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/ 28
Maintenance Data parts48heating Document 3039C
pee! §00.5351582 - Fax: 806-448-9304
~ [email protected]
FOR YOUR SAFETY — An odorant is added to the gas used by this appliance.
If you smell gas:
\ 4. Open windows
| 2. Don't touch electrical switches
3. Extinguish any open flame
4, Immediately call your gas supplier
FOR YOUR SAFETY — Do not store or use gasoline or other flammable liquids or
vapors in the vicinity of this or any other appliance.
WARNING: Elevated water temperature can be hazardous. Consult heater installation
instructions for Consumer Product Safety Commission water temperature guidelines
before setting temperature. Mix thoroughly before entering. Use an accurate |
thermometer to measure water temperature. |
Installation, Operating
and Servicing Manual
for
XE | ff
POOL and SPA L2
HEATER
TYPE EG
“46 TELEDYNE LAARS nnn
cowrents ase S10. Hi Limi Swen 8
‘Section 1/General Information 3 ‘5/11, Removal of Gas Burners 19,
T/1 introduction 3 Bf para ngecon of eat Exchange 8
1/2 beeaon i Berard coin Het Enchanan i
1 Ramey i Sha, hutomats Flow Conta Vave 2
1/4, Heater Capacity 3 ‘Section 6/Appendix 23
section 2/Aasemiy Instructions ‘ “tous eetng Char. Fg. 30 2B
Gi Genera ‘ Persist tyre ES 23
3/2. Reverable Heat Exchanger ‘ Fowto rer Furs 2
2/3, assem 3 apacten and Dimensions, Fig. 32 2
Section 3/Installation instructions: 5 TTT
Sit Genera :
3/2, Outeor instalation : ence ace
3/3, Inder lstalaon é ean
3/4. Gas Supply and Piping 6 Installation of Top Assemblies, Fig. 2&3 5
3/5, Water Piping 6 Installation Draft Hood or Vent Cap/Stack,
3/6, Pressure Ree Valve , aes 86
3/7, adjust of Pressure Flow Switch 3 cupibated Piping rangement Fig. 687 7
ye, Automat Clernatrs e Ne Poe use ot a8 ;
5/8, ete wine : ‘preaced Petes, Fig. 9 7
3/10, Tmedek tng 8 Teprsture Che 10 ;
secon 4/Opertng Instructions 3 Ringinen ef Pressure Fiow Suiteh,Fi. 1B
Gi Lighting and Shtdown 3 ‘rermostat Dil Face, ls 12 n
2/2. Streup Procesure 2 fester Drain Pugs Fa 12 i
4/3: Inetoutet Temperatues io Gos Pressre check 18 8
Ua Temperature Ontos ra serra creem checkout, Fags 18184, 14-16
ees i ie Sete Caste i Saliva
75, Spring and Fal Opes ih ge Sereator and Plot Burner Replacement,
eis 6
iz ptioreneate Backs u Visofiame Removal, Fig. 20 17
478. Pool Energy Saving Tos B Sas Vaee Removal Fi. 22 a
479. Periodic Inspection 2 Pressure Switch Testing and Removal, Fig, 22 7
Section 5/Maintenance 13 ‘Thermostat Removal and Replacement, Fig. 23. 18
3/1 Gener! Pecatons 5 MeL such Testing one Replacement
5/2. Reguleted Go Pressure 8 he i 18
5/3, Elctnea! Trout Shooting 8 cas Burner Replacement Fig. 25 3
Bf Pot enertor Replacement 6 feat Bronenger apectin, Fig 2 20
5/8, Vsotome Pet Ughter 6 Meat xchange’ Removal P27 2
56. Testing Poste Unk 18 Meat Exchanger Ceoning F 26 2
BY? Gus Valve Repaceent " tina Pew contol Valve Disessembly, Fig.29. 22
Bra. Testing Pressure Sitch 0 Expioges Oring, Type EG, Fi. 31 2
15/9, Testing Temperature Control 18 Capacities and Dimensions of Heaters, Fig.32 26 Section 1/General Information
4/1, INTRODUCTION
This instruction manual supplies assembly, installation, ‘SIZING CHART — POOL HEATERS
peration and maintenance information for the Teledyne ‘To use the table, frst determine the temperature rise
Taars XE Swimming Pool and Spa Heater. A check-out that will be required (that i, the difference between
procedure is included in Section § for quickly isolating the desired pool temperature and the average air
troubles should they occur. temperature during the coldest month you intend to
{t is strongly recommended that the installation pro- use your pool). Next, ealeulate the square footage of
qedure in Section 3 be reviewed before a heater ts your pool (length times width). The table lists the
installed. Experience has shown that most service calls Jeuibum ‘square footage recommended for each
are brought about by improper installation, rather than heater model to accomplish a given temperature rise,
faulty operation of heater. Before installing check local
and state codes. Temperature Maintenance Selection Table
1/2, DESCRIPTION _ ODE NONE
‘The XE is a compact, high performance pool and spa eye. 1% _175_260_225 100
heater. The water velocity is carefully balanced in the heat, Fie Wa Svar Foot
‘exchanger to prevent both scale formation internally and Fase nae oe 7 Fs
‘generation of corrosive condensate externally. As equipped, Boe 9e 682 300 12041581
fhe unit is suitable only for the heating of swimming pools, BSF 95552750 1028 1265
and spas and should not be used under any cireumstances BF 303 sol 659. O55 1054
a3 a heating boiler or as @ general service water heater or ast 202305 5k 7m oa
{for heating of sale water pools. Consult factory for the pro-
per Teledyne Laars products applicable to these functions. Use this table if you wish to keep your pool heated
XE heaters are design certified by the American Gas continuously during the swiming season. Table is
Association as complying with the latest American based on 3'2 mph average wind and average pool
National Standards Institute Standard Z 21.56b-1982 depth of 5.5 feet,
Gas Fired Swimming Pool Heaters.
1/3. WARRANTY
‘The XE is sold with a limited warranty. Details of the
warranty are specified on the written warranty furnished
with the heater. See written warranty farnished with
heater for the length of the warranty period of various
heater parts.
