1. DL manuals
  2. Waterco
  3. Swimming Pool Heater
  4. Turbotemp 200HD
  5. Installation And Operation Manual

Waterco Turbotemp 200HD Installation And Operation Manual

Manual is about: 240 VAC NATURAL GAS/LP GAS

Summary of Turbotemp 200HD

  • Page 1

    Www.Waterco.Com warning ! Installation and operation manual for your safety - read before operating • if you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. • improper installation, adjustment, alteration, service or...

  • Page 2

    Section 1. Heater identification ............... 2 information (hin) heater data rating plate ......................... 2 section 2. Introduction ............................ 3 important notices ...................................... 3 warranty information ................................. 4 code re...

  • Page 3: Heater Data Rating Plate

    I pg 02 section 1. Heater identification information heater identification information (hin) to identify the heater, see the data rating plate on the inner front panel of the heater. There are two designators for each heater, one is the model number and the other is the heater identification number ...

  • Page 4: Introduction

    Introduction turbotemp (australia) pool and spa heater congratulations on your purchase of a turbotemp high performance heating system. Proper installation and service of your new heating system and correct chemical maintenance of the water will ensure years of enjoyment. The turbotemp is a compact,...

  • Page 5

    I pg 04 section 2. Introduction warranty information the turbotemp pool heater is sold with a limited factory warranty. Specific details are described in the waterco warranty terms and conditions booklet included with the product. Waterco pool and spa’s high standards of excellence include a policy ...

  • Page 6

    Consumer information and safety the u.S. Consumer product safety commission warns that carbon monoxide is an “invisible killer”. Carbon monoxide is a colorless and odorless gas. ! Warning 1. Carbon monoxide is produced by burning fuel, including natural gas and propane. 2. Proper installation, opera...

  • Page 7

    I pg 06 section 2. Introduction ! Danger safety information the turbotemp pool heaters are designed and manufactured to provide many years of safe and reliable service when installed, operated and maintained according to the information in this manual. Throughout the manual, safety warnings and caut...

  • Page 8

    Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should attempt to convert heater from one fuel to the other. Do not attempt to alter the rated input or type...

  • Page 9

    I pg 08 section 2. Introduction ! Caution label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Wiring errors can also destroy the control board. • connect heater to 240 volt, 50 hz., single phase power only. • verify proper operati...

  • Page 10: Installation Instructions

    Installation instructions this product must be installed and serviced by a professional service technician, qualified in pool heater installation. Waterco strongly recommends that all vents, pipes and exhaust systems be initially and periodically tested for proper operation. This testing can be acco...

  • Page 11

    I pg 10 section 3. Installation sequence of operation an electronic temperature sensing thermistor in the manifold adapter inlet controls the heater operation. When the inlet water temperature drops below the temperature set on the operating control, the burner controller supplies power to the combu...

  • Page 12

    Specifications these installation instructions are designed for use by qualified personnel only, trained especially for installation of this type of heating equipment and related components. Some states require installation and repair by licensed personnel. If this applies in your state, be sure you...

  • Page 13

    I pg 12 section 3. Installation plumbing connections the turbotemp heater has the unique capability of direct schedule 40 pvc plumbing connections. A set of bulkhead fittings is included with the turbotemp to insure conformity with waterco’s recommended pvc plumbing procedure. Other plumbing connect...

  • Page 14

    Water connections the heater requires proper water flow and pressure for its operation. See figure 5 for the recommended installation. The filter pump discharges to the filter, the filter discharges to the heater, and the heater discharges directly to the pool or spa. A manual bypass valve should be...

  • Page 15

    I pg 14 section 3. Installation flow switch if the heater is installed more than 1.5 m above the pool or more than 1.2 m below the pool level, you will be beyond the limits of the pressure switch and a flow switch must be installed. Locate and install the flow switch externally on the outlet piping ...

  • Page 16

    Gas pipe sizing heater size distance from the meter 0 to 15 m 16 to 30 m 31 to 60 m 200 25 mm 32 mm 32 mm 300 32 mm 32 mm 40 mm 400 32 mm 40 mm 50 mm sediment trap/drip leg install a sediment trap/drip leg and union located outside the heater panels in accordance with national code requirements. Do ...

  • Page 17

    I pg 16 section 3. Installation 8. Shut off the gas supply to the heater. 9. Disconnect the manometer hose. 10. Tighten the small screw inside the pressure tap. 11. Open the gas supply to the heater. 12. Verify that the seal connection in the pressure tap is closed by testing for leaks with soapy wa...

