

The acceptable spacing from the terminal to
obstructions and ventilation openings are
specified in Table 1.

7.

Because the flue gases and terminal are at very
low temperature it is not necessary to fit a
Terminal guard to protect against burns. If a
guard is required for any other reason the
following is recommended.

For the T win Flue T erminal:

Model B (black plastic coated).

For the Single Flue T erminal:

Model H (black plastic coated).

All are available from:

Tower Flue Components Ltd.

Tower House.

Vale Rise.

Tonbridge

KENT

TN9 1TB

01732 351555

7

100 Gas Condensing Pool Heater 01/06/02

3:4 Sealed Systems

The Pool Heater is supplied with an Expansion
V essel (see Technical Data for details), a Pressure
Gauge, a Safety Valve and Filling Loop following the
guidelines given in the Code of Practice BS 7074 :1.

Please check that the supplied Expansion Vessel is
adequate for the proposed system. The f ollowing
procedure is suggested.

1.

Choose a vessel pressure by taking the static
head of the system, adding 0.3 bar, and taking
the nearest larger figure.

2.

Select the Vessel V olume from the tab le below
by finding the System Volume and V essel
Pressure.

3.

Choose that size or larger from the manufactur­ers’ range.

Vessel System Volume

Litres

Pressure 50 60 70 100 150

Bar

Vessel V olume

0.5

448812

1.0

8881218

1.5

8 12121824

T ab le 2.

A design as detailed below should be used for the
filling connection, it utilises a BS 1010 stop valve, a
double non-return valve and filling loop fitted at low
level and should be installed with the approval of
the local W ater Undertaking.

3:1 Air Supply

It is NOT necessary to have a purpose provided air
vent in the room or internal space in which the
Heater is installed.

Where the Heater is installed in a cupboard or
compartment no air vents are required. How ever the
User may wish to ensure that is ventilated to
provide air circulation.

3:2 Water Supply

The central heating system should be in accord­ance with the relevant recommendations given in
BS.6798, BS 7593:1992 and, in addition, for
smallbore and microbore systems - BS.5449:1.

The domestic hot water system, if applicable,
should be in accordance with the relevant recom­mendations of BS.5546.

Copper tubing to BS 2871:1 is recommended for
water carrying pipework.

The Mains W ater supply should be clean and able to
produce the required flow rate, see the T echnical Data.
New pipework must be flushed through before con­necting.

The 100W incorporates a strainer and flow regulator
set to 8.5 l/m on the Cold W ater Mains Inlet, this can
be removed in countries with warm climates. The In­let pressure should not exceed 10 bar , a reducer should
be fitted if it does.

Any hot water storage cylinder MUST be of the
indirect type and should preferably be manufactured
of copper.

The hot water cylinder, & ancillary pipework, not
forming part of the useful heating surface should be
lagged, to prevent heat loss and any possible
freezing, particularly where pipes run through roof
spaces and ventilated underfloor spaces.

Draining taps MUST be located in accessible
positions, which permit the draining of the whole
system, including Heater and hot water storage
vessel. Draining taps should be at least ½ in.
nominal size and be in accordance with BS.2879.

3:3 Condensate Drain

Refer to Fig. 1:5, 5:1, and 10:2

A condensate drain is provided on the Heater , this
drain must be connected to the household drainage
point, or soakaway on site. All pipework and fittings
in the condensate drainage system MUST be made
of plastic. Refer to British Gas publication “Guid­ance notes for installation of domestic condensing
boilers”

The drain outlet on the Heater is :

Polypipe, 21.5mm pushfit overflow pipe.

ALTERNATIVE METHODS OF FILLING A SEALED
SYSTEM

Method A

Method B

Hose Unions

Air Inlet

Valve

Temporary Hose

Mains

Water

Supply

Mains

Water

Supply

Test Cock

Stop Valve

Drain &
Fill

Double
Check Valve
Assembly

Drain &

Fill

Cistern &
Overflow

Pressure
Pump &
Reducing
Valve If
Required

Stop Valve

3:5 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 .

The Heater is supplied for 230V ~ 50Hz. Single phase.
Fuse rating is 3A.

Fig. 3:4

8

100 Gas Condensing Pool Heater

20/10/03

The method of connection to the mains electricity
supply MUST facilitate complete electrical isolation
of the Heater, pref erably by the use of a fused doub le
pole switch having a 3mm (1/8in.) contact separation
in both poles and servicing only the Heater and sys­tem controls.

The point of connection to the mains should be read­ily accessible and adjacent to the Heater , except that,
for shower room installations, the point of connection
to the mains MUST be situated outside the bathroom.

Note. Where a room sealed appliance is installed in

a room containing a basin or shower , the appliance,
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.

4. INSTALLATION WIRING
4:1 Wiring

The designs below are in order of preference, the
Quick Fit P ool Control Panel (CCP02) being the easi­est, quickest and most comprehensive solution.

Design 4 is the least preferred as it does not utilise
all the features of the Heater Control.

Heater Connections are shown prefaced with ‘HTR’
in the diagrams below .

Fig. 4:1

9

100 Gas Condensing Pool Heater 01/06/02

LNE

Certikin Mk2 Oil Pool Heater

Pool Pump

Up to 16 A

Lights

Up to 6 A

Pool Pump

Rated to
suit pump

RELAY

T.S

> HTR, Permanent Live

> HTR, Pool Demand

< HTR, Pool Pump

Pool Pump

Up to 3 A

More than 3 A

Trip

L

N

N

T.S

> HTR, Permanent Live

> HTR, Pool Demand

Pool Pump

Trip

L

N

T.S

> HTR, Permanent Live

Pool Pump

Trip

L

N

> HTR, Pool Demand

DESIGN

#

NOTES

Takes full advantage of all the features of the Certikin

Oil Pool Heater.

Pool Pump control providing overrun and Frost Protection action.

Provides the fastest installation

Optional connections for Lights and Space Heating all provided.

1

2

3

4

Takes full advantage of all the features of the Certikin

Oil Pool Heater. Considerable installation time.

Pool Pump control providing overrun and Frost Protection action.

Optional Space Heating only available with more wiring.

Limited application of Certikin Oil Pool Heater.

Moderate installation time.

No Pool Pump control, Overrun or Frost Protection action.

Non-preferred application of Certikin Oil Pool Heater.

Moderate installation time.

No Pool Pump control, overrun or Frost Protection action.

Optional Lighting only available with more wiring.

Optional Space Heating only available with more wiring.

Optional Lighting only available with more wiring.

Utilising the CCP02 "Quick Fit" Oil Pool Heater Control

Optional Space Heating only available with more wiring.

Optional Lighting only available with more wiring.

T.S = Time switch

T.S = Time switch

T.S = Time switch

HTR = Oil Heater

HTR = Oil Heater

HTR = Oil Heater

CCP02

IMPORTANT: Remove link, Live to Pool Demand, in Oil Heater

IMPORTANT: Remove link, Live to Pool Demand, in Oil Heater

OR, Certikin Condensing 100 Pool Heater

OR, Certikin Condensing 100 Plus, Pool Heater

4:2 Installation Of Heater

Suggested procedure:

1.

Position to suit system and terminal limitations.

2.

Mark & Drill Flue hole(s). (see Fig. 4:8).

3.

Remove the Electrical Tray and the Lower Case
from Heater module.

4.

Plumb tails to pool, gas heating and hot water .

5.

Test for leaks.

6. Replace the Low er Case and Electrical tray.

Space Required for Installation and Service.

Right or Left 30 mm 1 in.
Above 30mm 1 in.
Below 25mm 1 in.
In Front 450mm 18 in.

T able 3

4:3 Fixing the Heater

1.

Position to suit system and terminal limitations.

2. Secure the frame, vertical, to the wall or floor

with the bracets provided..

3.

Mark the wall or ceiling for the flue exit points
and core drill the wall to give a 0 to 3 degree
slope down towards the Heater . The recom­mended core drill is 90mm for the Twin Pipe.

