Hayward In Ground Pool, Spa Gas Heaters User Manual

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IN GROUND POOL/SPA GAS HEATERS INSTALLATION & OPERATIONS MANUAL

FOR YOUR SAFETY:

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, injury, or death.

•Do not store or use gasoline or other flammable vapors or 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 neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department.

•Installation and service must be performed by a qualified installer, service agency or the gas supplier.

This product must be installed and serviced by authorized personnel, qualified in pool/spa heater installation. Improper installation and/or operation can create carbon monoxide gas and flue gases that can cause serious injury, property damage, or death.

CONTENTS	Pg
GETTING STARTED	2
INSTALLATION	10
LOCATING THE HEATER	11
ALTITUDE OF INSTALLATION	13
AIR SUPPLY	14
FLUE GAS VENTING	15
GAS SUPPLY	19
WATER PIPING	21
ELECTRICAL CONNECTIONS	24
CHECK-OUT & START-UP	25
CONTROL SETUP	26
GAS TESTING	28
WATER TESTING	31
MAINTENANCE & SERVICE	31
WATER CHEMISTRY	31
WINTERIZATION	32
COMPONENT SERVICE	32
TROUBLESHOOTING	39
PARTS	49

SAVE THESE

INSTRUCTIONS

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GETTING STARTED

WHAT TO EXPECT WHEN OPERATING YOUR POOL HEATER

This flow chart provides guidance to protect pool users and product by maintaining good water quality.

INSTALLATION

Verify that product installation was performed to local codes and according to this manual.

INITIAL USE OR SPRING STARTUP

Check all pool / spa water piping. Do not connect product to water piping.

IMPORTANT FOR POOL USER HEALTH AND PRODUCT PERFORMANCE

Verify Chlorine or Bromine level every 2-3 days

Verify PH level every week

Verify Alkalinity level every 3-4 weeks (2 weeks if using an Automatic Chlorine or Bromine Feeder)

Verify Water Hardness and Total Dissolved Solids (TDS) every month (it is recommended that a pool professional perform this testing)

IS POOL/SPA IN

CHEMICAL BALANCE?

CONNECT WATER PIPING TO PRODUCT, BYPASS TO OPEN POSITION

IS HEATING/COOLING

NEEDED WITHIN 1 WEEK?

BYPASS TO CLOSED POSITION, WATER DIRECTED TO PRODUCT

TURN ON ELECTRIC POWER AND GAS AS REQUIRED. START PRODUCT. PROGRAM REQUIRED WATER TEMPERATURE ON PRODUCT CONTROL PANEL.

DISCONNECT NO WATER PIPING TO

PRODUCT

PRODUCT

OPEN

POOL/SPA

SET BYPASS TO

OPEN POSITION, NO WATER DIVERTED

FROM PRODUCT

PRODUCT

CLOSED

POOL/SPA

ENJOY YOUR POOL/SPA

IS HEATING/COOLING NEEDED FOR REST OF YEAR?

TURN OFF ELECTRIC NO POWER AND GAS AS

REQUIRED

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PLEASE READ BEFORE PROCEEDING

Basic safety precautions should always be followed, including the following:

Failure to follow instructions can cause death and/or severe injury.

This is the safety-alert symbol. When you see this symbol on your equipment or in this manual, look for one of the following signal words and be alert to the potential for personal injury.

WARNING warns about hazards that could cause death and/or severe injury or major property damage and if ignored presents a potential hazard.

CAUTION warns about hazards that could cause minor or moderate personal injury and/or property damage and if ignored presents a potential hazard. It can also make consumers aware of actions that are unpredictable and unsafe.

NOTICE indicates special instructions that are important but not related to hazards.

See product rating plate for manufactures information.

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HEATER CONSTRUCTION

Figure1: Sub-Assemblies

Top Flue Cover

Rain Shield

Assembly

Heat Exchanger

Assembly

Upper Side

Panels

Gas

Control

Combustion

Blower

Front Access Panel

Water Pressure

Switch

Water

Temperature

Switches

Drain Plug or

Relief Valve

Lower Side

Control Bezel Panels

and Control

Boards

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Table1: SPECIFICATIONS

Features:

120 or 240VAC, 60Hz, 1-phase, 5.5A maximum current

Forced draft combustion with silicon nitride hot surface ignition

Cupronickel water tubes standard

Integral low loss bypass, maximum water flow for all models is 125 GPM

Model	Gas Input	Minimum	Thermal	Heater	Heater
	Natural or Propane	Water Flow	Efficiency	Width	Weight
*xxx*	btu/hr	gpm	%	in.	lbs.
150	150,000	20	82.7	19	135
200	199,900	20	83	22	140
250	250,000	25	84	25	165
300	300,000	25	82.7	26	175
350	350,000	30	83	31	195
400	399,900	30	84	34	195
500	500,000	40	83	40	245
250ASME	250,000	25	84	28	195
400ASME	400,000	30	84	36.5	225
500ASME	500,000	40	83	40.5	260

GAS REQUIREMENTS

	OPERATING PRESSURES			Natural Gas (inwc)				Propane Gas (inwc)
	Gas Manifold Pressure*			1.8 - 2.2					6.8 - 7.0
	Gas Inlet Pressure, Minimum			4.5					10.0
	Gas Inlet Pressure Maximum			10.5					13.0
	GAS ORIFICE DRILL SIZES			#25					#43
	GAS ORIFICE DRILL SIZES (500kbtu/hr)			#22					2.3mm
*Pressure range for allowable heating value variation.
		Heater Width						22.2
											22.2
				2.2			2.2	22.2
					22.2

2.2

2.2

22.2

22.2

22.2

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Wiring Connection Diagram

WARNING - Risk of Electric Shock Before working on any electrical equipment, turn off power supply to the equipment.