  • Page 18

    Outdoor installation (australia) locate the heater in an open, unroofed area and on a level surface that is protected from drainage or run-off. Install the heater in an area where leaves or other debris will not collect on or around the heater. It is recommended that a non-combustible base be a plat...

  • Page 19: Indoor Installation

    I pg 18 section 3. Installation indoor venting — general requirements note: remove or cover “outdoor only” label located on heater outside panel with “indoor installation” label (p/n 474275) included in accessory bag (p/n 473607). If installing the heater next to or near an air conditioning unit or ...

  • Page 20

    Heater clearances — general requirements indoor installation and outdoor shelter the following clearances must be maintained from the nearest walls: (see figure 12 and figure 12a) top .............................. 15 cm. (6 in) exhaust side ......... 15 cm (6 in.) header side ........... 15 cm (6 i...

  • Page 21

    I pg 20 section 3. Installation combustion air supply for indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area (in accordance with as/nzs 5601.1). The minimum requirements for the air supply specify that the room in...

  • Page 22

    Note (*) combustion air intake duct connection kit (part number 6844326) for all turbotemp heater models can be purchased separately. See page 52 for parts list. Do not use pvc pipe for flue exhaust vent. Flue exhaust vent temperatures can be in excess of 400° f. Flue exhaust vent must be category i...

  • Page 23

    Corrosive vapors and possible causes area likely contaminants chlorinated swimming pools and spas pool or spa cleaning chemicals. Acids, such as hydrochloric or muriatic acid. New construction and remodeling areas glues and cements, construction adhesives, paints, varnishes, and paint and varnish st...

  • Page 24

    Vent installation – indoor installation or outdoor shelter always vent the heater to the outdoors, see note*. • vent it vertically using double wall vent connector pipe. Locate the heater so as to minimize the length of horizontal venting and the number of vent elbows required. Horizontal vent runs ...

  • Page 25

    I pg 24 section 3. Installation table 6a. – maximum number of elbows per vent lengths maximum number of elbows per vent lengths maximum elbows allowed [c] total vent length (c=a+b) [a] horizontal maximum vent length [b] vertical vent length 3 2m (6.6 ft.) 0.67m (2.2 ft.) 1.33m (4.4 ft.) 3m (9.8 ft.)...

  • Page 26

    2. Install the metal flue collar in the vent body of the heater (located under the outside vent cover). Fasten the metal flue collar to the vent body with two #10 sheet metal screws. Use high temperature silicone rtv to seal the flue collar to the vent body. Before connecting the metal flue collar t...

  • Page 27

    I pg 26 section 3. Installation 5. Use approved fire stop for floor and ceiling penetrations. Use approved thimble for wall penetrations. Use a approved roof flashing, roof jack, or roof thimble for all roof penetrations. Do not fill the space around the vent (that is, the clear air space in the thi...

  • Page 28

    Note after installation, installer must check for correct and safe operation of the heater. Flue gases may escape into the dwelling with any cracks or loose joints in the vent pipe, or improper vent installation. The vent pipe must be of a sealed-seam construction and for operating temperatures less...

  • Page 29

    I pg 28 section 3. Installation 4. Install vent pipe so that it can expand and contract freely as the temperature changes. Support the vent pipe according to applicable codes and vent manufacturer’s instructions. Pipe support must allow the vent pipe free movement out and back, from side to side, or...

  • Page 30

    8. Vent termination – horizontal the terminal must be located (see figure 17): • at least 76 mm (3 in) and at most 304 mm (12 in) out from the wall (see figure 18), following the vent manufacturer’s instructions • at least 304 mm (12 in) above finished grade or the normally expected snow accumulatio...

  • Page 31

    I pg 30 section 3. Installation horizontal or vertical venting flexible duct (flex-vent) (see figures 15, 16, 17 & 19) do not combine exhaust vent pipes to a common exhaust vent in multiple unit installations. Run separate vent pipes. ! Caution 150 mm (6 in.) flex-vent (vertical or horizontal)* no. ...

  • Page 32

    Control panel indexing on an outdoor shelter installation, the exhaust discharges into a vent pipe. Orient the heater so that the vent pipe does not interfere with adjustment of the operating controls. The control panel located on the top panel can be rotated to any of the three sides of the heater ...