4:4 Terminal

The terminal can be fixed vertical or horizontal. The
flue pipe must always be connected to the extended
outlet of the terminal. The spacing is 120mm and a
core drill of 90mm is recommended.

See Fig. 4:8

4:5 Twin Pipe Assembly

All the Twin Pipe components for this appliance are
lightweight plastic and utilise a push-fit system.
V ery few f asteners are required and their use is
detailed on the instructions provided with the
components.

Important:

All Twin Pipe Installations must comply with the
following.

1.

The Flue pipe must slope back to the Heater by
three degrees (1 in 20) on all horizontal runs. The
air pipe can be above or below horizontal.

2.

Flue Pipes must be supported every 1000mm,
minimum.

3. All connections should be made with the Socket
end furthest from the heater.

4. Use the supplied CentraCerin or Silicone
Grease to ease the fitting of sections.

5.

The combined Equivalent Length of Air and Flue
should not exceed 22m horizontal, or 30m
vertical and including any terminal parts.

6.

The straight equivalent lengths of bends in a
horizontal design are as follows:

45 degrees, 1.3m.
90 degrees, 4m.

For more complex designs please see the details
provided with the components

It is recommended that:

1.

That 45 degree bends are always used with
vertical flues and where possible used in prefer­ence to 90 degree bends in horizontal installa­tions.

2.

Straight Flue pieces may be reduced in length
by cutting square. It will ease assembly if the
cut edge is cleaned, chamfered and greased
before insertion.

4:6 Plumbing

Prepare the flow and return pipe work on the base of
the Heater. If the requirement f or Space Heating
exceeds 50,000 Btu/h (15kW), the Flow and Return
pipework from the Heater must be 28mm until the
heat load allows smaller bore pipework.

New pipework must be flushed through before
connecting.

4:7 Gas Connection

The 15mm gas connection point is provided. A
minimum of 20mb. (8in. w.g.) must be availab le at
the Heater inlet, with the Heater and other con­nected appliances firing. Check for gas soundness
(B.S. 6891: 1988) in pipework to Heater using a
manometer. Open the gas coc k. Gas soundness
within the Heater should be checked using sense of
smell and/or leak detection fluid. Check the burner
bar pressure with a manometer connected to the
control and adjust if required with the pressure
regulator.

10

100 Gas Condensing Pool Heater

01/06/02

FIXING POSITIONS

TWIN FLUE POSITIONS

Fig.4:5

Flue Duct

Air Duct

100mm

Condensate Drain
Connection

(connects to drain point
on Flue Spigot Adapter)

Flue Spigot
Adapter

Drain Point

Twin Pipe Heater
Mounting Box
Assembly

Connects to condensate
drain point on Condensate
Drain Trap

11

100 Gas Condensing Pool Heater 01/06/02

PLAN VIEW

FRONT VIEW

Suggested fixings
3 into the floor OR
2 into the wall.

Fig.4:3

4:8 Condensate Connection

The position of the plastic condensate drain pipe is
shown in

Fig 5:1

Where possible an internal termination of the
Condensate discharge pipework should be used.

Installation pipework must be in plastic to a suitable
drain location with a gradient of 2.5° (45mm/ meter
run) minimum. If connected to another drainage
trap, an air break is required between the Heater
drain and that trap. (

See Fig.10:2

). Internal runs
must be in a minimum of 19mm pipe. External runs
MUST be made in a minimum of 32mm pipe,
starting inside the building, and if possible insulated
to defer problems from freezing.

Whichever method is used it should be checked
during commissioning to prove there is a leakfree
working connection from the Heater to the drain. The
simplest way to do this is to carefully pour some
water into the Heater flue and check it emerges at
the drain.

The British Gas booklet “Guidance for the installa­tion of Domestic Condensing Boilers” should also be
referred to .

5 SPACE HEATING
5:1 Typical Radiator System Design

General Principals

No special requirements are need for the selection
of radiators, normal sized radiators are acceptable.

The Manufacturer recommends using a programma­ble room thermostat, alternatively a separate room
thermostat and timeswitch can be used.

The Heaters include a pump overrun device so it is
essential that there is an open circuit for water to
flow between the flow and return. An Automatic
Bypass is incorporated in the appliance which
should be sufficient for most system designs.

The Heater includes integral frost protection. If the
temperature approaches freezing it will first try and
use the heat in the pool by running the Pool Pump .
If this does not raise the temperature it will run the
Heater. It will do this even when turned to Off, and
can only be inhibited by removing the P ermanent
Live supply to the Heater .

Thermostatic radiator valves can be used.
The Heater Pump is factory set at Speed 3 and

should not be alterered.
The Heater waterside is completely copper so all

good corrosion inhibitors are suitable. Inhibitor is not
required for Pool only applications .

The design temperature difference across the
Heater for optimum operating efficiency is 20°C. If
thermostatic valves or zone valves are used ensure
the minimum flow shown in the T echnical Data on

page 1 is possible.

5:2 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, f or Earth
Continuity, Polarity, Short Circuit and Resistance to
Earth.

The 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

2

to
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
sliding out the bottom tray which is held by mag­nets, removing the single screw retaining the
Electrical Tray then releasing the screws retaining
the Chassis Cover .
The Heater internal wiring is shown in

Fig.5:2a &

Fig. 5:2b

.

Connections are made by push fit connectors
Connections are as follows :-

3 Way T erminal 4 Wa y T erminal

Earth Pool Pump
Neutral Neutral
Permanent Live Heating Demand

Pool Demand

A link is factory fitted between the Permanent Live
and the Pool Demand and should be remov ed if a
separate switched supply is provided f or P ool
Heating.

For systems using an external programmer , the
electrical wiring should follow the relevant control
manufacturer’ s recommendations, with the s witched
live from the controls returning to Pool Demand and/
or Heating Demand in the 4 way push-fit connector .