WARNING - Risk of Electric Shock. All electrical wiring MUST conform to applicable local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can cause death, shock, burn, and/or serious property damage. To reduce the risk of electric shock, do NOT use an extension cord to connect unit to electric supply. Provide a properly located electrical receptacle. To reduce the risk of electric shock replace damaged wiring immediately. Locate conduit to prevent abuse from lawn mowers, hedge trimmers and other equipment. Do NOT ground to a gas supply line.

Figure2: Wiring Diagram

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Table2: CERTIFICATION AND COMPLIANCE

	CERTIFICATION CODES AND STANDARDS	USA	CANADA
	DESIGN CERTIFIED	CSA	CSA
	DESIGN COMPLIANT	ANSI Z21.56	CSA 4.7
	INSTALLATION COMPLIANT GAS	NFPA 54/ANSI Z223.1	CAN/CSA-B149.1-2
		NFPA 58
	INSTALLATION COMPLIANT ELECTRIC	ANSI/NFPA 70	CSA C22.1 – Canadian
		NEC	Electrical Code, Part I
	EMISSIONS	SCAQMD 1146.2
	SHIPPING COMPLIANT	ISTA 3B	ISTA 3B

CONFORMANCE WITH CODES: The heater shall be installed in accordance with all local and state codes and with the requirements of the authority having jurisdiction of the installing site. The heater installation must conform to the latest edition of the above listed installation codes.

SAFETY INFORMATION

WARNING – Read, Understand, and Follow all instructions in this manual and on the equipment. Failure to follow instructions can cause severe injury and/or death.

WARNING – Suction Entrapment Hazard.

Suction in suction outlets and/or suction outlet covers which are damaged, broken, cracked, missing, or unsecured can cause severe injury or death due to the following entrapment hazards:

Hair Entrapment- Hair can become entangled in suction outlet cover.

Limb Entrapment- A limb inserted into an opening of a suction outlet sump or suction outlet cover that is damaged, broken, cracked, missing, or not securely attached can result in a mechanical bind or swelling of the limb.

Body Suction Entrapment- A negative pressure applied to a large portion of the body or limbs can result in an entrapment.

Evisceration/ Disembowelment - A negative pressure applied directly to the intestines through an unprotected suction outlet sump or suction outlet cover which is damaged, broken, cracked, missing, or unsecured can result in evisceration/disembowelment.

Mechanical Entrapment- There is potential for jewelry, swimsuit, hair decorations, finger, toe or knuckle to be caught in an opening of a suction outlet cover resulting in mechanical entrapment.

WARNING - To Reduce the risk of Entrapment Hazards:

oWhen outlets are small enough to be blocked by a person, a minimum of two functioning suction outlets per pump must be installed. Suction outlets in the same plane (i.e. floor or wall), must be installed a minimum of three feet (3’)

[1 meter] apart, as measured from near point to near point.

o Dual suction fittings shall be placed in such locations and distances to avoid “dual blockage” by a user. o Dual suction fittings shall not be located on seating areas or on the backrest for such seating areas.

o The maximum system flow rate shall not exceed the flow rating as listed in TABLE1: SPECIFICATIONS.

o Never use Pool or Spa if any suction outlet component is damaged, broken, cracked, missing, or not securely attached.

o Replace damaged, broken, cracked, missing, or not securely attached suction outlet components immediately.

oInstall two or more suction outlets per pump in accordance with latest ASME, APSP Standards and CPSC guidelines. Follow all applicable National, State, and Local codes.

o Installation of a vacuum release or vent system, which relieves entrapping suction, is recommended.

WARNING – Failure to remove pressure test plugs and/or plugs used in winterization of the pool/spa from the suction outlets can result in an increase potential for suction entrapment as described above.

WARNING – Failure to keep suction outlet components clear of debris, such as leaves, dirt, hair, paper and other material can result in an increase potential for suction entrapment as described above.

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WARNING – Suction outlet components have a finite life, the cover/grate should be inspected frequently and replaced at least every seven years or if found to be damaged, broken, cracked, missing, or not securely attached.

CAUTION – Components such as the filtration system, pumps and heater must be positioned so as to prevent their being used as means of access to the pool by young children. To reduce risk of injury, do not permit children to use or climb on this product. Closely supervise children at all times. Components such as the filtration system, pumps, and heaters must be positioned to prevent children from using them as a means of access to the pool.

WARNING – Hazardous Pressure. Pool and spa water heating and circulation systems operate under hazardous pressure during start up, normal operation, and after pump shut off. Stand clear of circulation system equipment during pump start up. Failure to follow safety and operation instructions could result in violent separation of the pump housing and cover, and/or filter housing and clamp due to pressure in the system, which could cause death, severe personal injury and/or property damage. Before servicing pool and spa water circulation system, all system and pump controls must be in off position and filter manual air relief valve must be in open position. Before starting system pump, all system valves must be set in a position to allow system water to return back to the pool. Do not change filter control valve position while system pump is running. Before starting system pump, fully open filter manual air relief valve. Do not close filter manual air relief valve until a steady stream of water (not air or air and water) is discharged.