‘Warranty claims must be made to an authorized Laare
representative or to the factory. Claims must include
Serial and model number, installation date and name
of installer. Shipping costs are not included in warranty
coverage, Use this table if you wish to raise your pool tempera
ture by a given amount within 24 to 48 hours, Table
HEATER COneca 7 is based on 314 mph average wind and average pool
Before installing the heater, see Sizing Chart (Fig. 1) to depth of 3.5 feet.
make sure the heater to be installed has sufficient
capacity for the pool aize and expected use. Use the
Intermittent Heating Selection Table (Thrift Heating)
Tv Seas Fie of Pool
Intermittent Heating Selection ‘Table for maximum _
operating economy, and particularly if fast pool heating SIZING GUIDE — SPAS AND HOT TUBS
is desired (24 to 48 houre). Use the Temperature Main- “This guide is based on spa or hot tub gallonage and shows
tenance Selection Table if minimum pool heating 1s hhow many minute ae required foreach IOdegreetemper-
desired or if a longer heating period is acceptable ature rise, The rie fs the difference between initial water
temperature and desired spa or hot tub temperature.
Tampa 1 Bare
Tis te ao 22 os wD OS @
oi 12 4 te we 2) 21 23 2 7 29 30
bre 8 ew IS we IT
FIG.1 Section 2/
Assembly Instructions
2/1. GENERAL
‘There are two types of XE heaters—the Low Profile and
the Stacktop. The heaters are shipped in either two or
three packages for assembly at poolside, or at the ware-
house before delivery to the job site.
‘The XE Low Profile Heater (Outdoor Only) comes in two
packages:
1, Heater Assembly.
21 Grate Top Assembly.
‘The XE Stacktop Heater (Indoor or Outdoor) requires
three packages:
1, Heater Assembly
2. Stacktop Assembly
3, Draft Hood for indoor installation OR Vent Cap/
Stack for outdeor installation.
See tables below for proper part numbers.
Low Profile Models —
‘ouToO0R ONLY
vas | _ 18s
175 | 0158
20 | 0187
2s | Dis
L ‘ee | oes
Stack Top Models—
inpooR/oUTDOoR
as | 0160 | D025 | _o00s
| as | pier | poze | D006
aso | ore | doar | boo?
zs | pies | 00s | D008
#oo_| ores | 0050 | pcs
a oh
| )
marr x000 L | Seweat
2/2, REVERSIBLE HEAT EXCHANGER
Betore assembling the Pool Heater and the selected Top
‘Assembly, note that the XE heater can be installed with
the water connections at either side.
‘The heater assembly is shipped with the water con-
nections on the right side of the heater. Left side water
connections can often simplify installation and improve
faccess for heater service and maintenance, The change
from right to left is easily made either at the warehouse or
at poolside before installing the selected top assembly.
Follow these step-by-step instructions and the accompany-
ing drawing:
1, Remove screws and lift out gap closures. (2&8)
2, Remove and discard shipping screw located between
drain and plug on side of heater opposite water con-
nections, (41
8. Remove drain valve (large hex.) located under water
conneetions. (5)
4. Remove all grommets (2each side). (6&7)
5. In order, lift out the retainer and insulation (1)
over the temperature sensing bulb, remove the lower
flue collector (8) and the front and rear insulation
lock covers. (9).
6, Disconnect white wires at pressure switch and at gas
valve, Pull wires through and coil them on top of heat
exchanger,
7. Remove temperature sensing bulb from header by
loosening cap screw and sliding retainer bracket off of
bulb flange. Pull bulb away from heat exchanger, and
carefully drape over front of heater.
8, Disconnect black wire from pressure switch and
unfasten the location clip in the door opening. Disconnect
pressure switeh tube at header, and place pressure switch
and tubing on top of heat exchanger.
‘9. Lift out heat exchanger, turn and replace with water
connections on left side of heater.
10, Reconnect tubing to header, straightening the tub-
ing as required to bring pressure switeh to the top left of
the door opening, Fasten tubing to inner panel and recon-
rect black wire to one of the pressure switch terminals,
11, Re-install temperature sensing bulb in header
and route wire leads carefully against side of heater,
cover bulb area with insulation and re-install insulation
retainer,
12, Reroute black and white wires on left side of heater,
fasten securely clear of the heat exchanger. Reconnect
white wires at pressure switch and gas valve,
18, In order, replace front and rear insulation block
covers (9) and lower flue collector (8).
14, Replace gap closures* (2 & 3). Tighten screws
securely.
15. Replace grommets* (6&1).
16. Reinstall drain plug® (large hex.) (5).
Complete the heater assembly by attaching the selected
top assembly and install the heater according to the in-
structions which follow.
Note: These items must be replaced opposite their original
positions (they are relative to the heat exchanger)
BT ak 2/3. ASSEMBLING THE XE HEATER
(2) Place Top Assembly (Grate Top or Stack Top) on
the Heater Assembly so that the flue collector (attached
to the Top Assembly) seats on the lower flue collector
(on the heater assembly). See Fig. 2. The flue collector
is designed to seat loosely, allowing movement for align-
ment of the screw holes.”
(2) Align the two screw holes on the back and the two in
front of the heater, insert self-threading screws (fur-
nished) and tighten. See Figure 3.
“Do not remove the flue collector from the grate top or
stack top assemblies under any circumstances, Removal
of the flue collector voids the warranty.
FIG. 2 FIG. 3
direct roof water drainage by gutters and the like, From
the point where the flue products leave the heater, that
point must be a minimum of 4 feet below, 4 feet hori
zontaliy from or 1 foot above any door, window or
mravity inlet to a building.
Low Profile (Grate Top) Models
IMPORTANT: When locating a low profile heater, con-
sider that high winds can roll over or deflect off
adjacent buildings and walls and create a draft reversal
causing flame rollout which might damage the controls.
Normally, placing the heater at least three fest from
any wall will prevent this condition. (If conditions are
severe, a heater with Stacktop and Vent Cap/Stack
should be selected).
Stack Top Models
XE Stacktop heaters can be installed outdoors if equipped
‘with the factory-supplied Vent Cap/Stack. Refer to Sec-
tion 2/1 for the correct part number or check rating plate
on the heater.