12

100 Gas Condensing Pool Heater 01/06/02

INST ALLA TION DIMENSIONS

FLUE POSITIONS AND SERVICE ACCESS

Fig 4:8

13

100 Gas Condensing Pool Heater08/09/03

HEATER HYDRAULIC SCHEMATICS

Fig. 5:1

Safety Valve Drain

From Pool

Heating Flow

Heating Return

Fill & Drain

Condensate Drain

To Pool

Condensate Trap

Pump

Safety Valve

Diverter Valve

Auto Bypass

Valve

Expansion Vessel

Heat Exchanger

Pool Heat Exchanger

Auto

Air

Vent

Safety Valve Drain

From Pool

Heating Flow

Heating Return

Fill & Drain

Condensate Drain

To Pool

Condensate Trap

Pump

Safety Valve

Diverter Valve

Auto Bypass

Valve

CW Inlet

Three Way Valve

Water to Water

Heat Exchanger

Filling
Loop

Pool Heat Exchanger

Heat Exchanger

Expansion Vessel

Auto

Air

Vent

HW Outlet

100W100

Front View

C

L

100

Rear Flue
Side View

Twin pipe

Maximum 22m horizontal

90mm

90° bend = 4.0m

45° bend = 1.3m

Suggested core drill

Service Access

Front 450mm Above 30mm

Sides 30mm

Equivelant lengths: Minimum 200mm

Maximum 30m vertical

Side Flue

Flue

Air

390

110

500

1750

1850

1850

120

100

SCHEMATIC WIRING

Fig.5:2a

14

100 Gas Condensing Pool Heater 14/03/03

100

SUPPLY

E

N

L

HT

N

Ls

L

Lp

COM

AIR

NOAIR

O/H

O/H

SENSOR

SENSOR

12 Way connector

GV1

GV2

N

4 Core to Gas Valve

Fan

4 way Molex

10 way Molex

GV1 GV2

1 Amp 20mm

IGNITION BOARD

Or

Or

Br

Br

R

W

BkGyBr

R

Bk

Br

B

G/Y

G/Y

G/Y

B

G/Y

V

Gy

Br

R

OrWBk

Gy

V

G/Y

B

Brown

Red

Orange

White

Black

Blue

Grey

Violet

Green & Yellow

B

L

N

Pressure

Switch

O/H

P

o

o

l

P

u

m

p

Heating Demand

P

o

o

l

D

e

m

a

n

d

PUMP

E

N

Lp

CONTROL BOARD

INTERNAL

G/Y

E

N

N

2

5

0

m

A

A

S

L

R

C

POOL DMD

HTG DMD

HTR PUMP

POOL PUMP

BURNER

P

r

e

s

s

u

r

e

S

w

i

t

c

h

B

u

r

n

e

r

S

e

n

s

o

r

P

o

o

l

S

e

n

s

o

r

C

o

m

m

o

n

R

R

B

Or

Y

Yellow

W

B

Br

B

Gy

V

Sensor

Pool

3 PORT VALVE

B

R

O

W

N

RESET

SWITCH

Or

Br

Lockout Neon

14/03/03

Air Pressure Switch

NO

NC

S

e

n

s

o

r

Flue Stat

O/H Stat

M4733

10k

B

SCHEMATIC WIRING

15

100 Gas Condensing Pool Heater

21/10/03

Fig.5:2b

100W

DRIVER PCB

X1

X2

X3

X4

X5

X6

X7

X8X10

CH SET MAX

MODUREG

DHW

SENSOR

NC

NC

24V

FLOW SWITCHES

PUMP

CVI VALVE ASSEMBLY

1

8

NC

R

Y

W

R

V

G

y

Y

W

R

P

Br

B

HW SET MAX

R/B

Bk

G

y

/

B

k

NC

G

y

W

R

Or
B

B
Br

Br

B

Br

FAN

PRESSURE

OH STAT

LOCKOUT

NEON

FLUE STAT

W

W

OVERRUN

PUMP

230 V

CH

Bk

B

B

G/Y

G/Y

B

G/Y

Spark Electrode

230 V

Br

Or

Set Maximum CH Pressure

1

2

3

Fuse 315 mA

Fuse 2 A

P Pink

Set Minimum CH pressure

SWITCH

12 11 9 6

5

3

12

G/Y

8

Br

Cold

5

6

3

10k

10k

SUPPLY

E

N

L

R

Br

R

Or

W

Bk

Gy

V

G/Y

B

Brown

Red

Orange

White

Black

Blue

Grey

Violet

Green & Yellow

L

N

Pressure

Switch

O/H

P

o

o

l

P

u

m

p

H

e

a

t

i

n

g

D

e

m

a

n

d

P

o

o

l

D

e

m

a

n

d

CONTROL BOARD

G/Y

N

2

5

0

m

A

A

S

L

R

C

POOL DMD

HTG DMD

HTR PUMP

POOL PUMP

BURNER

P

r

e

s

s

u

r

e

S

w

i

t

c

h

B

u

r

n

e

r

S

e

n

s

o

r

P

o

o

l

S

e

n

s

o

r

C

o

m

m

o

n

R

R

B

Or

Y

Yellow

Y

W

B

Br

B

Gy

V

Sensors

Pool

Burner

Or

Br

Bk

3 PORT

E

N

L

VALVE

B

r

B

G/Y

01/06/02

6. COMMISSIONING

6.1 General Information

For Systems with Space Heating

The elimination of air from systems is essential to
minimise the occurrence of heat exchanger and
general system noise.

Metal swarf and flux chemicals make a very ag­gressive mixture, the destructive nature of which
can be drastically reduced by flushing. Conse­quently this is a mandatory step in the commission­ing procedure.

Low water content, fabricated Heaters are vulner­able to damage by air , particularly when the system
water is ‘hard’. (Contains a lot of dissolved calcium
salts). The result of this damage is evident in noisy
Heaters and reduced service life.

Removal of air from a system mainly takes place
when the water is stopping, starting or not moving
at all. It is removed most easily when it is in large
bubbles, but the action of the pump is to chop it up
so that it becomes a foam, which is extremely
difficult to remove.

Two or three second bursts on the pump at the
initial stage will reduce the risk of foam formation.

Sloping the pipe runs towards the vent points will
greatly aid air removal. Sloping pipes are not just a
feature of gravity systems but can greatly aid the
pumped system because air can move towards a
vent when the pump stops.

Air is dissolved in water but is released when
heated. Always run a system at maximum tempera­ture for at least 15 minutes to enable this potential
problem to be removed during commissioning.

6.2 Procedure

MODEL 100 ONL Y :

If the Heater has just been filled
with very cold water, the b uilt in F rost Thermostat
could attempt to fire it, if it has a permanent live
and no switched live, this is completely normal. It is
recommended that the gas cock is turned off during
this early stage.

Pool Only Systems

There is an Automatic Air Vent inside the Heater,
ensure that the cap is open before filling with mains
water through the Filling Loop.
With the gas off, run the heater to circulate the
water and remove the air . T urning the supply on and
off will pulse the pump and help the air to rise to the
Automatic Air Vent.
When completely clear of air, re-pressurise and
remove filling loop.

Turn the gas back on. The Heater is ready f or use .
The Heater is fitted with automatic ignition and will
start when the gas cock is open, Mains is con­nected to the Heater and the controls are calling for
heat.

For the Model 100 only:

It has a built in delay, and
the Heater can be held off for 120 seconds. How­ever, for commissioning purposes, switching off
using the System Isolating Switch will avoid the
delay.

For Systems with Space Heating

It is strongly suggested that the following stages of
commissioning are followed, and not an immediate
connection of all services. This procedure pre vents
substantial amounts of air being dispersed through
the system as small bubbles.
Carry out electrical tests as stated in Electrical
Connections if not already done so.

With all radiator valves open, fill the system from
the Filling Loop, but do not start the pump.

With the temporary hose connected, fill from the
mains supply , then follo w the procedure below .

Check for water soundness and rectify where
necessary.

DO NOT TURN ON GAS

Drain the system by opening all draincocks. This
will flush the system of flux and swarf.
Pour ¾ of the inhibitor in and fill the system with
clean water and vent air from radiators and
pipework.

Pour in all the inhibitor , and fill to required pressure
plus 0.3 bar to allow for venting.

Switch on the electrical supply to the Heater and
switch the programmer ON.

Switch OFF after about five seconds and vent all
points again.

Repeat this for 5 minutes.

Re-pressurise if required.
T urn on pump (do not turn on gas) and run for at

least 30 minutes.
Stop pump at five minute intervals and vent until no

more air can be removed and air noises are no
longer produced at the Heater. While the system is
venting check again for water soundness.

16

100 Gas Condensing Pool Heater22/07/03

Rating Table(1040 Btu/ft³) (38.8 MJ/m³

)

kW

Btu/h sec/ft³ m³/2 mins

22

75064 49.9 0.0680

24

81888 45.7 0.0742

26

88712 42.2 0.0804

TURN ON THE GAS

Check for gas soundness (BS 6891) in pipework to
the Heater using a manometer.

Open the gas cock and after purging the system,
the Heater will light automatically .

Run the system at maximum thermostat setting.
Gas soundness within the Heater should be

checked using sense of smell and/or leak detection
fluid.

Continue running for 15 minutes, venting every 5
minutes.

The Main V alv e gradually raises the pressure to the
set point. Allow at least 60 seconds for the Model
100 and 100 seconds for the Model 100W for the
final pressure to stabilise. NB The Pilot has no
adjustment.

IMPORTANT. It is essential when setting the burner
pressure that the inlet pressure is at least 20 mbar
with the Heater and any other connected appliances
running.

Check the burner pressure is correct by using a
manometer connected to the control.

(See the
Datatable inside the cover , the c hart below and
Fig.6:2a & 6:2b)

The pump speed is set by the Manufacturer at £
and should not be changed.

Re-pressurise to required pressure.

With the system hot, check again for water sound­ness. Refit the case to the Heater . Add remainder
of corrosion inhibitor. If there is a Space Heating
system balance in the normal way to obtain even
heating of all radiators.