  • Page 33

    I pg 32 section 3. Installation 1. All wiring must be in accordance with all applicable codes and must be wired by a licensed electrician to as3000 wiring rules. 2. The heater, when installed, must be electrically grounded and bonded in accordance with local codes or, in the absence of local codes, ...

  • Page 34

    Remote control connections 1. Switch off power to heater at main circuit breaker panel. 2. Unbolt and remove the access door panels. 3. Open control box cover (see figure 23). 4a. To connect a 2-wire control (such as the pentair water pool and spa intellitouch™ or easytouch™) or a timer: - remove th...

  • Page 35

    I pg 34 section 3. Installation turbotemp wiring diagram (3-wire system) plug –12 pin 240v – red jmp 1 jmp 1 external control interface circuit disabled, heater membrane pad enabled external control interface circuit enabled, "pool on" and "spa on" keys disabled. "off" key on membrane pad remains fu...

  • Page 36

    Turbotemp electrical schematic ladder diagram figure 26. L1 l2 240 vac 240 vac igniter l1 s1 s2 l2 f1 f2 blower gnd gnd class ii transformer 24 vac 24 vac 24v operating control 24 vac logic th ind air flow switch hi limit switch water pressure switch com no ags switch val gas valve thermistor sensor...

  • Page 37: Operation Instructions

    I pg 36 section 4. Operation operation instructions basic system operation start pump, make sure the pump is running and is primed, to close the water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. Follow the lighting/operating instructions bel...

  • Page 38

    F. Before operating the appliance for the first time or after it has been off for an extended time, perform the following checklist: 1. Remove debris or other articles from inside the heater and the area around the heater and its exhaust vent. Make sure the ventilation openings are clear of debris o...

  • Page 39

    I pg 38 section 4. Operation to turn off gas to appliance 1. Press the off button on operating control. 2. Switch off all electric power to the unit. 3. Turn off the outside external manual shut-off gas valve, see figure 27. 14. If the appliance will not operate, follow the instructions below “to tu...

  • Page 40

    Star wheel a reference scale is on the back of pressure switch turn star wheel clockwise toraise pressure set point if pressure switch is more than 1.2m (4 ft.) below water level turn star wheel counterclockwise to lower pressure set point if pressure switch is more than 1.5m (5 ft.) above water lev...

  • Page 41

    I pg 40 section 4. Operation risk of explosion or fire causing burns or death if safety interlocks are disabled. Do not attempt to operate heater when service heater light is on or if blower or burner will not start. Instead, follow instructions under “to switch off gas to the appliance,” and call a...

  • Page 42

    Figure 33. Maximum temperature set point 1. Unbolt and remove the door panels (see figure 33). 2. Access the control panel board on the underside of the top cover. Locate the yellow button on the corner of the control board. 3. Push the max. Temp. Set point button on the back of the control board (s...

  • Page 43: Troubleshooting Instruction

    I pg 42 section 5. Troubleshooting troubleshooting instruction initial troubleshooting only qualified, trained service technicians with appropriate test equipment should service the heater. Remember that all parts of the system affect heater operation. Before starting this troubleshooting procedure,...

  • Page 44

    Heater will not fire - a start go to “heater willnot fire - b” page 37 heater should fire on demand for heat. Check fireman’s switch circuit connections (time clock, wiring, external controller relay). Remove jumper. Check wiring between transformer and j7 terminals on control board and between j7 a...

  • Page 45

    I pg 44 section 5. Troubleshooting heater will not fire - b start increase pool/spa temperature setting on membrane pad above actual water temperature. Heater should fire on demand for heat. If not, and no other red led’s light, replace control board. Service pump/filter and eliminate other flow obs...

  • Page 46

    Heater will not fire - c start go to “initial troubleshooting” continue to observe heater for several minutes. Cycle heater on and off several times. Observe for delayed or rough ignition, poor combustion, premature extinction of flame, evidence of boiling, or operation of any diagnostic led. Go to ...

  • Page 47: Important! Read Me First!

    I pg 46 section 5. Troubleshooting heater will not fire - d start important! Read me first! Gas flows during ignition try, but burner does not fire. No no yes go back to chart “heater will not fire-c” (page 44). Check voltage across igniter leads; ok? Replace ignition control module. No yes replace ...

  • Page 48

    Diagnostic led’s: ags, afs, hls, ps, thermistor do not jumper a safety switch to remedy a failed switch. Note: es1 is a spare and should be jumpered. Caution service pump and filter to restore proper flow. After ser- vicing, verify proper operation of pressure switch (ps). Replace thermistor or cont...