WARNING – Separation Hazard. Failure to follow safety and operation instructions could result in violent separation of pump and/or filter components. Strainer cover must be properly secured to pump housing with strainer cover lock ring. Before servicing pool and spa circulation system, filters manual air relief valve must be in open position. Do not operate pool and spa circulation system if a system component is not assembled properly, damaged, or missing. Do not operate pool and spa circulation system unless filter manual air relief valve body is in locked position in filter upper body. Never operate or test the circulation system at more than 50 PSI. Do not purge the system with compressed air. Purging the system with compressed air can cause components to explode, with risk of severe injury or death to anyone nearby. Use only a low pressure (below 5 PSI), high volume blower when air purging the pump, filter, or piping.

WARNING – Risk of Electric Shock. All electrical wiring MUST be in conformance with applicable local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can shock, burn, and cause death or serious property damage. To reduce the risk of electric shock, do NOT use an extension cord to connect unit to electric supply. Provide a properly located electrical receptacle. Before working on any electrical equipment, turn off power supply to the equipment. To reduce the risk of electric shock replace damaged wiring immediately. Locate conduit to prevent abuse from lawn mowers, hedge trimmers and other equipment. Do NOT ground to a gas supply line.

WARNING – Risk of Electric Shock. Failure to ground all electrical equipment can cause serious or fatal electrical shock hazard. Electrically ground all electrical equipment before connecting to electrical power supply.

WARNING – Risk of Electric Shock. Failure to bond all electrical equipment to pool structure will increase risk for electrocution and could result in injury or death. To reduce the risk of electric shock, see installation instructions and consult a professional electrician on how to bond all electrical equipment. Also, contact a licensed electrician for information on local electrical codes for bonding requirements.

Notes to electrician: Use a solid copper conductor, size 8 or larger. Run a continuous wire from external bonding lug to reinforcing rod or mesh. Connect a No. 8 AWG (8.4 mm2) [No. 6 AWG (13.3 mm2) for Canada] solid copper bonding wire to the pressure wire connector provided on the electrical equipment and to all metal parts of swimming pool, spa, or hot tub, and metal piping (except gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool, spa, or hot tub.

IMPORTANT - Reference NEC codes for all wiring standards including, but not limited to, grounding, bonding and other general wiring procedures.

WARNING – Risk of Electric Shock. The electrical equipment must be connected only to a supply circuit that is protected by a ground-fault circuit-interrupter (GFCI). Such a GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push reset button. Power should be restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts power to the electrical equipment without the test button being pushed, a ground current is flowing, indicating the possibility of an electrical shock. Do not use this electrical equipment. Disconnect the electrical equipment and have the problem corrected by a qualified service representative before using.

CAUTION – These heaters are intended for use with permanently-installed pools and may be used with hot tubs and spas if so marked. Do not use with storable pools. A permanently-installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its original integrity.

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WARNING – Risk of Hyperthermia. To avoid hyperthermia the following “Safety Rules for Hot Tubs” are recommended by the U.S. Consumer Product Safety Commission.

1.Spa or hot tub water temperatures should never exceed 104°F [40°C]. A temperature of 100°F [38°C] is considered safe for a healthy adult. Special caution is suggested for young children. Prolonged immersion in hot water can induce hyperthermia.

2.Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness, which could lead to unconsciousness and subsequently result in drowning.

3.Pregnant women beware! Soaking in water above 100°F [38°C] can cause fetal damage during the first three months of pregnancy (resulting in the birth of a brain-damaged or deformed child). Pregnant women should adhere to the 100°F [38°C] maximum rule.

4.Before entering the spa or hot tub, users should check the water temperature with an accurate thermometer; spa or hot tub thermostats may err in regulating water temperatures by as much as 4°F (2.2°C).

5.Persons taking medications, which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants, should not use spas or hot tubs.

6.If the pool/spa is used for therapy, it should be done with the advice of a physician. Always stir pool/ spa water before entering the pool/spa to mix in any hot surface layer of water that might exceed healthful temperature limits and cause injury. Do not tamper with controls because scalding can result if safety controls are not in proper working order.

7.Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure problems should obtain a physician’s advice before using spas or hot tubs.

8.Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above normal body temperature of 98.6°F [37°C]. The symptoms of Hyperthermia include: drowsiness, lethargy, dizziness, fainting, and an increase in the internal temperature of the body.

The effects of Hyperthermia include:

Unawareness of impending danger.

Failure to perceive heat.

Failure to recognize the need to leave the spa.

Physical inability to exit the spa.

Fetal damage in pregnant women.

Unconsciousness resulting in danger of drowning.

DEFINITIONS:

Suction Outlet: The Suction Outlet is a fitting, fitting assembly, cover/grate and related components that provide a means for water to exit the pool and return into the pump circulating system. This fitting may also be referred to as the “Main Drain”

Bypass Valves: A valve or series of valves that direct the pool water to flow or not flow through the heater. CSA: Canadian Standards Association

CGA: Canadian Gas Association

ANSI: American Nation Standards Institute

NFPA: National Fire Protection Association NEC: National Electric Code

SCAQMD: South Coast Air Quality Management District ISTA: International Safe Transit Association

Pressure measurement units:

Inches of Mercury (inHg) is typically used with atmospheric pressure measurements.

Pounds per square inch (PSI) is typically used with water “pressure”, “suction” or system measurements.

Inches of Water (inwc) is typically used with gas or air pressure measurements (1.0 inHg = .49 PSI = 13.5inwc)

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INSTALLATION:

This manual contains instructions for installation, operation, maintenance, troubleshooting, and parts lists for the proper operation of the swimming pool/spa/hot tub heaters. It is strongly recommended that the installer read the manual before installing the swimming pool/spa/hot tub heater. If after reviewing the manual any questions remain unanswered, contact tech services or local representative. Following heater installation, the installer should leave all manuals with the consumer for future reference.