If fitted, set the cylinder thermostat to 60oC, or
lower if preferred.

Complete the Logbook and pass to the user when
explaining and demonstrate the operation of the
system. Their instructions are in the first pages of
this Installation Instructions.

Note: The Heater is fitted with a syphon trap that in­cludes a blocked drain detection device. This is to
safeguard the Heater and help defer the effects from
the possible freezing of the condensate pipework in
extreme weather .
The user should be made aware of this feature and,
that in the event of blocked condensate pipework, for
example frozen condensate pipework, the Heater will
automatically stop functioning. It will start again as
soon as the blockage has cleared.

COMMISSION CHECK LIST (HYDRAULIC)

The key points which must be observed closely, are
shown below .

* With radiator valves and vents open fill the

system.
* Do not use pump. Do not light gas
* Check for and rectify leaks.
* Drain to flush system.
* Refill system, adding ¾ of the inhibitor .
* Do not light Heater .
* V ent all radiator and air release points.
* Run pump for 5-10 second bursts and revent.
* Do not light Heater .

* Run pump for at least 30 minutes.
* Stop at 5 minute intervals to vent.
* Continue venting until no more air noise can be

heard.
* Light Heater and run at max thermostat setting.

Continue for 15 minutes, venting every 5

minutes.
* Add remainder of inhibitor .

T able 6:2

17

100 Gas Condensing Pool Heater 20/10/03

GAS VALVE

Fig 6:2a

18

100 Gas Condensing Pool Heater

01/06/02

IN

OUT

GAS INLET

GAS OUTLET

INLET PRESSURE POINT

OUTLET PRESSURE POINT

GAS VALVE

Fig 6:2b

100W

100

6.3 SETTING UP THE CONTROLS

It is recommended that you familiarise yourself with
the functions of the Control. These are detailed in
the

User Instructions Section

, and the

Heater

Control Section

.

There are two options that should be set to suit the
user and it also recommended that the Fault Logs
are cleared.

1. The display is factory set for
Fahrenheit Centigrade, it can be altered to
show Centigrade.

2. If the Heater is also providing Space Heat
ing/DHW , the f actory setting of Pool priority
may want to be changed to Heating priority .
Priority means, whichever is chosen has to
be up to temperature before it heats the
other.

These settings can be altered, and other data
viewed in ‘Setup Mode’

Setting Heating Knob On or Off Fascia Indicator

1 Heater temperature * Actual temperature Set temperature e.g 20 & 70

Factory setting Alternative

2 Display Units °F = Fahrenheit °C = Centigrade °C or °F
3 Priority P = Pool H = Heating P or H
4 Filter Pressure log # Number of Operations Resets to zero Yellow Filter LED On
5 Not used
6 Not used
7 Version Number __e.g. 010

* In this position with the Pool Temperature Control off, the Heater can be run for test purposes, if there is a Space

Heating demand, by turning On the Heating Temperature Control Knob.

# Reset the log by turning the Heating Temperature Control Knob On or Off.

T able 6:3. Contr ol Display in Setup Mode.

PROCEDURE T O ENTER SETUP MODE

T o enter Setup Mode turn both T emperature Control
Knobs to OFF.
The following must be carried out within 5 seconds.

1. Turn on the Mains supply to the Heater.

2. Turn the Pool Temperature Control Knob ON.

3. Turn the Heating T emperature Control Knob ON.

4. Turn the Pool Temperature Control Knob OFF.

5. Turn The Heating Temperature Control Knob OFF.
The Control is now in ‘Setup Mode’ and displaying
the Heater temperature. Additional data is displayed
as the Pool Temperature Knob is rotated.

See Fig.

6:3 & T able 6:3

Settings that can be altered are changed by turning
the Heating Temperature Control Knob On or Off.

To leave ‘Setup Mode’ and retain the new settings,
turn off the Mains supply for a few seconds at any
time.

Note: At power-up the Display is also used to show
fault conditions. If an unexpected display is shown
please check the Fault Finding Section 10:2.

Fig 6:3

ON

bar

0 4

2

1 3

u

s

e

r

i

n

s

t

r

u

c

t

i

o

n

s

i

n

s

i

d

e

u

s

e

r

i

n

s

t

r

u

c

t

i

o

n

s

i

n

s

i

d

e

100

s

e

e

i

n

s

t

r

u

c

t

i

o

n

s

2

3

4

5

6

7

1

Heater Temperature
Actual & Setting

Setting Knob

Adjusting Knob

Display units
°C or °F

Priority
P = Pool
H = Heating

Filter Log

Not Used

Ver sion
Number

Overheat LED

Filter LED

19

100 Gas Condensing Pool Heater

01/06/02

6.4 Pump Pressure Switch

The pressure switch, ensures that the heater operates
only when the filter pump is in operation. It is factory
set at 0.12 bar (1.75 PSI) for deck level installations.
When the heater is located below the level of the spa
or pool, it may be necessary to reset the pressure
switch to compensate for the no-flow static head. If it
is necessary to reset the pressure switch, we
recommend the following procedure:

PUMP PRESSURE SWITCH ADJUSTMENT

1. With pump and heater on, turn adjustment
knob clockwise until a click is heard from the
gas valve.

2. Turn adjustment knob counter clockwise ¼
turn.

3. Turn pump off and on several times.
Heater should shut off immediately. If it does
not, repeat steps above until proper
adjustments is made.

Adjustment
Knob

NOTE:

If heater is installed outside of the limits
shown below, a flow switch must be used in place of
the pressure switch when mounted and wired adjacent
to the heater.

TWO SPEED PUMPS

In some cases, the flow on the low speed is insufficient
to operate the heater. This is apparent when the
pressure switch cannot be further adjusted or if the
heater makes banging noises. In these cases, the
pump must be run at high speed when heating the
water.

CAUTION:

Do not operate the heater without the
functionof a properly adjusted pressure switch or flow
switch.

6.5 Responsibility

It is the responsibility of the Installer to ensure that
the Heater is properly commissioned. It is essential
that the commissioning procedures detailed in this

manual are carried out by a qualified engineer.

Fig. 6:4a

Fig. 6:4b

1.5 m Max

1.5 m Max

20

100 Gas Condensing Pool Heater

01/06/02

7:1:1 Control Fault Diagnostics

Before commencing a diagnosis it is recommended
that you familiarise yourself with the functions of
the Controls. These are detailed in the

Users

Instructions Section 1:4

and in

Heater Control,

Section 2:4

The Control will diagnose and display

most of its own faults.

Self Check

The Control does a full self check during power up.
It also briefly lights all the LEDs and the Tempera­ture Display so they can be checked for operation.

Demand Inputs

The front panel LEDs for P ool Demand and Heating
Demand are triggered from the Mains Inputs and the
chosen Priority. If they are not lit check the supplied
voltage, connections and Priority setting.

Relay Outputs

LEDs on the Control Board, beside the relays, are
directly connected to the relay outputs and show if
there is an output voltage to the Burner, Internal
Pump or Pool Pump . If they are not lit check the
output voltages, if correct replace the board. If lit,

check voltage at the component, replace if correct.

7: FAULT FINDING
7:1 Heater Control

If the Heater fails to start, make the following checks .

1. Is the mains electricity supply switched On?

2. Is there a Demand for Pool or Space Heating?

3. For Space Heating is the Heater Thermostat
set to the desired temperature?

6. Check the fuses which should have been
fitted to the mains electricity supply to the
Timeswitch/Heater . If the fuse has blown.
Replace it. If it blows again, call a Service
Engineer.

7. Is the Filter LED lit? If it is, check Pool Pump
is running and the Filter is not blocked.

8. Is the Overheat LED lit? If it is press the Reset
on the Control Panel.

If the fault is not permanently corrected by one of
these actions it is likely that a component is faulty
and will need replacing. This should only be carried
out by someone competent to do so.