See Fig. 4 for proper installation of Vent Cap/Stack.
Section 3 /
Installation Instructions
3/1, GENERAL
‘The heater must be installed in accordance with all local
codes and ordinances and the latest National Fuel Code,
‘ANSI 2220.1
3/2, OUTDOOR INSTALLATION OF LOW-PROFILE
AND STACK-TOP MODELS
Heater must be located in an open, unroofed area. Mini
‘mum clearances from combustible material and for service
access must be maintained as follows:
Blank side and 6" Minimum clearance from
rear of heater: combustible material
12” Minimum clearance from
combustible material and for
Piping side
Front ofhester: 18” Minimum clearance for
‘The above clearances also apply to non-combustible materials,
because the heater requires air circulation for proper operation.
‘The heater is design-certified for installation on a combustible
floor surface.
‘The XE heater is design certified for installation on
combustible floors.
‘Do not install the heater in locations which will permit
the accumulation of leaves or other combustible material
around the base of the heater.
‘Do not install heater in a location that will allow sprin-
Klers to operate near heater equipment since the water
may cause damage to the controls andjor electronics.
‘Do not install this appliance under an overhang less than
4 feet from the top of the appliance. ‘The area under the
overhang must be open on three sides. Overhangs must be
such that flue products are not diverted into living spaces.
Heaters installed under overhangs must be protected from
—_
ef
7
3/3. INDOOR INSTALLATION OF STACKTOP
MODELS
XE heaters, when equipped with the Stacktop assembly
‘and the proper draft hood, are design certified for indoor
installation. The draft hood must be the one furnished by
the factory and must be installed without modification.
See Section 2/1 for correct draft hood part number or
check rating plate on heater.
Install Draft Hood directly on top of heater. See
Fig. 4 for proper installation of Draft Hood,
The Draft Hood must be connected to a vent of the
same or larger size, terminating at least two feet (2')
above any portion of the roof or other object which is
within 10’ of the stack. The vent should have a listed cap
installed which permits a full equivalent opening for flue
products. See Fig. 6
Heater Clearance — Indoor Installations
‘Minimum clearances to combustible material and for
service access must be maintained as follows:
‘Top of heater: 44” Minimum clearance from
combustible material.
Blanksideané 6"”_-Minimum clearance from
rear of heater: combustible material
Piping side: 12” Minimum clearance from
combustible material and for
Frontofhester: 18” Minimum clearance for
‘The XE heater is design certified for installation on
‘combustible floors. comin on mt The above clearances also apply to non-combustible materials,
because the heater requires air circulation for proper operation,
‘The heater is design-certfied for installation on a combustible
floor surface.
Note: 2, AnUnderwritere Labora-
1. DraftHood must sit directly. tories listed vent cap is
ontop of the heater as shown required to eliminate down
land must not be altered in any draft and allow your heater to
manner, function property
3. Use approved root fitting
FIG. 5
Combustion and Ventilation Air Supply
When the heater is installed in a room or enclosure,
there must be uninterrupted openings to outside air for
combustion and ventilation, The table below shows the
net free opening areas required at both ceiling and floor
for each heater model. Teledyne Laars does not recom-
mend installations which depend on infiltration for
combustion
TNet Free Opening Area
Mode! ‘A Calling ‘i Floor
125/175 [V4 sq. ft. (72sq.in.) | ¥% 59. ft. (7289. in.)
250 34 sq. ft. (108 sq. in.) | 84 sq. ft. (108 sq. in.)
325, 34 sq. ft. (108 sq. in.) | % sq. ft. (108 sq. in.)
400 Lsq. ft. (144sq.in.) | 15g. ft, (14489. in.)
Special precautions for LP gas heaters
Liguified petroleum gas is heavier than air, and for that
reason is especially hazardous. Pool heaters using LP
gas should not be installed in pits, basements or the like.
Heaters should be located at a safe distance from LP
as storage or filling equipment. Consult local code and
fire protection authorities relative to specific installa-
tion rules,
9/4. GAS SUPPLY AND PIPING
Heaters are normally fitted for operation at altitudes
below 2.000 feet, Heaters fitted for higher altitudes are
marked with a sticker or tag on manifold. CHECK RATING
PLATE FOR CORRECT GAS. Provide gas pipe size as follows:
Provide a union in gas line outside the heater jacket.
Provide mainline gas pressure as follows (measured in
inches of water column)
Maximum 10”
Maximum 1d”
Minimum 6”*
Minimum 11”
Natural Gas:
LP Gas:
"5.5" minimum for Model EG-600.
The Pressure Regulator is pre-set at the factory and nor
mally does not need adjustment.
For correct procedure for gas pressure measurement,
see Fig. 14,
Tf mainline gas pressure is inadequate, check for too
smalls pipe size between meter and heater, or for gat
meter with limited capacity.
Before operating the hester, test all gas connections for
leaks.
Do not pressure test gas piping with heater connected or
serious damage to the gas controls will result.
3/5. WATER PIPING
1, Figures 6&7 shows typical water piping for pool deck
equipment.
2. You will notice that the figure shows the installation of
a manual by-pass valve between the heater inlet and outlet.
‘This valve is only to be installed if the system filter-flow
rate exceeds 100 gallons per minute. The manual by-pass is
‘not necessary when the water system flow rate is less than
100 gallons per minute, because under these conditions an
automatic by-pass valve built into the heater maintains
proper flow through the heater.
3. Pipe, fittings, grids and any other element of the filter
system may be made of plastic materials, if acceptable by
the authority having jurisdiction. However, they may be
damaged by the momentary “‘backsyphoning” of hot
water from the heater when the pump stops running. ‘To
prevent such a backflow, install a check valve and “heat
sink” pipe in the piping between the filter and the heater,
as shown in Figure 8. Teledyne Laars recommends the
Installation of safety ‘Fireman's Switch” with a time
clock, or allowing the pump to run 15 minutes after the
heater is shut off, if operated manually, to dissipate the
excess heat from the heater and the piping system.