NOTICE: The installation instructions are intended for the use of a qualified technician, specifically trained and experienced in the installation of this type of heating equipment. Some states or provinces require that installer be licensed. If this is the case in the state or province where heater is located, the contractor must be properly certified.

THE USE OF A POOL COVER IS RECOMMENDED. A pool cover reduces heat loss, conserves chemicals, lowers the load on filter systems and may provide a valuable safety feature

EQUIPMENT INSPECTION: On receipt of the heater, inspect the heater carton(s) for damage. If any carton(s) is damaged, note it when signing for it. Remove the heater from the carton(s) inspect it and advise the carrier of any damages at once.

NOTICE: Do not drop the heater from a pickup truck tailgate to the ground. This may damage the heater.

UNCRATING THE HEATER: Follow these steps to

remove the shipping carton from the heater:

1.Remove the corrugated carton from the heater. The carton, top pad, bottom pad, and the four corner posts can be recycled.

2.There are four (4) external screws (see figure3) used to secure the heater to the wood pallet. All four must be removed to separate the heater from the pallet.

Figure3: External Shipping Screw Locations

Front shipping screws and brackets

Rear shipping screws and brackets

3.To access the four (4) internal screws (see figure4), open the front access panel by removing the single top screw. Then remove the two (2) screws and brackets which hold the heater base pan to the pallet shown in Figure3. Next open the rear access panel by removing the four (4) screws holding this panel. Then remove the two (2) screws and brackets which hold the heater base pan to the pallet as shown in Figure3.

4.Lift the heater clear of the corrugated bottom pad and off of the pallet. Discard bottom corrugated tray and pallet appropriately.

Figure4: Internal Shipping Screw Locations

Front shipping screws

Rear shipping screws

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SPRINKLER HEADS: The heater is designed to handle the wettest weather conditions that are typical of rain and high humidity. Sprinkler heads force high-pressure water into the unit from the side at an odd angle. Make sure there are no sprinkler heads near the heater that will spray on or into the unit. Many sprinkler systems are connected to a well system, whose water is high in minerals, Sulphur, salt and other aggressive contaminates, that will leave a buildup on the unit and electronics causing corrosion and shortens life.

NOTICE: Damage from sprinkler interaction is not covered under the warranty agreement. Make sure that sprinklers are placed at a sufficient distance away so that normal wind will not carry the mist to the Heater.

NOTICE: If located in an oceanfront area, the Heater should be placed out of direct spray of sand and salt. This will clog, damage, and corrode the unit. You may also consider protecting the unit by creating a physical barrier outside of the minimum clearances between the unit and the prevailing beachfront wind. Damage caused by sand or salt spray is not covered by the warranty.

LOCATING THE HEATER:

Locate the pool/spa heater in an area where leakage of the heat exchanger or connections will not result in damage to the area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, with drain outlet, be installed under the heater. The pan must not restrict airflow. This heater must be installed at least (5) feet from the inside wall of a pool (in-ground or above-ground)/spa/hot tub unless separated from the pool/spa/hot tub by a solid barrier. The heater must be installed such that the location of the exhaust gas vent assembly outlet relative to adjacent public walkways, adjacent buildings, openable windows, and building openings complies with the National Fuel Gas Code (ANSI Z223.1/NFPA 54) and/or CAN/CGA B149 installation codes.

1.Level surface for proper rain water draining and removal.

2.Suitable electrical supply line. See rating plate on the heater for electrical specifications. A junction box is not needed at the heater; connections are made inside the unit electrical compartment. Minimum wire size to be selected per NEC.

3.Electric disconnect switch that will interrupt all power to the unit. This switch MUST be within line of sight of the heater.

4.The heater does not require additional vent piping when installed outdoors.

5.Do not install in a location where growing shrubs may in time obstruct a heater’s combustion air and venting areas.

6.Do not install this appliance under an overhang less than 72in from the top of the appliance. The area under the overhang must be open on (3) sides.

7.Do not install the heater where water spray from ground level can contact the heater. The water could reach the controls causing electrical damage.

8.Do not install under a deck.

9.Do not install within 24in of any outdoor HVAC equipment.

10.Do not install where water may run-off a roof into the heater. A gutter may be needed to protect the heater.

CAUTION: Make sure the heater is not located where large amounts of water may run-off from the roof into the unit. Sharp sloping roofs without gutters will allow massive amounts of rainwater, mixed with debris from the roof to be forced through the unit. Failure to follow the instructions may result in property damage and void warranty.

11.Any enclosure around the heater must provide a combustion air vent large enough to accommodate input ratings of all gas appliances in the enclosure. See AIR SUPPLY section for more detail

12.For minimum exhaust vent clearances for all building openings, including but not limited to vented eaves, doors, windows, or gravity inlets, see Figure5. In Canada, the heater must be installed with the top of the vent at least 10 feet (3m) below, or to either side of, any opening into a building.

OUTDOOR AND INDOOR INSTALLATION AND SERVICE CLEARANCES: For both outdoors and indoors installations, the installation clearances from combustible materials and service clearances shown in Table3 and Figure5 must be maintained. Do not install heater in a closet or enclosed space (consult NFGC)

*If the heater is to be installed with vinyl siding at back, increase the clearance in Table3 to 12 inches to avoid potential discoloration of siding

Table3: Installation Required Clearances (in.)