IMPORT ANT - E

LECTRICAL SAFETY

IT IS

ESSENTIONAL THAT BEFORE ANY P ANELS ON COMPONENTS

ARE

REMOVED FROM THE HEATER, THAT THE MAINS ISOLATOR IS

SWITCHED

OFF

.

Displayed Faults

The Control board detects and displays certain fault
conditions. The display alternates between two
codes.

Display Reason Action

Err / No

Control board fault.

Power Off then On
again. If not corrected
replace board.

Oc / thb

Boiler sensor

Check connections,

Open Circuit.

if correct, replace
sensor.

Oc / thp

Pool sensor

Check connections,

Open Circuit.

if correct, replace
sensor.

Sc / thb

Boiler sensor

Check connections,

Short Circuit.

if correct, replace
sensor.

Sc / thp

Pool sensor

Check connections,

Short Circuit.

if correct, replace
sensor.

Log

The Control keeps a log of the number of times the
Pressure Switch operates. These can be e xamined
and reset to zero in Setup Mode. The Temperature
Display units and Priority can also be checked and

altered in this mode.

Setup Mode

T o enter Setup Mode turn both temperature control
knobs to OFF.

The following must be carried out within 5 seconds.

T o enter Setup Mode turn both Temperature Control
Knobs to OFF.
The following must be carried out within 5 seconds.

1. Turn on the Mains supply to the Heater.

2. Turn the Pool Temperature Control Knob ON.

3. Turn the Heating T emperature Control Knob ON.

4. Turn the Pool Temperature Control Knob OFF.

5. Turn The Heating Temperature Control Knob OFF.
The Control is now in ‘Setup Mode’ and displaying

the Heater temperature.
The Display can now show additional data as the
Pool Temperature Knob is rotated.

See Fig 7:1 and

Table 7:1

Settings that can be altered can be changed by
turning the Heating T emperature Control Knob On or
Off.

To leave ‘Setup Mode’ and retain the new settings,
turn off the Mains supply for a few seconds at any
time.

21

100 Gas Condensing Pool Heater

10/03/03

TABLE 7:1

FIG 7:1

ON

bar

0 4

2

1 3

u

s

e

r

i

n

s

t

r

u

c

t

i

o

n

s

i

n

s

i

d

e

u

s

e

r

i

n

s

t

r

u

c

t

i

o

n

s

i

n

s

i

d

e

100

s

e

e

i

n

s

t

r

u

c

t

i

o

n

s

2

3

4

5

6

7

1

Heater Temperature
Actual & Setting

Setting Knob

Adjusting Knob

Display units
°C or °F

Priority
P = Pool
H = Heating

Filter Log

Not Used

Ver sion
Number

Overheat LED

Filter LED

22

100 Gas Condensing Pool Heater 01/06/02

CONTROL DISPLAY IN SETUP MODE.

Setting Heating Knob On or Off Fascia Indicator

1 Heater temperature * Actual temperature Set temperature e.g 20 & 70

Factory setting Alternative

2 Display Units °F = Fahrenheit °C = Centigrade °C or °F
3 Priority P = Pool H = Heating P or H
4 Filter Pressure log # Number of Operations Resets to zero Yellow Filter LED On
5 Not used
6 Not used
7 Version Number __e.g. 010

* In this position with the Pool Temperature Control off, the Heater can be run for test purposes, if there is a Space

Heating demand, by turning On the Heating Temperature Control Knob.

# Reset the log by turning the Heating Temperature Control Knob On or Off.

7.2 Ignition Faults
Model 100 Only

WARNING: BEFORE COMMENCING OR COM-

PLETING ANY ELECTRICAL WORK ON THE
APPLIANCE, IT IS RECOMMENDED THAT THE
BASIC SAFETY CHECKS FOR EARTH CONTINU­ITY, SHORT CIRCUIT , POLARITY AND RESIST­ANCE T O EARTH ARE MADE. ALL WORK
CARRIED OUT SHOULD FOLLOW GUIDELINES
LAID DOWN BY THE I.E.E.

The Ignition sequence in the Heater is straight
forward and faults can easily be traced if these
simple steps are followed.

Demand to Heat
Pool Thermostat closed
Boiler Thermostat closed
Ignition Control energised
Flue Stat closed
Overheat Stat closed
T rap not b locked
Pressure Switch open
Fan energised.
Pilot Ignition
Main Burner Ignition

If there is a request to heat the Pool, or if con­nected, the Space Heating, a mains signal will
appear at the POOL DEMAND or HTG DEMAND
connector in the Heater.

For Pool Heating

If the Pool Thermostat Board finds the P ool is
below the set temperature it will put mains on the
BURNER connection of the Pool Thermostat
Board.This is indicated by the LED on the Pool
Thermostat Board. This is connected to the Ignition
Board at its Ls, (Switched Live) connection and the
boiler will then start its ignition process.

For Space Heating (if connected)
If the Pool Thermostat Board finds the Pool is up to
temperature or it has been set for Heating Priority ,
it will put mains on the BURNER and HTR PUMP
connections. This is indicated by the LEDs on the
Pool Thermostat Board. The BURNER signal is
connected to the Ignition Board at its Ls, (Swiched
Live) connection and the boiler will then start its
ignition process. The HTR PUMP signal is used to
move the 3 way valve to Heating.

Ignition

Both the 100 and the100W follow the same se­quence however there are indicators on the 100 to
show these steps. The description below uses the
100 to describe the process.

Lamps on the edge of the Ignition Board indicate
the stages in the ignition sequence. Please refer to
the lable inside the Heater .
Permanent live has to be connected to the L
terminal then the Power lamp lights .

A call for heat powers the Ls terminal and the
Running and Pump lamps light.

Provided the Flue Stat, Overheat Stat and Heater
are cold, the fan starts up. The pressure switch
detects the correct airflow and that the condensate
drain is not blocked then, switches over. This is
indicated by the Fan lamp illuminating.

The Pilot lamp illuminates, the pilot gas valve
opens and the Ignition Control Board provides a
spark at the pilot electrode.

(If the L and N supply are
reversed the Heater will not progress beyond pilot
ignition. This is indicated by the Phase Reversed neon
behind the knob lighting.)

The pilot flame is detected and the Ignition Control
Board stops sparking and then energises the main
gas valve and the Burner lamp is illuminated.

The pilot flame lights the burner, and it stays alight
until turned off by the control thermostat, system
controls, or in the case of a fault condition a safety
thermostat.

The flue thermostat will trip if the flue exceeds a
pre-set temperature. The ov erheat thermostat will
trip if the water flow rate is insufficient, both are
indicated by the Lockout lamp illuminating.

NOTE: The Heater has a b uilt-in dela y timer . It is
indicated by the Running lamp flashing.

For testing, switching the Mains Supply off for a few
seconds, then back on again will reset the delay.

Fault Diagnosis

The fault Diagnosis chart shows the normal and
fault sequences for the Ignition Board indicator
lamps.

T o diagnose a f ault, use the following procedure.

• Turn off the system Mains supply.

• Set all thermostats and timers to a call for

heat position.

• Turn on the system Mains supply and watch

the Ignition Board indicator lamps.

Compare the lamps with the diagnosis chart oppo­site to determine the fault and cause.

23

100 Gas Condensing Pool Heater20/10/03

INDICATOR LIGHTS

Fig 7:2a

24

100 Gas Condensing Pool Heater

01/06/02

100

Fig. 7:2b

25

100 Gas Condensing Pool Heater20/10/03

By using the flow charts basic problems can be identified.
If the particular fault cannot be immediately identified, follow the charts from beginning to end

Before commencing, always check that the Mains is ON and the system controls are calling for heat, the gas cock is open.

Test the electrical system for short circuit, polarity, and resistance before attempting any electrical fault finding.

BOILER ACTION

Ensure Mains is ON.

Hot Water

required.

required.

Turn on any

Hot Water tap.

Ensure Clock/Thermostat

is set to call for heat.

Demand for heat

Fan and Pump start.

For HW Diverter Valve moves

to demand position.