PVC: DO NOT INSTALL PVC PLASTIC PIPING
DIRECTLY TO THE HEATER INLET/OUTLET
HEADER, PVC pipe does not have the high tem:
perature capabilities required to insure safe and re
Tisble operation of your heater, A check valve and
“heat sink” as shown in Figure 8 is required whenever
PVC is used.
b.CRVC: High Temperature plastic piping (CPVC),
schedule 40, can be connected directly to the heater
Tnlet/Outlet header, however, a check valve as shown
in Figure 8 is recommended.
Distance from Heater Model
meter was] is | 20 | 325 | #00 |
050" we po |e [am [we
50-100" wf | aye fame | ame
300-200" we | nae fe [we [aye
For LP Gas use size smaller except 126 size which requires
34" from 0°50’
The above are Teledyne Laars recommended pipe sizes.
Check local cade requirements for compliance.
Do not use a restrictive gas cock.
NOTE: If galvanized piping is used, all joints be-
tween copper and galvanized piping must be made
with dielectric insulated fttings.
‘The Universal Flange Coupling furnished with
the heater accepts threaded 134” iron pipe, un-
threaded 1%” iron pipe and 1¥4” copper’ pipe
without adapter. See Figure 9.
4, Anti-syphon protection is built into the heater. No
separate Hartford loop is required, 5, No water flow adjustments are necessary unless ex-
ternal by-pass valve is required.
6. Do not install any valve or other variable restriction
in the return piping between heater outlet and pool.
7. Hnormal filtration rate exceeds 100 gpm:
1. Provide manual by-pass valve shown in drawings.
(Figs. 6 & 8)
», Install thermometer in threaded drain provision to
the right of header casting. See Figure 10.
. Set by-pass as follows:
(4) Clean filter.
(2) Close by-pass valve.
(8) Close heater main gas valve,
(4) Start filter pump.
(5) After 3 minutes note and record thermometer
reading (this is pool temperature),
(6) Open heater main gas valve and start heater.
(1) Gradually open manual by-pass valve until ther
mometer reads the temperature differential shown in
the table below. The valve must be as near closed as
possible and still maintain this temperature rise.
‘The chart also lists the minimum flow rates for
filter systems used with the heater,
[ABOVE POOL TEMP. | winimum
TEMP. DIFF. _| filter system
move | MIN. Max | "vin GPM
1a [2 28 20
| a5 | 2 36 20
250 | 26 38 es
335 | 28 38 30
aoo_| 30 38 20
(8) Be sure thermometer reading remains constant
for at least 8 minutes.
(9) Remove handle from by-pass valve, since this is
now a permanent adjustment to your system.
‘The automatic by-pass valve in the heater will take
over and will maintain proper flow through the heater
atall times.
3/8. PRESSURE RELIEF. VALVE
A pressure relief valve is not furnished with the XE
heater. Check local building and plumbing codes to
determine whether a pressure relief valve is required.
‘A 75 PSI rated relief valve is recommended for pro-
tection of components of the filtering system if there is
a water shut-off valve installed between the heater and
iF
SERS
pustic
Now: Se Secon 315
FIG. 8
sooner, | aE
Bee LT
~ t wearer [OPTIONAL LOCATION
=
L
roroot PIPING DIAGRAM FOR SPA POOLS
“Typical Piping Ot
FIG. 6 FIG.7
USE OF PLASTIC PIPE
{Where permitted
by cod
e
(CHECK VALVE wera Se ‘inet
nes
TEMPERATURE CHECK
TNO the pool. If a pressure relief valve (GD
tenet used, the stancard 30" brash)
pipe plug should be left in place.
3/7. SPECIAL ADJUSTMENT OF PRESSURE
FLOW SWITCH
‘The pressure low switch has been pre-set at the factory
for normal pool installations, Do aot tamper with this
switch, unless one of the following conditions prevail:
1. The heater is installed % feet or more beluie the
surface of the pool, or
2, Any part of the filter system piping is 3 feet or more
bore the top of the heater jacket.
In such cases. follow the detailed instructions for adjust-
ing the switeh contained in Fig. 11.
(On some installations the piping from the heater to
the pool is short, therefore the back pressure is too low
to activate the pressure switch. On this type of instaila~
tion, install a directional fitting where return piping
‘enters the poul. The back pressure will be increased and
the heater will operate properly’
NOTE: If heater is installed more than 15 feet below
the pool surface, or more than 6 feet above the pool
surface, the adjustment shown in Fig. 11 should not be
used. Consult factory
POOL FILTER MUST BE CLEAN
BEFORE ADJUSTMENTS ARE MADE
1. Turnheater ON/OFF
taggle switch to OFF.
‘Set pool thermostat to MAX.
(ies titer thoroughly
Star ter systom
Turn ON/OFF toggle switch to ON. Heater should
6, Turn pressure switch adjustment screw counter
Clockwise very slowly unt the neater goes OFF.
7. Turn pressure adjustment screw clockwise Y turn
Hester should came back ON.
8, CAUTION: Check pressure switch adjustment by
turing iter pump OFF. Heater should shut ft
immediately. tt does not shut of start fiter pump
Immediately and repeat steps 8 and 7. then recheck
8, Set pool thermostat to desired temperature.
40. When pressure ewiteh is propery sot. the heater should
Come ON about 10 seconds after fiter pump Is states,
{and should shut OFF Immediately after pump shuts OFF.
FIG. 11
3/8, AUTOMATIC CHLORINATORS
‘A concentration of chlorine In the heater can be very
Gestructive. Heater damage caused by excessive concen~
trations of chlorine, for any reason, is not covered by the
heater warranty.
IMPORTANT:
1. The ehlorinator should be provided with an anti-
syphoning device so that if the piping drains
after the pump shuts off, chlorine will not
syphon into the heater
An electric chlorinator should be wired so it
cannot operate unless the filter pump is running.
If chlorinator has an independent clock control.
be sure the filter and chlorinator clock are syn-
chronized and chlorinator operates only’ within
the filter cyele time period,
3, If the chlorinator is equipped with its own pump,
it should be installed so it introduces the gas or
solution downstream from the heater. and if
possible, at a position lower than the heater
| putter’ fitting,
3/9. ELECTRIC WIRING — WARNING
Do not connect heater th any source of electricity
‘The Teledyne Laars XE has a built-in Thermoelectric
Generator. This provides # completely self-contained
electrical system, and no external connections are required,
‘Any attempt to make external electrical connections will,
Gamage the heater.