  • Page 49

    I pg 48 section 5. Troubleshooting diagnostic led’s: sfs no (hd) no (basic) no reset power to heater and retry. Heater should fire. Does the digital temperature display show error code “e05” or “e06”? Heater starts and runs ok, but temperature of exhaust climbs to 204°–260°c in 3-5 minutes. Heater s...

  • Page 50

    Symptom cause remedy loud, high-pitched whine flame is too rich. Verify pressure tap between gas valve and blower inlet. Verify that the gas regulator setting is 11 ± 5 pa. Contact a qualified technician or service agency to replace the gas orifice. Flame is “fluttery .” exhaust may have acrid smell...

  • Page 51: Maintenance Instructions

    I pg 50 section 6. Maintenance maintenance instructions care and maintenance the following maintenance is recommended every six months and at the start of every swimming season: 1. Inspect the heater panels and venting system to make sure that there are no obstructions to the flow of ventilating air...

  • Page 52

    Explosion hazard. Any heater installed with restrictive devices in the piping system downstream from the heater, (including check valves, isolation valves, flow nozzles, or therapeutic pool valving), must have a relief valve installed as described above. ! Warning fire or flooding hazard. If the uni...

  • Page 53

    I pg 52 section 6. Maintenance for outdoor heaters in freezing climates, shut the heater down and drain it for winter as follows: 1. Turn off electrical supply to the heater and pump. 2. Close the external manual shut-off gas valve (located outside the heater). 3. In colder climates where they may b...

  • Page 54

    Heat exchanger damage resulting from chemical imbalance is not covered by the warranty. ! Caution chemical balance pool and spa water your waterco pool heater was designed specifically for your spa or pool and will give you many years of trouble-free service, provided you keep your water chemistry i...

  • Page 55

    I pg 54 section 6. Maintenance what a disinfectant does two pool guests you do not want are algae and bacteria. To get rid of them and make pool water sanitary for swimming - as well as to improve the water’s taste, odor and clarity - some sort of disinfectant must be used. Chlorine and bromine are ...

  • Page 56

    Notice: failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger and will void the warranty. *start-up tds includes source water tds and any other inorganic salt added at start-up. Water chemistry parameters table 10. Alkalinity high or low: “t...

  • Page 57

    I pg 56 section 6. Maintenance repair parts are available from your pentair dealer. If your dealer cannot supply you, call customer support for complete electrical system parts breakdown (key nos. 1 through 4), see page 44. For complete burner system parts breakdown (key nos. 5 through 7), see page ...

  • Page 58

    For heaters manufactured between 1/12/2009 and 10/31/2013 (clamp lid tub design) note: kits also include clamp assembly, o-ring and silicon tube (see page 49) combustion chamber gasket lid nut/washer (9x) clamp lid tub design turbotemp replacement parts.

  • Page 59

    I pg 58 section 6. Maintenance repair parts – burner system model key part 200na 300na 400na no. Description qty. 200lp 300lp 400lp 1 gas valve assembly [australia] 474133z 474133z 474133z 2 19 mm union 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 38404-4097s 38404-4097s 38404-4097s 3 gas orifice 4 gas orifice...

  • Page 60

    Repair parts – water system 1 3 20 21 22 4 5 8 9 12 11 10 2 7 6 19 14 15 13 18 17 16 * not available separately. • not illustrated. Model key part 200na 300na 400na no. Description qty. 200lp 300lp 400lp 1 tube sheet coil assembly kit ( hd series) (includes key no.3) 1 2 manifold kit (includes key n...

  • Page 61

    I pg 60 section 6. Maintenance 2 6 7 8 9 10 3 4 16 11 15 13 1 5 14 repair parts – electrical system 12 17 1 heater display cover 1 42002-0035 42002-0035 42002-0035 2 igniter bracket 1 42001-0030s 42001-0030s 42001-0030s 3 igniter/igniter gasket kit incl. Key nos. 3 and 4) 1 77707-0054 77707-0054 777...

  • Page 62

    Waterco limited abn 62 002 070 733 zzm1439_02/2014 offices - australia nsw - sydney (head office) tel : +61 2 9898 8686 vic/ tas - melbourne tel : +61 3 9764 1211 wa - perth tel : +61 8 9273 1900 qld - brisbane tel : +61 7 3299 9900 sa/ nt - adelaide tel : +61 8 8244 6000 act distributor tel : +61 2...