Air Pressure switch

detects air flow.

Burner lights on

low flame.

Gas Valve opens for pilot.

Spark at electrode.

DHW: Burner to full rate.

CH: Low flame for 100 secs

then increases to full rate.

Flame modulates with heat demand.

Cycles ON and OFF if demand very low.

Demand Satisfied

USER CONTROLS

Operation Sequence

FAULT FINDING

Fault causes excess

temperature

Overheat trips

'Lockout' neon illuminates

A 'Demand' LED illuminates

Burner & Fan stop

100W

Fig 7:2c

26

100 Gas Condensing Pool Heater 20/10/03

Is 230V at L connection ?

Correct Mains Supply.

NO

Open any Hot mains tap.

Is the water flow rate OK ?

NO

YES

Remove, clean &

replace Flow Restrictor.

Check pressure and flow

rate of water supply.

Have the Diverter micro-

switches moved ?

Are Inlet & Outlet
pipes crossed ?

Replace diverter Valve.

Is there 230V to the pump

on its PCB terminals ?

YES

NO

NO

NO

Is the 2A PCB fuse OK ?

NO

Replace 2A PCB fuse.

NO

Are the micro-switches

operating electrically.

YES

NO

Replace the micro-

switch assembly.

Replace the main PCB

YES

Does the Fan start ?

Is the Pump free to rotate ?

Free or replace Pump

NO

YES

Does the pump start ?

NO

YES

Is there a spark ?

Has the O/H cutout tripped ?

Is there 230V to the Fan ?

NO

NO

NO

Has the Flue Stat tripped ?

NO

YES

YES

Reset or replace.

Reset or replace.

YES

Replace Fan.

Is there 230V from the CVI

Replace CVI board.

NO

Are the HT Lead & Electrode OK ?

Has the Pressure

Switch operated.

NO

YES

YES

NO

NO

Is there a blockage in the
Condensate Trap or tubes ?

Replace Electrode and Lead

Replace the CVI board.

NO

YES

Replace the Pressure Switch.

YES

YES

Does the Burner light ?

FAULT FINDING Hot Water Operation

NO

Is the Gas Inlet
pressure 20 mb

NO

Provide adequate Gas Supply

Replace CVI board, problem solved ?

if not replace CVI Valve

YES

Does Spark stop after Ignition ?

NO

YES

YES

Are the HT Lead & Electrode OK ?

Replace Electrode and Lead

NO

YES

Replace CVI board.

Is polarity of Boiler supply OK ?

NO

YES

Correct

Does Burner Flame increase to Maximum ?

Does the Flame reduce with water Flow Rate ?

Does the Flame reduce with the DHW Thermostat ?

Does the Flame stop before the O/H trips ?

YES

YES

YES

YES

Is the Thermistor reading

correct to Table A. ?

NO

NO

NO

NO

Replace Thermistor

NO

YES

Replace Main Board.

BOILER OPERATION SATISFACTORY

Is there upto 165mA on yellow lead to coil ?

NO

Replace Modureg Coil, now OK ?

YES

Start with system and boiler cold, with the power ON and no Hot Water taps open. Then Use a hot tap to operate the boiler.

0

20

10

30

40

50

60

70

80

90

33118

20198

12676

8176

5406

3657

2526

1780

1277

931

Temp °C

Ohms

TABLE A

YES

Has the Pilot lit ?

Check Pilot Injector, clean or replace.

NO

YES

Replace CVI

( CVI = Combined Valve & Ignition )

100W

Fig. 7:2d

27

100 Gas Condensing Pool Heater 20/10/03

100W

Is 230V at L connection ?

Correct Mains Supply.

NO

Is there 230V to the pump

on its PCB terminals ?

Is the 2A PCB fuse OK ?

NO

Replace 2A PCB fuse.

NO

Are the micro-switches

operating electrically.

YES

NO

Replace the micro-

switch assembly.

Replace the main PCB

YES

Does the Fan start ?

Is the Pump free to rotate ?

Free or replace Pump

NO

YES

Does the pump start ?

NO

YES

Has the O/H cutout tripped ?

Is there 230V to the Fan ?

NO

NO

NO

Has the Flue Stat tripped ?

NO

YES

YES

Reset or replace.

Reset or replace.

YES

Replace Fan.

Is there 230V from the CVI

Replace CVI board.

NO

YES

YES

Does the Burner light ?

FAULT FINDING Pool or Space Heating Operation

Is the Gas Inlet
pressure 20 mb

NO

Provide adequate Gas Supply

Replace CVI board, problem solved ?

if not replace CVI Valve

YES

Does Spark stop after Ignition ?

NO

YES

YES

Are the HT Lead & Electrode OK ?

Replace Electrode and Lead

NO

YES

Replace CVI board.

Is polarity of Boiler supply OK ?

NO

YES

Correct

Does Burner Flame increase to Maximum ?

Does the Flame reduce as temperature rises to Maximum ?

Does the Flame reduce with the Boiler Thermostat ?

Does the Flame stop before the O/H trips ?

YES

YES

YES

YES

Is the Thermistor reading

correct to Table A. ?

NO

NO

NO

NO

Replace Thermistor

NO

YES

Replace Main Board.

BOILER OPERATION SATISFACTORY

Is there upto 165mA on yellow lead to coil ?

NO

Start with system and boiler cold, with the power ON and no Hot Water taps open.

Set the system controls to call for heat.

0

20

10

30

40

50

60

70

80

90

33118

20198

12676

8176

5406

3657

2526

1780

1277

931

Temp C

Ohms

TABLE A

YES

Is there a spark ?

Are the HT Lead & Electrode OK ?

Has the Pressure

Switch operated.

NO

NO

NO

Is there a blockage in the

Condensate Trap or tubes ?

Replace Electrode and Lead

Replace the CVI board.

NO

YES

Replace the Pressure Switch.

YES

YES

NO

Has the Pilot lit ?

Check Pilot Injector, clean or replace.

NO

YES

( CVI = Combined Valve & Ignition )

YES

Replace CVI

Replace Modulating Coil, now OK ?

8. SER VICING

8.1 Heater Servicing

Health and Safety Statement :

This product contains no asbestos.

Routine

T o ensure continued efficient oper ation 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
once per year should be adequate.
It is law that any service work should be carried
out by Corgi registered personnel.

1.

Clean burner and combustion chamber .

2.

Check pilot and burner gas supply .

3.

Check condition of ignition sensing probe.

4.

Check Heater pipework joints for leaks.

5.

Check the case seals.

6.

Check condensate pipework for leaks.

7.

Check heat exchangers, and the flue and air duct
are clear of any obstruction, and not leaking.

8.

Check the F an and its seal.

9.

Check and clear the condensate exit on the
secondary heat exchanger by removing the
Condensate Outlet and the Inspection Covers

(Fig. 10:1).

10.

Check and clear the condensate syphon.

Follow the procedures given in Changing Components
for parts removal in addition to the following notes.

Heat Exchangers

Remove the panel in front of the secondary heat
exchanger to gain access to inner inspection
panels on the secondary and to view the primary
(the lowest inspection panel also gives a view of
the primary). Also view from beneath the primary .
Clean as required. If in doubt, drain the system and
remove for inspection.

Condensate Syphon

With a suitable bowl to catch the water , unscre w
the drain cap(s) on the underside of the Syphon
T rap and dr ain the water. Remo ve any solids and
replace the cap(s). (

See Fig 10:3

)

8.2 Changing Components

THERE ARE NO REP AIRABLE ITEMS, IF NO T
WORKING AN ITEM MUST BE REPLACED .

The Heater is in two major sections, the Case, and
the Electrical Chassis, The Major Components
Diagram shows where the items are to be found.
(pages 23-24)

Behind the Case

1. Fan.

2. Air Pressure Switch.

3. Flue Thermostat.

4. Control Sensor.

5. Overheat Cut-off Device.

6. HT Lead.

7. Pilot Assembly.

8. Burner.

9. Main Injector.

10. Combustion Chamber Insulation.

11. Primary Heat Exchanger.

12. Secondary Heat Exchanger.

For the 100W only

13. Pump Overrun Thermostat.

Servicing inside the Electrical Chassis

T o Remove the Electrical Chassis

• Disconnect the electrical supply from the
Heater and system.