3/10. AUXILIARY TIME CLOCK WIRING
Tf-a time clock is used to control filter pump operation it
should have a separate low voltage switeh to turn off
heater hefire turning off pump. If the low voltage
switeh (fireman switeh) timing ix adjustable, set switch
to shut off heater approximately 15 minutes ahead of
filter pump. This allows the residual heat to be carried
into the pool water and prevents excessive heat build-up
in the heat exchanger
TYPICAL TIME CLOCK WIRING
ae
[SUGGESTED TIME CLOCKS: INTERMATIC 101-201, T104R-201
[PARAGON 81011-0, 4101420
To incorporate a timeclock auxiliary switeh into the
contvol wiving of the heater, do the following:
1. Remove door to gas valve compartment.
2. Remove factory-provided wire nut from white wire
tagged “fireman switch", and separate the ends.
8. Connect the field installed wires from the timeclock
auxiliary switch to these ends with wire nuts. Field
provided wire should have at least 9/64” thick insulation
land a temperature rating of 105°C. or greater
Be sure that the run of wire between heater and
switching device is fairly short or the resistance of the
wire will reduce available millivoltage to a critical level
for operating the gas valve. Also, the contact points of
the switching device must be silver or some other low
resistance alloy. Section 4/ Operating Instructions
4/1, LIGHTING AND SHUTDOWN
Full lighting and shutdown instructions are included
fon the rating plate attached to the heater inside the
controls compartment.
‘When lighting or relighting the pilot always turn the
temperature control to its lowest setting and turn the
gas valve and toggle switeh to OFF. WAIT FIVE MIN-
UTES
Tt is always a safe practice to keep the head and face
well away from the lower firebox opening when lighting
the pilot should there be accumulated gas in the firebox,
a reduced pilot flame or a pilot burner that is out of
position,
@ Lighting
Step 1.
Press Gas Valve Knob and turn clockwise to OFF. WAIT
FIVE MINUTES. NOTE: At least five minutes is
required for the natural air flow to clear the accumula:
tion of any unburned gases from the combustion cham:
ber, which could flashback, if ignited.
eS
\\ 1
WW L=J4
‘GENERAL CONTROLS VALVE HONEYWELL VALVE]
|| | enenar cowrnots vaLve
Step 2.
rn Gas Valve Knob counter-clockwise to PILOT
iO.
HONEYWELL VALVE!
1
Step 3.
Light Pilot using VISOFLAME Lighter Tube.
General Controls valve:
Press valve knob down and light gas at VISOFLAME
tube, Hold valve knob down for 80 second, then
release.
Honeywell valve:
Depress gas valve knob and lock in place with wire
lateh, Immediately depress VISOFLAME button
‘and light gas at VISOFLAME tube. Release wire
lateh on gas valve knob after 30 seconds.
‘The VISOFLAME lighter tube permits ignition of
the pilot at arms length without bringing the head or
face near the firebox opening or the burner tray. The
VISOFLAME tube is also used to prove pilot ignition
—"depress gas valve knob (on General Controls
valve) or VISOFLAME button (on Honeywell valve)
and flame will return to the lighter tube and be
visible if pilot is lit. Step 4.
‘Turn on main burners by turning knob counter:
clockwise to ON position.
o
a
‘GENERAL CONTROLS VALVE °
HONEYWELL VALVE
5. Replace door,
6. Position toggle switch to ON,
7, Turn the Temperature Control to appropriate setting
to bring on the main burners.
NOTE: The on/off toggle switeh must be ON for
heater to operate.
© Relighting
If pilot goes out, repeat steps 1 through 4.
© Shutdown
Step 1.
‘To shut off main burners, turn knob to pilot position.
Or move toggle switch to OFF.
1 for
ry
|
®
ol
HONEYWELL VALVE
- lo
(GENERAL CONTROLS VALVE
Step 2.
For complete shut off, press knob and turn to OFF|
position,
o
\ \ [GENERAL CONTROLS VALVE
\
HONEYWELL VALVE
10
4/2. START-UP PROCEDURE
In a new pool, it is strongly recommended that the filter
be operated with the heater off long enough to com-
pletely clean and clear the pool water and filter system.
‘This action will remove construction residue and dirt
from the water, and at the same time rapidly All the
filter with sediment, The resulting pressure variations
in the system would cause the heater to cycle on and
off severely. While this cycling would not damage the
heater in any way, it is inefficient and uneconomical
sinee little effective water heating would result. To
start heater:
1. Start filter pump.
2, Make sure pilot has stable flame.
8, Turn gas valve knob to ON.
4, Position toggle switch to ON.
5, Set pool thermostat to fourth mark on dial. Heater
should come on. Until the pool reaches approximately 70
‘degrees there will be a considerable amount of condensate
Gripping from the heat exchanger into the firebox. This
will stop after pool reaches temperature.
CAUTION! Keep all objects off the vent sereen. Blocking
air flow will damage heater and invalidate warranty.
IMPORTANT: Special safety controls on the heater prevent
heater from coming on unless the filter system is oper-
ating. When raising the temperature of a cold pool, remove
all time clock stops so the filter system and heater can
operate continuously until pool temperature reaches the
selected temperature set on the thermostat. When the
selected temperature is reached, the heater will automatic
ally shut off and the filter system will continue to operate,
Replace time clock stops to provide for a single filter,
cycle each 24 hours according to the recommendations
of the filter manufacturer.
This time eycle may not be long enough to keep the
pool water at the desired ewimming temperature. Adjust
MON” time until heater shuts off on its own controls
before the time elock shuts down the filter system.
4/3, INLET-OUTLET TEMPERATURES
Do not be concerned about the fact that the outlet
piping, carrying the heated water to the pool, does not
feel hot. The outlet pipe on the XE carried a large volume
‘of pool water, which has by-passed the heater, mixed with
a relatively small volume of heated water; thus the temp-
erature difference between inlet and outlet pipes is so small
that it would be difficult to sense by touching them.