	Heater Panel	Outdoor	Indoor
		Clearance	Clearance
	Top	Unobstructed	36
	Front	18	18
	Back*	6	6
	Water Side Connection	12	12
	Opposite Water Side	6	6
	Connection

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EQUIPMENT PAD: Place the heater on a level surface such as concrete or a fabricated slab (pad). This allows proper drainage of condensation and rainwater from the base of the unit. If possible, the pad should be placed at the same level or slightly higher than the filter system equipment pad.

FLOORING: This heater may be installed on either non-combustible flooring or combustible flooring that does not reduce the bottom clearance of the heater. Ultralite™ or equivalent concrete-over-foam HVAC pads are acceptable.

Figure5: Outdoor Minimum Clearances

			Free
			from rain
	4 ft.	4 ft.	run off or
	minimum	minimum	blockage
			from
3 ft.	4 ft.		above
minimum	minimum
Force Air
Inlet	10 ft. minimum

ANCHORING: The heater is equipped for installation of factory supplied tie-down brackets when required by local codes. Follow all relevant Local, State and National requirements regarding wind load anchoring. The brackets are shipped in the consumer kit. You will need the following to complete the installation:

Tie-down brackets	(FACTORY-SUPPLIED, qty = 4)
Sheet metal screws	(FACTORY-SUPPLIED, qty = 4)
Concrete tapping screws	(FIELD-SUPPLIED, Tapcons®, qty = 4, stainless steel, size to be ¼”diameter with a minimum
	length of 1-1/2”)
Fender washers	(FIELD SUPPLIED, stainless steel, qty = 4, size to be at least 1-1/2”)

INSTALLING TIE-DOWN BRACKETS:

1.Locate the tie-down brackets and the sheet metal screws.

2.Obtain the Tapcons®. Be sure the overall length of the concrete tapping screw is at least1-1/2”.

3.Remove the front (1 screw) and rear access panel (4 screws).

4. Position the heater on the pad so that all Tapcons® can “bite” into the pad. Observe local codes regarding pad construction, some jurisdictions specify a minimum thickness for concrete pads.

5.Position the tie-down brackets into the slots in the front of the heater base pan so they are positioned as shown in Figure6. Install the sheet metal screws through the holes in the bracket to secure the bracket to the heater base pan.

6.Install the Tapcons® through the inner set of holes in the tie-down brackets into the pad (see figure7).

7.Repeat Steps 6 & 7 at the rear of the heater.

8.Tie down is completed when (4) brackets are secured to the heater and the pad. Re-install the access panels in locations (front and rear), front shown

Figure6: Tie-Down Installation Locations	Figure7: Use 2nd Hole for Ground Mount of
	Tie-Down Brackets with 2 Holes

Install supplied screws at these locations.

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GAS CONVERSION:

Where permitted by local codes, the factory-installed gas train may be changed from natural gas to propane or from propane to natural gas, using the appropriate conversion kits. Gas conversions are to be performed only by a qualified service agency. Detailed instructions are included with each kit.

ALTITUDE OF INSTALLATION:

Heaters may be installed at any altitude up to 10,100 ft. above sea level, provided the appropriate modification(s) are performed. The altitudes which require modification vary depending on the model. Parts necessary to convert the heater for outdoor installation at altitudes up to 7,700 ft. (minimum) are included with the heater.

WARNING: Failure to comply with the appliance and vent package installation instructions and service instructions in this manual may result in equipment damage, fire, asphyxiation, or carbon monoxide poisoning. Exposure to products of incomplete combustion (carbon monoxide) can cause cancer and birth defects or other reproductive harm.

Conversion is accomplished by replacement of the blower air inlet plate, and for indoor applications, installation of the appropriate vent pressure switch. The blower air inlet plates are clearly marked with the compatible heater model(s), vent configuration(s), and altitude range(s). Care should be taken to verify the correct plate and vent pressure switch is being used to ensure proper heater performance. The vent pressure switch will be provided with the indoor adapter kit, or if you have an older indoor adapter kit, order p/n FDXLVPS1931 for the high-altitude indoor vent pressure switch. Table4 lists the maximum altitudes for which each model is designed with: a) no modifications, b) the included conversion plate installed, and c) the accessory conversion kit FDXLHAK1930 installed (sold separately).

Table4 High Altitude Conversions in (ft.)

Model		Outdoor Installation				Indoor Installation *
	No		Included	Kit	No	Included		Kit
	Modifications		Conversion	FDXLHAK1930	Modifications	Conversion Plate	FDXLHAK1930
	to Heater		Plate Installed	Installed	to Heater	Installed		Installed
150FDN	7,700		N/A	10,100	10,100	N/A		N/A
150FDP	7,700		N/A	10,100	2,000	10,100		N/A
200FDN	10,100		N/A	N/A	10,100	N/A		N/A
200FDP	5,400		10,100	N/A	2,000	10,100		N/A
250FDN	5,400		10,100	N/A	2,000	10,100		N/A
250FDP	2,000		7,700	10,100	2,000	7,700		10,100
300FDN	10,1001		N/A	N/A	10,100	N/A		N/A
300FDP	2,000		10,100	N/A	2,000	10,100		N/A
350FDN	2,000		10,100	N/A	2,000	10,100		N/A
350FDP	2,000		7,700	10,100	2,000	7,700		10,100
400FDN	10,100		N/A	N/A	10,100	N/A		N/A
400FDP	2,000		7,700	10,100	2,000	7,700		10,100
500FDN	10,100		N/A	N/A	10,100	N/A		N/A
500FDP	5,400		7,700	10,100	5,400	7,700		10,100

* All indoor installations at altitudes above 2,000 require a vent pressure switch to be installed in addition to the blower inlet plate. The vent pressure switch is included with the appropriate indoor vent kit (UHXNEGVT1xxx or UHXPOSHZ1xxxx), or the highaltitude vent pressure switch kit FDXLVPS1931.