For the 100W only:

Remove the single fixing screw.

• Slide the Electrical Tray forward a short wa y,
then lower onto the brack et if supprt
required.

• Remove the cover over the components.

• If complete removal required, disconnect all
the leads and remove the plastic nut holding
the Presssure Gauge retainer.

DO NOT STRAIN THE CABLES, USE THE SUP­PORT PRO VIDED.

8.2.1 Control boards

• Lower the Electrical T r ay.

• Remove the screws that retains the inner
cover. Dissconnect all the leads from the
board to be changed.

Inside the Electrical Chassis

1 . Control Boards.

2. Gas Valve.

3. Pump

4. Safety Valv e

5. Pressure Gauge.

For the 100W only

6. Divertor Valve

7. Water to Water Heat Exchanger .

8. DHW Sensor.

9. Inlet Flow regulator and strainer.

28

100 Gas Condensing Pool Heater

20/10/03

8.2.2 Gas V alve - 100 Model Onl y

• Lower the Electrical T r ay.

• Turn the Gas Cock off .

• Pull off the electrical connector from the Gas
Valve.

• Release the pilot feed tube.

• Undo the four shoulder bolts at each end of
the valve.

TAKE CARE TO SUPPORT THE VALVE AS IT IS

RELEASED.

• Replacement is the reverse.

• When secure, attach a manometer to the
burner pressure tapping on the right hand
side of the valve.

• The Pilot Adjuster is factory set.

Model 100W Only:

832.3 Sequence Controller

• Remove the Electrical Tray.

• Identify the CVI valve, the red pod beside it
contains the Sequence Controller.

• Prise off the multiway connectors from the
CVI Sequence Controller pod.

• Pull off the HT Lead from the Controller .

• Pull the pod awa y, and replace.

• Re-assembly is the reverse.

Fig 8:2.2

• Turn on gas and electrical supply .

• The gas valve slowly opens to its setting
ensure it has fully opened before adjusting.

• Set burner gas pressure with the gov ernor.
(see T echnical Data inside of cover .)

8.2.4 CVI V alve

• Remove the Electrical Tray.

• Turn the Gas Cock off.

• Pull off the red pod.

• Pull off the two leads from the Modureg
solenoid.

• Release the pilot feed tube (8mm AF).

• Undo the two screws holding the valve lower
retainer.

• Undo the gas cock.

• Undo the four shoulder bolts and remove the
flange to the gas cock.

• Release the CVI outlet connector , and
withdraw valve.

• Re-assembly is the reverse.

CVI Pressure Set Up

• Check Inlet pressure is at least 20 mbar
when operating.

• Remove the g rey co ver.

• Remove one of the yellow leads from the
Modureg and its grey plastic cov er .

• Attach a manometer to the outlet pressure
tapping.

• Set to Hot Water Only, turn on a tap and
check burner gas pressure is 1.8 mbar.
Adjust the 9mm brass nut on the Modureg to
correct.

• Replace the yellow lead and the boiler will go
to high fire, 11.3 mbar . Adjust with the nylon
7mm nut on the Modureg whilst pressing
down on its shaft.

• Replace the grey co ver .

• Ensure the system controls are calling for
POOL demand and set a Pool temper ature to
bring on the Heater. The Heater will fire at low
rate for 100 seconds. Adjust the small
potentiometer on the Driver board to 5.0 mbar.

• After 100 seconds the boiler will go to high
fire, adjust the large potentiometer on the
driver board to the desired maximum output,
factory setting 11.3 mbar.

For the Pool Thermostat Onl y:

• Remove the Control Knobs.

•

For the 100 Control Board Only:

• Release the Overheat Reset Switch.

• Slide out the board to be changed.

• Re-assembly is the reverse.
NOTE

Replace the rear restraint to the Pool
Thermostat board before re-fitting the board
connectors.

For the 100W Control Board Only:

• Adjust the burner pressures. See CVI
PRESSURE SETUP in CVI Valve section

below .

29

100 Gas Condensing Pool Heater

20/10/03

IN

OUT

INLET PRESSURE POINT

OUTLET PRESSURE POINT

100W

100

8.2.6 Pump

• Remove the Electrical Tray .

• Close the CH Flow and CH Return valves.

• Drain the boiler through the Fill and Drain
Valve.

• Disconnect the cable at the Pump including
those in the terminal strip opposite the
capacitor.

• Remove the terminal strip from the old pump.

• Undo the Pump nuts and remove the Pump.

• Re-assembly is the reverse,

• Note a brown and blue have a black sleeve
and these go to terminal 1 and 2
respectively. The black goes to 7.

• Ensure the fibre washers are in place.

8.2.7 Diverter V alve

• Remove the Electrical Tray .

• Close the CH Flow and CH Return valves.

• Close the DHW Cold In valve and open a
Hot tap to drain the pipework.

• Drain the boiler through the Fill and Drain
Valve.

• Remove the circlip on the Diverter V alv e to
release the switching head.

• Undo the five water connections to the valve
and remove.

8.2.12 Removing the Case

• Lower the Electrical T ra y.

• Undo the two M5 screws at the base of the
Case.

• Lift the Case straight up about half an inch
(12mm).

• Gently pull the Case straight forward off the
hidden studs at the top of the Heater. (Thecover
hangs on two studs in keyhole slots)

8.2.5 Pressure Gauge

• Remove the Electrical Tray .

• Loosen the Plastic Nut that holds Gauge
retainer.

• Squeeze the top and bottom latches on the
gauge, and push out of its retainer.

• V alv e off the Flow and Return connections.

• Release the pressure in the boiler .

• Unscrew the pressure sensor , it ma y need a
temporary plug to avoid leaks.

• Re-assembly is the reverse.

Fig 8:2.4

• Replace unit with new or factory exchange
unit.

• Re-assembly is the reverse, ensure the fibre
washers are in place.

8.2.8 Safety V alve

• Remove the Electrical Tray .

• Close the CH Flow and CH Return valves.

• Drain the boiler through the Fill and Drain
Valve.

• Remove the Pressure Gauge from the
Safety Valve.

• Undo the water connections to the Safety
Valv e and remo ve.

• Re-assembly is the reverse, ensure the fibre
washer is in place.

8.2.9 Water to W ater Heat Exchanger

• Remove the Electrical Tray .

• Close the CH Flow and CH Return valves.

• Close the DHW Cold In valve and open a
Hot tap to drain the pipework.

• Drain the boiler through the Fill and Drain
Valve.

• Remove pump and pipes for easy access.

• Undo the four water connections to the heat
exchanger and pull clear .

• Re-assembly is the reverse, ensure the fibre
washer is in place.

8.2.10 Flow Regulator and Strainer

• Remove the Electrical Tray .

• Close the Cold Water In valve.

• Open a Hot tap to drain the pipework.

• Remove the Mains Cold In V alv e.

• Carefully prise out the Flow Regulator and
Strainer (boiler side).

• Clean Strainer and restrictor.

• Re-assembly is the reverse.

8.2.11 DHW T emperature Sensor

• Remove the Electrical Tray .

• Remove the electrical connection from the
DHW Temperature Sensor and unclip from pipe.

• Re-assembly is the reverse.

30

100 Gas Condensing Pool Heater 01/06/02

• Examine the sealing strip for damage and
replace if necessary.

• Place the Case somewhere safe from
damage

IMPORT ANT: F AILURE T O CORRECTL Y LOCA TE

THE APPLIANCE CASE COULD RESUL T IN
LEAKAGE OF COMBUSTION PRODUCTS
INTO THE ROOM.

8.2.13 Fan Assembly

• Lower the Electrical T ra y.

• Remove the Case.