4/4, TEMPERATURE CONTROLS
The XE temperature control is factory-set to cover @
range from approximately 70° at the lowest setting to
107° at the highest setting in increments of 5° as indi- cated by the eight marks on the face of the dial. (See
Fig. 12). Use a pool thermometer to determine the best
swimming temperature for you and position the Safe-T-
Lok at that setting.
‘The pool heater Is equipped with an ON/OFF switch.
‘This ewiteh is intended to permit shutting off the heater
without requiring access to the Main Gas Valve, but should
be used with diseretion. See paragraph 4/5 “Spring and
Fall Operation.”
IMPORTANT: The XE Temperature Control eannot be cal-
ibrated in the field. If the control is faulty, replace
according to instruction in 5/8. Do not use the temper
ature control to shut off the heater. The ON/OFF switch
will shut the heater off except for the pilot light. The
heater ean be completely shut off only by turning the
main gas valve to OFF.
= 4
4/5, SPRING AND FALL OPERATION
During periods when pool is used intermittently, do not
turn the heater "OFF." Best results will be obtained by
turning the thermostat down to MIN, This will prevent
the pool and surrounding ground from becoming “chilled,”
and also permit the pool to be raised to swimming temper-
ature in a shorter time. If heater will not be used for a
period of time, turn gas valve to OFF position or use
ON/OFF toggle switeh.
CAUTION: In areas where freezing weather occurs
drain heater before first frost. Shut off all gas valves.
Drain the heater by opening the drain cock(s), and re-
moving all drain plugs. (See Fig. 18)
Disconnect copper tubing connected to the pressure
switch when “winterizing” your pool heater. To recon.
rect tubing to pressure switch, see Section 5/5 “Testing
Pressure Switch.”
HEATER DRAINS
Oo
One
Left Side
‘a apen drain coc
rcountereiocewise A)
"
Leave all drain cocks open and drain plug out until ready.
to use heater again, Heater must be level 10 permit
adequate draining.*
‘When compressed air is used to blow out lines it is still,
necessary to follow the above procedure. Be sure drains
are left open after draining.
The XE pool heater és not designed to be used as a
heating boiler and ét will not function properly when
80 used. Consult factory for proper models for this
application.
The XE is not designed for continuous use as an
“anti-freezing” device for pools. And operating the
heater for long periods at pool water temperatures
less than 70°F. will seriously damage the heater and
‘may create a dangerous condition by fouling the e:
ternal heat exchanger passages, which results in i
complete combustion of the fuel
If your area has only the occasional short cold snap,
the stagnant water in the heat exchanger can still freeze
any time the filter pump shuts down. To protect the
heater during such periods, run the filter pump con-
tinwously. Remove all time clock stops during the
danger period. Should you not wish to maintain pool
temperature, shut down and drain your filter system
and the pool heater as described above,
4/6. POOL WATER CHEMISTRY
‘The mineral content of your pool water inereases every
day. This is due to the natural evaporation which re-
moves only distilled water and leaves the minerals
behind. Also the regular addition of algaecidal and
sanitizing chemicals adds greatly to the mineral content
of the pool. If the concentration of minerals in the pool
is permitted to become too high, the minerals will pre-
cipitate out of the water and deposit on the walls of the
pool, in the filter and in the tubes of the heater.
For this reason it is very advantageous to drain the
pool regularly (at least every two years). This pre-
cautionary measure will save you from expensive re-
pairs to your pool finish, filter system and heater.
Another important safety precaution — always keep
the pH of your pool water between 74 and 7.6. This will
add years to the life of your pool finish, filter system
‘and heater.
Algaecidal and sanitizing chemicals are either alka-
line or acid, Sodium and calcium hypochlorites are
alkaline. Chlorine gas and practically all other dry
chlorine pool products are acid. Whichever type of
chlorine is used, it is extremely important that pH be
checked frequently and adjusted as indicated and that
pool water be changed when dissolved solids become
excessive. It is generally recommended by pool sanita-
tion chemical suppliers that total alkalinity of pool
water be kept in the 60 to 80 ppm range when sodium
or calcium hypochlorites are used and the 80 to 100
ppm range when other dry (acid) chlorine products or
chlorine gas are used,
4I7, THERAPEUTIC POOLS (SPAS)-
SAFETY RULES
‘Therapeutic pools or “spa” pools are usually piped and
controlled so that very warm or hot water, often with air
injection, is forced at high velocity into a confined area of
@ swimming pool or into a small separate pool. Both the ‘energy of the water and the heat furnish certain hydro-
therapeutic benefits. ‘These pools are excellent for relaxa-
tion, body-conditioning and for arthritic and rheumatic
problems, but can be hazardous. The Consumer Product
Safety Commission has recommended the following
“Safety Rules for Hot Tubs”:
1. Spa or hot tub water temperature should never exceed
104P (40°C). A temperature of 100F (38°C) is con-
sidered safe for a healthy adult. Special caution is sug-
iested for young children.
2, Drinking of alcoholic beverages before or during spa or
hot tub use can cause drowsiness which could lead to
unconsciousness and subsequently result in drowning.
3, Pregnant women beware! Soaking in water above 102F
(39°C) can cause fetal damage during first three months of
pregnancy (resulting in the birth of a brain-damaged or
deformed child). Pregnant women should stick to the
100F (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 temper-
‘tures by as much as four degrees Fahrenheit (2.2°C).
5. Persons with medical history of heart disease, circulatory
problems, diabetes or blood pressure problems should
Obtain their physician's advice before using spas or hot
tubs.
6. Persons taking medications which induce drowsiness,
such as tranquilizers, antihistamines or anticoagulants,
should not use spas or hot tubs.
4/8. POOL ENERGY SAVING TIPS
The following recommendations are offered to assist in
conserving fuel use, and in minimizing the cost of oper-
ating your pool heater without sacrificing pool comfort
unduly.
(2) Reduce the heater thermostat setting to maintain a
78 degree or lower temperature. The National Swim-
ming Pool Institute and the American Red Cross hold
that the most healthful swimming temperature is 78
degrees, Be certain that you are using an accurate pool
thermometer. A variance of four degrees — from 78
degrees to 82 degrees — will use as much as 40% more
gas.