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High-Altitude Conversion Procedure:

1.Identify the altitude of the installation site. This may be done using a GPS device, or by looking up the altitude for the geographic location. Altitudes for all locations in the United States and Canada may be found using the zip/postal code database at www.zip-codes.com. If the altitude for the installation site is greater than 10,100 ft., the heater may not be installed. Note that if installing outdoors, some heaters may be compatible with your altitude without modification. Table4 lists the altitude ranges for heaters without modification. All indoor heaters installed above 2,000 ft. require the appropriate vent pressure switch, see indoor installation kit instructions.

2.Select the appropriate blower air inlet plate to use based on the heater model, vent configuration (outdoor or indoor), and altitude needed. Extra plate(s) are included with the heater, packaged in the plastic bag with this manual. Each plate has a label which identifies which model(s), vent configuration(s), and altitude range(s) for which it is designed. Table4 lists the maximum installation altitudes using the included conversion plate(s). If installing above 7,700 ft., the high-altitude kit FDXLHAK1930 (sold separately) may be necessary.

3.If installing indoors, select the appropriate high-altitude indoor vent pressure switch from the indoor adapter kit or from the FDXLVPS1931 kit. Each switch has a label which identifies which model(s) and altitude range(s) for which it is designed.

4.If connected, turn pump, main gas valve, and heater power off, remove heater front access door.

5.Remove the 4 #10 hex head screws that fasten the blower air inlet plate to the blower, and remove the blower air plate and discard. Save the 4 screws as they will be needed to install the new plate. See Figure29: Blower

6.Install the appropriate blower plate from the kit using the 4 screws. It may be helpful to drive the screws in and out of the plate outside of the heater first to “thread” the holes before installing it in the heater.

7.If the installation is configured for indoor venting, a special high-altitude vent pressure switch must be installed. Follow the instructions provided in listed vent kits (see Tables 6 and 9), and use the appropriate blower air inlet plate and vent pressure switch for your altitude.

8.Re-install heater front door, if connected, turn pump, main gas valve, and heater power back on.

9.Activate heater and check for proper operation.

AIR SUPPLY:

Indoor installations and outdoor shelters (confined spaces) must be provided with adequate combustion and ventilation air openings to assure proper heater operation. These openings must be sized according to the requirements stated in paragraphs below (ALL AIR SUPPLY FROM INSIDE THE BUILDING or ALL AIR SUPPLY FROM OUTDOORS whichever applies to the installation). These air openings must never be obstructed when heater is in operation. These confined spaces shall be provided with 2 permanent openings, one commencing within 12 inches of the bottom and one commencing within 12 inches of the top of the enclosure. The openings shall communicate directly or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Ducts shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches. When air blowers are used in spa/hot tub installations and are located in proximity to the heater, caution must be observed to ensure sufficient combustion air is available to the heater for proper combustion. A separate blower air duct is recommended. Table 3 indoor clearances apply.

ALL AIR SUPPLY FROM INSIDE THE BUILDING: The confined space shall be provided with 2 permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space (a space whose volume is not less than 50 cubic feet per 1,000 btu/hr of total input all gas utilization equipment installed in the combined space shall). Each opening shall have a minimum free area of 1 square inch per 1,000 btu/hr of the total input, but not less than 100 square inches. See Table5 and Figure8.

ALL AIR SUPPLY FROM OUTDOORS: When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 btu/hr of total input See Table5 and Figure9B. When communicating with the outdoors (either directly or through vertical ducts), each opening shall have a minimum free area of 1 square inch per 4,000 btu/hr of total input rating of all equipment in the enclosure. See Table5 and Figure9A. When installing a heater below ground (in a pit, for use with Natural Gas only), combustion and ventilation air openings must be provided as shown in Figure10.

Table5 Combustion and Ventilation Air

Requirements (sq. in.)*

	Free Area per	Total Input	Combustion	Ventilation
	Total Btu	(Btu/hr)	Air Free Area	Air Free Area
	Requirement
			Required	Required
	1 sq. in. per	150,000	150	150
		200,000	200	200
	1,000 Btu/hr
		250,000	250	250
	(Indoor Air)
		300,000	300	300
		350,000	350	350
		400,000	400	400
		500,000	500	500
	1 sq. in. per	150,000	75	75
		200,000	100	100
	2,000 Btu/hr
		250,000	125	125
	(Outdoor Air thru
		300,000	150	150
	Horz duct)
		350,000	175	175
		400,000	200	200
		500,000	250	250
	1 sq. in. per	150,000	37.5	37.5
	4,000 Btu/hr	200,000	50	50
	(Outdoor Air	250,000	62.5	62.5
		300,000	75	75
	direct or thru Vert
		350,000	87.5	87.5
	duct )
		400,000	100	100
		500,000	125	125

*For detailed methods of providing combustion and ventilation air, see latest edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54).