• Undo the wing nut holding the Fan Protection
Hoop.

• Pull the electrical connectors off the Fan.

• Gently pull the pressure tubing off the
tappings on the Flue Hood.

• Undo the two screws holding the Flue Hood
and slide forward and aw ay.

• Re-assembly is the reverse.

8.2.14 Air Pressure Switch

• Lower the Electrical T ra y.

• Remove the Case.

• Pull the electrical connectors off the Air
Pressure Switch.

• Gently pull the pressure tubing off the both
tappings on the switch.

• Undo the M4 nut and wing nut holding the Air
Pressure Switch to its bracket on to the Back
Panel

• Lift off its studs and rotate out of its bracket.

• Re-assembly is the reverse.

8.2.15 Flue Thermostat

• Lower the Electrical T ra y.

• Remove the Case.

• To replace pull the electrical connectors off the
Flue Thermostat.

• To reset press Red Button.

• Re-assembly is the reverse.

8.2.16 Pump Overrun Thermostat

• Remove the Electrical Tray .

• Remove the Case.

• Note the three wire colours and positions.

• Pull the electrical connectors off the Pump
Overrun Thermostat.

• Undo the two M4 screws holding the Thermostat.

• Re-assembly using Heat Sink Compound is
in the reverse order .

8.2.17 Control Sensor

• Lower the Electrical Tray .

• Remove the Case.

• Unclip the sensor.

• Pull the electrical connectors off the Control
sensor.

• Re-assembly is the reverse.

8.2.18 Overheat Cut-off Device

• Lower the Electrical Tray .

• Remove the Case.

(To Reset, Press Red Button)

• Pull the electrical connectors off the Over
heat Cut-off device.

• Unscrew from its mounting.

• Re-assembly is the reverse.

• Lower the Electrical Tray .

8.2.19 Electrode and HT Lead

• Lower the Electrical T r ay.

• Remove the Case.

• To Replace pull off the HT lead from the Control
Board/Sequence Controller.

• Undo the left and right screws holding the
Front Burner Baffle.

• Remove the front baffle.

For the 100 Only:

• Release the tube nut holding the electrode to
the Pilot Burner.

• Carefully withdraw the Electrode and HT
Lead.

For the 100W Only:

• Push the Electrode towards the burner and
pull down and clear.

• Re-assembly is the reverse.

8.2.20 Pilot Assembly

• Lower the Electrical T r ay.

• Remove the Case.

• Undo the left and right screws holding the
Front Burner Baffle and remove . If access is
restricted also remove the lower baffle.

• Release the tube nut holding the electrode to
the Pilot Burner.

• Undo the Pilot tube from the Pilot Assembly
and gently lever downwards away from the
Pilot. It has to be removed and replaced
with the injector clipped into position.
Undo the two screws retaining the Pilot
Assembly.

• Re-assembly is the reverse

NB The pilot is not adjustab le.

31

100 Gas Condensing Pool Heater

20/10/03

8.2.24 Combustion Chamber Insulation

• Lower the Electrical T r ay.

• Remove the Case.

• Remove the Front Baffle, then undo the four
M5 screws holding the lower baffle onto the
Back Panel

• Remove the Burner, as in 10.

• Undo the four screws holding the Chamber
to the Back P anel and lower downwards and
away .

• Replace the Insulation Panels in the
Chamber.

• Re-assembly is the reverse.

8.2.25 Primary Heat Exchanger

• Lower the Electrical T r ay.

• Remove the Case.

• Remove the front baffle.

• Remove or cover the Burner.

• Remove the Comb ustion Chamber.

• Unclip the Control sensor .

• Pull off the wires to the Overheat Cut Out
device.

• Drain the Heater of water .

• Undo the flow and return connections to the
Heat Exchanger and lower aw ay .

• Re-assembly is the reverse.

8.2.21 Burner

• Lower the Electrical T r ay.

• Remove the Case.

• Remove the Front Baffle.

• Remove the Combustion Chamber front by
releasing the four screws.

• Undo the Pilot tube from the Pilot Assembly
and gently lever downwards away from the
Pilot. It has to be removed and replaced with
the injector clipped into position.

• Pull off the HT lead.

• Pull the Burner forward off the two studs at
the rear.

• Remove the Pilot Assembly.

• Re-assembly is the reverse.

8.2.22 Main Injector

• Lower the Electrical T r ay.

• Remove the Case.

• Remove the Burner .

• Undo the Main Injector from the manifold.

• Re-assembly is the reverse.

8.2.26 Secondary Heat Exchanger

• Lower the Electrical T r ay.

• Remove the Case.

• Remove the Flue Thermostat.

• Remove the Fan Assembly.

• Drain the Heater of water.

• Undo the flow and return connections to the
secondary Heat Exchanger.

• Release the Condensate connection
clamping plate.

• Undo the four screws holding the Secondary
Heat Exchanger to the Back Panel and lift
away .

• Re-assembly is the reverse.

32

100 Gas Condensing Pool Heater 01/06/02

9. PARTS

9.1 Spares

Ke y Item Part Number GC Number

1 Primary Heat Exchanger M0593
2 Secondary Heat Exchanger (17 kW) M0797
3 Burner (Model 100) M3727
3 Burner (Model 100W) M3728
4 Ceramic Board Set M1089 106 404
5 Fan Assemb ly M0910 106 435
6 Ignition Board (Model 100) M4750
6 Driver Board (Model 100W) M0614 173072
8 Contol Board M4735
9 Pool or Heating Sensor SPCOH2/002
10 Sequence Controller M0672 173066
11 Gas V alve (Model 100) M3783
12 Gas V alve (Model 100W) M0671
13 Air Pressure Switch M4176

Main Injector (4.1mm) M0919 106 386
14 Overheat Thermostat (Model 100) M3781 379 314
15 Overheat Thermostat (Model 100W) M0868 173068

Pilot Injector (Model 100) 7709 386 673

Pilot Injector (Model 100W) M0663 381656

Electrode (Model 100) 7710 386 744
16 HT Lead Assembly (Model 100) M3895
17 Electrode & Lead (Model 100W) M0666

Pilot Assembly (Model 100) 7716 381 865

Pilot Assembly (Model 100W) M0662 106437
18 Flue Thermostat 7717 379 308
19 Clip-on Sensor (22mm) M3338
20 Clip-on Sensor (15mm) M3337
21 Condensate T rap M3805
22 Safety Valve M0480 379831
23 Three Way V alve M0608 173071
24 Pressure Gauge SPCOH2/003
25 Expansion Vessel M0610
26 Plate Water to W ater Heat Exchanger M0612 106436
27 Grundfos Pump M0623 383722
28 Pool Water to Water Heat Exchanger M4374
29 Pool Pump Pressure Switch 651284
30 Bypass Valve M1091
31 Diverter Valve M4531

33

100 Gas Condensing Pool Heater

20/10/03

34

100 Gas Condensing Pool Heater 20/10/03

9:2 Electrical Components

100 & 100W

16

6

9

8

10 DIAGRAMS
10:1 Major Components

Fig.10:1

35

100 Gas Condensing Pool Heater

01/06/02

14/15

30

28

31

29

22

13

27

11

24

2

1

18

5

19

10:2 Example Condensate Disposal Methods

Fig.10:2

75mm Running Trap

Air Break

Strap-On Boss

1:20 Fall ( 2.5 Degrees )

Washing Machine

Trap

Air Gap

Air Gap

110mm Soil Pipe or Drain

Soakaway

Insulate against
freezing

150mm Land Drain
Filled with Gravel
750mm deep

Condensate
Drain from
Heater

Air Pressure Switch

pipe connection

Vent

Syphon

Connect To Waste

Drain Cap

Bypass

10.3 Condensate Drain Trap

Note: Internal - minimum 19mm pipe

External - minimum 32mm pipe

Condensate
Drain for
Twin Pipe Flue

Fig. 10:3

36

100 Gas Condensing Pool Heater 01/06/02

M4728 20/10/03