(2) Heat pools only during the three month summer
swimming season. Heating a pool for three rather than
five months will reduce gas consumption by an ad-
ditional 889%.
(8) Note the proper setting for your pool heater temper-
ature control and use the Safe-T-Lok to discourage further
adjustment.
(4) Set your filter time clock to start the pump no
earlier than 6 a.m. during the pool heating season. This
the time when nightly heat loss stabilizes.
(5) For pools which have only weekend use, heater
thermostat setting should be reduced by eight or 10
degrees during the week. Thermostat should be reset to
the 78 degree level before use.
(6) During the winter and when on vacation for more
than one week, turn off the pool heater, including the
pilot light.
(1) Shelter the pool where possible from prevailing
winds by using well trimmed hedges or other land-
scaping, cabanas or fencing as windbreaks.
(8) Use a pool cover where practical. This will reduce
heat loss, conserve chemicals, and reduce dirt load on
filtering systems.
(9) Before relighting the pilot light and the heater at
the beginning of each swimming season have a compe-
tent swimming pool heater technician inspect it and
2
make any needed adjustments. Follow a regular
gram of preventive maintenance, An annual inspection
and de-liming of the heat exchanger when necessary
will maintain heating efficiency.
4/9, PERIODIC INSPECTION
‘The XB has been designed and constructed for a long per-
formance life when installed and operated properly under
normal conditions. Regular inspections, as gutlined below,
are strongly recommended as a means of keeping your
heater operating efficiently throughout the year.
1. Keep leaves and debris off of grate top on low-profile
heaters. On outdoor stack-top models, check that vent
cap/stack is fastened securely and is clear of debri
Check for and clear any accumulation of flammable de-
bris, leaves, paper, ete. from beneath the heater or
nearby.
2. Check venting of indoor stack-top heaters for loose
ness and leaks, Make certain that all openings to outside
air are unobstructed.
3, Inspect the internal wet surfaces of the het
changer annually, and remove any accumul
scale in the tubes. The XE has beon designed for scale-
free operation in most areas of the country, but ex-
tremely high mineral content in the water in some
locales makes totally scale-free operation impossible.
Instructions for this inspection are given in paragraph
5/11.
4, The external condition of the tubes can be inspected
for soot accumulation by placing a mirror between and
under the burners when the heater is firing. If soot has
accumulated it must be removed and the bad combustion
‘causing it corrected. If there are any questions contact
the factory for instructions.
5, Check for spider webs in pilot and burner orifices
especially at spring start-up.
8. Make a visual check of the burner and pilot flame.
Flame pattern should be as shown.
MAIN BURNER,
FLAME PATTERN
PiLoT
FLAME PATTERN
7. Inspect the gas and electric millivolt controls an-
ually to ensure safe and dependable operation,
Specifically, these include:
2, High Temperature Limit Switch. See Par. 5/9.
’. Water Pressure Switch. See Par. 5/7.
¢. Automatic Gas Valve. See Fig. 18.
‘Moisture and dust can infiltrate these controls after
many years, and can eventually cause deterioration. A
regular inspection schedule with repair or replacement
as needed will keep your XE performing properly.
Keep this manual for reference by you or your service
technician when inspecting or servicing the heater. Section 5/ Maintenance
8/1. GENERAL PRECAUTIONS
‘This section contains instructions for use by a qualified
serviceman in making tests and repairs to your XE,
Step by step procedures are included for trouble shoot-
ing the electrical millivolt-control system, and it is
strongly advised that these and other procedures be
reviewed before undertaking actual repair.
Remember that most complaints about the heater are
not related to the heater at all, but to other things that
affect its operation. Most often these are things like
improper heater installation, inoperative pump, clogged
filters and strainers, closed valves in the circulating
system, inadequate gas supply, improperly adjusted
time clocks. A quick-reference Trouble Shooting Chart
is included at the back of this manual. See Fig. 30.
5/2, REGULATED GAS PRESSURE
It is desirable to check the main line gas pressure and
the regulated gas pressure in the heater manifold to
make sure both are adequate to operate the heater. (See
paragraph 3/4). A slack-tube manometer is a convenient
way to check this, and a kit is available from factory.
Instructions for operating the manometer are included
with the test kit, but the proper connection is shown in
Figure 14.
5/3, ELECTRICAL TROUBLE SHOOTING
‘The XE pool heater may have either a General
Controls gas valve or a Honeywell gas valve. The elec-
trieal troubleshooting procedures in the following pages
are illustrated with the General Controls valve, The
procedure is the same with the Honeywell valve if it is
‘understood that the two center terminals in the General
Controls valve (with Jumper) are replaced by a single
terminal on the Honeywell valve. See Fig. 18 for wiring
hookup on each valve.
TESTING MAIN LINE
GAS PRESSURE
[Attach slack tube manometer to heater Jacket
Open both valves on manometer.
Shut off ges to heater by Using shutoff cock
‘ahead of heater controls.
Remove 4 NPT test plug in upstream shutoff
valve as illustrated
5, Serew in Ya" NPT fitting from manometer kit
Attach manometer hose to fitting and to one of
the manometer valves.
6, Open all gas valves light plot and bring on main
‘gas burners.
7. Mainline gas pressure will register on the ma
hometer. With burners on, readings should be
2s follows:
'5" to 10” WO — Natural Gas
117 to 14” WC — LP Gas,
TESTING MANIFOLD REGULATED
GAS PRESSURE
Attach slack tube manometer to heater jacket.
Open both valves on manometer
Shut off manual main gas valve.
Remove 44" NPT Plug on valve outlet face and
screw in Yq" fitting {rom manometer kit. Con-
fect manometer hose to iting and to one of the
‘manometer valves,
5. Wait five minutes. Relight pilot as instructed on
rating plate and bring on main burners
6, Manometer should register as foll
4° WC — Natural Gas
9" Wo— LP Gas
7. To adjust gas pressure: Remove regulator cap
screw on top of valve marked “Reg. Adj.". Turn
Screw acjustment clockwise to Increase or coun
terclockwise to decrease gas pressure,
FIG. 14 ELECTRICAL SYSTEM TROUBLE SHOOTING SEQUENCE
Heater Does Not Come On.