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Figure8: Air from Inside Building Installation 1 square inch per 1,000 btu/hr of the total input

Table3 Indoor Clearance Apply

Vent Cap

		Rise 1in/ft.
	Drip	Ventilation
	Tee
		Air
	Gas Shut
	Off	Combustion
		Air
	Sediment Trap	Level Floor/Slab

Figure9: Air from Outside Building Installation

A)1 square inch per	B)1 square inch per
4,000 btu/hr of	2,000 btu/hr of
total input	total input

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Figure10: Air Below-Ground

(Pit for Natural Gas only Installations)

1 square inch per 4,000 btu/hr of total input

Table3 Indoor Clearance Apply

	Ventilation	Vent Cap
			Combustion
	Air	Ground
			Air
		Rise 1in/ft.
	Drip
	Tee
	Gas Shut Off

Sediment Trap	Level Floor/Slab

FLUE GAS VENTING:

For installation outdoors, no additional venting is required for operation. Ensure top of unit remains unobstructed.

INDOOR INSTALLATION WITH NEGATIVE (CATI) OR POSITIVE (CATIII) PRESSURE VENTING SYSTEMS: The heater is designed such that it may be vented using either a negative-pressure or a positive-pressure venting system. The appropriate system of venting for a particular site will depend on many factors such as vent termination needs (horizontal/vertical), clearance of vent termination, length of vent and the cost of venting system. Table6 (CATI) and Table9 (CATIII) list the required indoor venting kits available for each system. Multiple forcedor induced-draft units should never be vented using common venting or vent terminations. Never common vent this heater with other gas-burning appliances.

NEGATIVE PRESSURE (VERTICAL ONLY, CATI) VENTING:

NEGATIVE PRESSURE CATI VENT SIZING: Size the vent pipe according to the venting Tables in the National Fuel Gas Code (ANSI Z223.1/NFPA 54) for a Category I gas appliance using single-wall or double-wall (Type B) gas vent. Vent pipe diameter should not be less than the size of the vent pipe adapter on the heater with the appropriate vent kit adapter installed (see Table6). Single-wall vent may be used in conditioned spaces only. Clearance to combustible materials for single-wall vent is 9 inches. Double-wall (Type B) vent may be used in conditioned spaces, but must be used in non-conditioned spaces. Clearance to combustible materials for double-wall vent is 6 inches. Smaller clearances may be available; consult the National Fuel Gas Code.

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Table6 Negative-Pressure (CATI) Indoor Vent Kits with Vent Pipe & Terminal Specifications

	Models	Indoor Vent Kit	Vent	Description	Vent Pipe	Vent Pipe	Vent
		Part Number	Dia(in)		Application	Material	Termination
							Requirement
	150	UHXNEGVT11506	6	Indoor Vent	Vent pipe to be	Single or
	200	UHXNEGVT12006	6	Adapter Kit,	installed according to
						Double Wall,
	250	UHXNEGVT12506	6	Negative	the venting Tables in		Vertical
	300	UHXNEGVT13008	8	Pressure	the National Fuel	Galvanized,	Only
						Non-Sealed
	350	UHXNEGVT13508	8	CATI, Vertical	Gas Code (ANSI
						Vent Pipe
	400	UHXNEGVT14008	8	Venting	Z223.1/NFPA 54) for
	500	UHXNEGVT15008	8	Applications	a Category I gas

CATI MECHANICAL DRAFT SYSTEMS: Vent systems requiring power venting must use mechanical draft systems listed in accordance with UL378 Draft Equipment. Selection of power venter and required clearances from combustible materials must follow draft equipment manufacture’s instructions, National Fuel Gas Code, local codes and the information in this manual.

NEGATIVE PRESSURE CATI VENT TERMINATION: Any vent extending through a roof or wall must be listed double-wall (Type B) vent, and pass through an approved roof jack, or roof thimble. A listed vent cap must be used. Terminations for Gas vents with listed 12in or less diameter size and located not less than 8ft from a vertical wall or similar building feature shall terminate per Figure11 and Table7 using the roof pitch to find the minimum termination height value of H. Terminations for Gas vents with listed 12in or less diameter size located less than 8ft from a vertical wall or similar building feature shall terminate not less than 2ft above the highest point where they pass through the roof and not less than 2ft above any portion of a building within 10ft horizontally

Figure11: Minimum Height from Roof for Vent Cap

Lowest Discharge

Listed

Cap

Roof Slope at X/12

Min. Height (H) from Roof to

Lowest Discharge Opening

Table7 Height Requirements for Negative Pressure (CATI) Vent Caps (see Figure11)

	Roof Slope	Min. Height H from Roof to
		Lowest Discharge Opening
		(ft.)	(m)
	Flat to 6/12	1.0	0.30
	Over 6/12 to 7/12	1.25	0.38
	Over 7/12 to 8/12	1.5	0.46
	Over 8/12 to 9/12	2.0	0.61
	Over 9/12 to 10/12	2.5	0.76
	Over 10/12 to 11/12	3.25	0.99
	Over 11/12 to 12/12	4.0	1.22
	Over 12/12 to 14/12	5.0	1.52
	Over 14/12 to 16/12	6.0	1.83
	Over 16/12 to 18/12	7.0	2.13
	Over 18/12 to 20/12	7.5	2.27
	Over 20/12 to 21/12	8.0	2.44

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51300004201B

POSITIVE PRESSURE (HORIZONTAL OR VERTICAL, CATIII) VENTING:

When installed according to the following instructions, heaters meet the criteria for category III venting.