If Heater Will Not Shut Off See Step 4.
Step 1.
Experience shows that most complaints about properly
installed heaters not coming on have nothing to do with
the heater itself. Usually something has happened to
reduce water flow through the heater. The protective
switches in the heater then operate to protect it
Any of the following could keep the heater OFF. Check
them first.
1. Be sure heater is properly installed. See Section 2.
2. Be sure filter is clean. Build-up of residue on the filter
can lower the pressure through the heater and shut
tote,
8. Make sure pump is not airlocked, clogged or inoperative.
4. Check main drain and skimmer valves to be sure they
are open.
5. Be sure thermostat control is set at mid-range or higher.
Move the control knob back and forth 6 or 7 times to
free the contacts, Often this is all that is required to
fix or clean thermostat contacts. Be sure that the toy:
gle switch is in the ON position.
If Heater Still Does Not Operate, Remove Control Compart-
‘ment Door And —
6. Make sure pilot is ON and adjusted properly. See
Para. 4/2,
7, Make sure gas valve is ON and gas pressure is available,
8, Make a careful visual inspection of all electrical con~
nections and wiring, Finding loose connection or @
charred wire can save a lot of time
If the pump and filter system is properly circulating
water and all the above items have.been checked, the
trouble is in the heater control systems. Go to Step 2.
NOTE: Keep the filter system running. The check-out
procedures in Steps I, 2, and 3 depend on the heater com-
ing on to tell you when the trouble has been located.
CAUTION: If filter is off, DO NOT let burners come on for
‘more than five seconds during service procedure. Shut off
operating gas valve until you know what the trouble is.
WIRING SCHEMATIC
PiLoT
GENERATOR
LO)
HIGH-UIMIT
SAFETY SWITCHES
THERMOSTAT
PRESSURE
‘SAFETY
swiren
ADDED HIGH-LIMIT
SAFETY SWITCH
cies Fic.
FusiBLe
NK
15 Soren So
Step 2.
‘This step will isolate the trouble in the protective Fusible
Link. (Part Number £-994)
lace jumper or any short circuit as shown.
If heater comes on with the jumper in place and shuts
loff when it is removed, the trouble is in the Protective
Fusible Link. See Paragraph 5/6.
If heater does not come on, GO TO STEP 3
TO PILOT GENERATOR
TO LIMIT SWITCH
‘TO THERMOSTAT
6
JUMPER
TO FUSIBLE LINK ELECTRICAL SYSTEM TROUBLE SHOOTING SEQUENCE.
Heater Does Not Come On.
If Heater Will Not Shut Off See Step 4.
Step 3.
‘This step will isolate the trouble area:
‘The protective controls or thermostat,
‘The gas valve, pilot generator or grounded wire harness.
Place jumper or any short circuit as shown below,
If heater comes on with jumper in place and shuts off
when it is removed, the trouble is in the protective con-
trols or thermostat. Go to Step 4.
If the heater does not come on, the trouble is either a
rounded wire harness, che gas valve or the pilot generator.
‘To test for grounded wire harness. disconnect harness
wires and replace jumper. If heater comes on, harness
is grounded. Inspect for pinched or pierced insulation,
& terminal touching a metal ground, loose strands of
wire grounded, broken or burned wires, ete
If heater does not come on, the trouble is in the pilot
generator or gas valve.
JUMPER
To test pilot generator
With jumper in place, connect leads from millivolt meter
to gas valve as shown below. Reverse leads if needle
deflects in opposite direction.
If meter reads more than 200 millivolts and the gas
valve doesn’t open, the gas valve is defective and should
be replaced.
If meter reads less than 200 millivolts, disconnect pilot
generator leads from valve and connect them directly to
the millivolt meter. To prevent pilot from going out
during this test the gas valve knob must be held down.
If meter does not read over 500 millivolts, the pilot gen-
erator is out of position at the pilot burner (reposition
land retest), oF the pilot generator is weak and should be
replaced. See paragraph 5/4. The generator must be
properly enveloped in the pilot flame to generate its full
potential,
If heater still does not come on after replacement of pilot
generator cartridge, the problem is in the gas valve,
Replace valve. See paragraph 5/7.
WARNING: Never leave a jumper on @ heater control to
keep the heater operating.
MILUIVOLT METER
CONNECTION
yo PILOT
GENERATOR
To Limit switch
‘To THERMOSTAT
Note: The two jumpered center terminals on the General
Control gas valve (illustrated) are replaced by a single
terminal on the Honeywell gas valve. See Fig. 18 A.
FIG. 16
6 Step 4.
If the heater comes on when the jumper is installed as in
Fig. 16 and shuts off when the jumper is removed, the
problem is in one or more of the protective switches or
their wiring.*
In this step, jumpers will be used to remove each of the
protective switches from the circuit, one at a time, to
Getermine which one is keeping the heater off.
* Check for terminals loose om wire end, loose
terminal screies, cut or broken wires
IMPORTANT: I water flow through the heater is stopped
after the hester has been on for more than three (3)
minutes. the residual heat in the firebox will heat the
stunding water in the tubes and travel to the pool thermo-
stat and the high-limit switches. This may prevent the
heater from coming ON for several minutes after starting
water flow through the heater. Cool the heater by turning
the Operating Gas Valve to OFF and let the pool water
circulate through the heater for ten (10) minutes before
proceeding with these tests.
NOTE: Keep filter pump running and turn the gas valve
ON so that heater will come on when the troublesome
switch is jumpered.
Remove control compartment. door.
shaft clockwise to the stop.
To find out which switch is keeping the heater off, add
Jumpers one at a time,
Rotate thermostat
1. First put a jumper wire here.
fneater comes on, the Pressure
Switch is keeping the heater off
‘See paracranh 5/8.
2. Connect jumper tothe white wire terminal on pressure
Switch and the white wire of wiring harness that is connected
{o.g2s valve terminal block. Ifthe heater comes on the High
Limit Switches are keeping heater aff. Se Pars 5/10.