VENT SIZING: Vent pipe diameter must match the vent pipe diameter on the heater (see Table9). The vent pipe must be single or double-wall stainless steel sealed vent as listed in Table9. Double-wall vent must be used in nonconditioned spaces. The maximum total length of vent pipe, and number of 90-degree elbows cannot exceed the limits specified in Table8.The venting system must be installed in accordance with the vent manufacturer’s installation instructions and guidelines. The installer is urged to visit the vent system manufacturer’s website (see below) and review the installation information found there.

Table8 Positive-Pressure (CATIII) Indoor Vent Maximum Vent Lengths

Using Specified Positive Pressure Indoor Vent Kits

Number of 90degree Elbows	Maximum Vent Pipe Length horizontal & vertical (ft.)
0	50
1	50
2	40
3	30

VENT TERMINATION: The vent system must terminate with a vent terminal approved for this pool heater. Termination may be either horizontal or vertical. See Table9a for approved vent terminals and 9b for termination locations.

OBTAINING VENT PIPE AND TERMINATIONS: A variety of vent components, including terminals, elbows, and straight lengths, are available for use with this appliance. Approved parts are listed in Table9 and in the service parts section in the back of this manual. If you need more specialized fittings, you may order them directly from the manufacturer, or one of their authorized dealers. To locate an authorized dealer for venting parts, contact the appropriate manufacturer at:

M&G DuraVent Inc.		Selkirk Corporation
6 Jupiter Ln.		Heatfab Division
Colonie, NY 12205	OR	130 Industrial Blvd
[phone]		Turners Falls, MA 01376
www.duravent.com		[phone]
DuraVent FasNSeal (W2)		www.heatfab.com
		Heatfab Saf-T Vent EZ
		Seal (CI Plus)

Notes for Table9 Positive-Pressure (CATIII) Indoor Vent Kits with Vent Pipe & Terminal Specifications

*For Heatfab single-wall vent pipe section length, “x” to be: 1, 2, 4, 5, or 7, where 1=6 inches, 2=12 inches, 4=18 inches, 5=24 inches, and 7=36 inches.

**For Heatfab double-wall vent pipe section length, “x” to be: 06, 09, 12, 18, 24, or 36, indicating the length of the vent pipe section in inches.

†For DuraVent vent pipe section length, “x” to be: 6, 12, 18, 24, or 36, indicating the length of the vent pipe section in inches.

‡For these horizontal terminals, the wall penetration is included from the vent manufacturer. On all others, it must be ordered separately.

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Table9 Positive-Pressure (CATIII) Indoor Vent Kits with Vent Pipe & Terminal Specifications

				Vent			Heatfab Saf-T Vent EZ Seal (CI Plus) or
			Maximum				DuraVent FasNSeal (W2)
	Heater	Indoor Vent Kit		Pipe	Appliance	Vent Pipe
			Installation				Vent Pipe	Horizontal	Vertical Vent
	Model	Part Number		Dia.	Adapter	Type
			Altitude (ft.)
				(in)			Part	Vent Terminal	Terminal
							Number	Part Number	Part Number
						Single-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
							960x *	9614TERM	5600CI
	150	UHXPOSHZ11506			Heatfab adapter
			10,100	6
	200	UHXPOSHZ12006			included in kit		HeatfabP/N	HeatfabP/N	HeatfabP/N
						Double-Wall
							CCA06Lx **	9614TERM	CCA06RC
						Single-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
							960x *	5690CI ‡	5600CI
					Heatfab adapter
	250	UHXPOSHZ12506	10,100	6
					included in kit
						Double-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
							CCA06Lx **	CCE06WP ‡	CCA06RC
						Single-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
					UHXDVA004		FSVLx04 †	FSTT4	FSRC4
					(4” Duravent
	250-				adapter)	Double-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
							W2-x04 †	FSTT4	W2-RC4
	FDN	UHXPOSHZ12504	2,000	4
	(NAT						HeatfabP/N	HeatfabP/N	HeatfabP/N
	ONLY)					Single-Wall
					UHXHFA004		940x *	9414TERM	5400CI
					(4” Heatfab
							HeatfabP/N	HeatfabP/N	HeatfabP/N
					adapter)	Double-Wall
							CCA04Lx **	9414TERM	CCA04RC
						Single-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
	300	UHXPOSHZ13008					980x *	5890CI ‡	5800CI
					Heatfab adapter
	350	UHXPOSHZ13508	10,100	8
					included in kit		HeatfabP/N	HeatfabP/N	HeatfabP/N
	400	UHXPOSHZ14008
						Double-Wall
							CCA08Lx **	CCE08WP ‡	CCA08RC
					UHXDVA006	Single-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
							FSVLx06 †	FSTT6	FSRC6
					(6” Duravent
					adapter)	Double-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
	400	UHXPOSHZ14006	2,000	6			W2-x06 †	FSTT6	W2-RC6
						Single-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
					UHXHFA006		960x *	9614TERM	5600CI
					(6” Heatfab
							HeatfabP/N	HeatfabP/N	HeatfabP/N
					adapter)	Double-Wall
							CCA06Lx **	9614TERM	CCA06RC
					UHXDVA006	Single-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
							FSVLx06 †	FSTT6	FSRC6
					(6” Duravent
					adapter)	Double-Wall	DuraVentP/N	DuraVentP/N	DuraVentP/N
	500	UHXPOSHZ15006	10,100	6			W2-x06 †	FSTT6	W2-RC6
						Single-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
					UHXHFA006		960x *	9614TERM	5600CI
					(6” Heatfab
					adapter)	Double-Wall	HeatfabP/N	HeatfabP/N	HeatfabP/N
							CCA06Lx **	9614TERM	CCA06RC

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