Instructor: Sales person: Phone: Sales person: Phone: Sales person: Phone: Sales person: Phone: Service Manager: Phone: Service Manager: Phone:

Transcription

1 LRZE HEATER

2 Zodiac Pool Systems, Inc Regional Extension Zodiac Academy Instructor: Sales person: Phone: Sales person: Phone: Sales person: Phone: Sales person: Phone: Service Manager: Phone: Service Manager: Phone: 2

3 IMPORTANT SAFETY INSTRUCTIONS The information contained in this technical guide is intended for Zodiac trained service personnel only. Electrical installation and repairs should only be performed by a certified electrician or Zodiac trained professional. and must comply with all national electric codes (NEC, Canadian, etc.). state and local law, ordinances, codes and regulations. If you have not received training, do not attempt any of the electrical repairs presented in this document. Contact Zodiac Pool Systems, Inc. at for assistance. Read and follow all instructions carefully. When servicing equipment, basic safety precautions should always be followed including those listed below. TO REDUCE THE RISK OF ELECTRICAL SHOCK: Disconnect main power to pool equipment area prior to any service or repairs. Keep all electrical equipment at least 10 feet (3m) from inside wall of pool or spa. Connect equipment only to a receptacle (cord models) or circuit (hardwired) protected by a ground fault circuit interrupter (GFCI). Use only copper conductors and supply wires suitable for the specific device. Replace damaged power cord(s) immediately and use only identical replacement parts. Do not bury power cord(s). Position cord(s) to minimize abuse from lawn mowers, hedge trimmers and other equipment. Do not install or service equipment if precipitation is present or imminent. TO REDUCE EQUIPMENT WATER PRESSURE HAZARD: Always turn pump off to release pressure prior to removing or installing in-line equipment. To avoid equipment damage, do not exceed water pressure (psi) specifications for the device. To reduce the risk of injury, do not permit children to operate, handle or play on equipment.

4 General Information Legacy is a naturally drafted Category l heater. Efficiency is 82% at sea level There are 3 models ( K Btu) LRZE is a dual thermostat, hot surface ignition heater. A Draft Hood is required when the heater is installed indoors, a Vent Cap is recommended in windy areas. Legacy Model Chart Model Size Ignition Source Fuel Type Heat Exchanger/Headers Altitude E = Electronic M = Millivolt N = Nat. Gas P = LP Gas Blank or - = Standard (Copper Heat Exchanger, Polymer Headers) Blank = Sea level Natural Gas (0 to 3000 ft.) Propane Gas (0 to 5000 ft.) LRZ N = Cupro-Nickel Heat Exchanger, Polymer Headers C = Bronze Headers, Copper Heat Exchanger (ASME Rating) S = Bronze Headers, Cupro- Nickel Heat Exchanger (ASME Rating) H = High Altitude Natural Gas (3,000 to 6,000 ft.) Propane Gas (5,000 to 10,000 ft.) J = Very High Altitude Natural Gas (6,000 to 10,000 ft.) Example: LRZE400NNH LRZ = Legacy heater 400 = 399,000 BTUs of input gas E = Electronic Ignition N = Natural Gas N = Cupro-Nickel Heat Exchanger with Polymer Headers H = Designed to operate at between 3,000 and 6,000 feet

5 R Connections Water Connections Gas Line Clearances Vent Outdoors - Open Unroofed Indoors 44 inches min. R Blank Side 8 inches min. Water Side 14 inches min.

6 Clearances Vent Outdoors - Open Unroofed Indoors 44 inches min. Front 18 inches min. Back 6 inches min. Notes: 6

7 Venting Outdoor Windy Area Vent Cap R Indoors Draft hood R

8 Plumbing Plumbing Configuration Standard Heater Front Pump In-Line Chlorinator Check Valve FROM POOL TO POOL Plumbing Configuration Reversed Order; Water Pressure Switch Tubing, Reversed, Replacement Kit part number R Heater Front Pump In-Line Chlorinator Check Valve FROM POOL TO POOL

9 Plumbing Configuration Heater Pump Check Valve Off-Line Chlorinator Plumbing Configuration Heater Pump Optional Isolation Valves Chlorinator By-pass Valve if needed Check Valve

10 Electrical- Wiring 240 VAC IGN FS W VAL GND IGN 120 L1 L2 IGN 240 Hot Hot Ground To HSI Wiring 120 VAC IGN FS W VAL GND IGN 120 L1 L2 IGN 240 Hot Neutral Ground To HSI

11 R Connection to Control System J 9 H2O J12 J17 Power Interface Board (PIB) J16 SPA POOL COMMON J15 J 6 J 3 Notes: 11

12 Setup for Control System GAS HEATER IS OFF PRESS POOL OR SPA SELECT SERVICE SETUP REMOTE POOL SPA POOL SPA MENU MENU Setup for Control System SELECT SERVICE SETUP REMOTE T-STAT SELECT SERVICE SETUP REMOTE POOL SPA POOL SPA MENU MENU Notes: 12

13 Setup for Control System SELECT SERVICE SETUP REMOTE T-STAT SELECT SERVICE SETUP REMOTE T-STAT POOL SPA POOL SPA MENU MENU Setup for Control System GAS HEATER IS OFF PRESS POOL OR SPA * REMOTE T-STAT * * ENABLED * POOL SPA POOL SPA MENU MENU Setup for Control System Set Spa Thermostat to Maximum (104 ºF). Leave Spa Enabled. * REMOTE T-STAT * * ENABLED * POOL SPA MENU

14 Operation Vent Top Flue Collector Heat Exchanger Combustion Chamber Burner Burner Tray Shelf Operation

15 Operation Heat Exchanger Operation Heat Exchanger

16 Components Inside the LRZE Ignition Control Transformer PIB Fuse Fusible Link Pressure Switch Gas Valve Burners HSI Flame Sensor Manifold Notes: 16

17 Transformer Location Yellow = Common Red = 24 VAC Transformer Not Used with LRZE In Line Fuse Location 250 Volt 2 amp. Fuse Holder

18 Universal Control Gas Valve Monitoring Circuit Thermistor J12 J 9 H2O J17 Power Interface Board (PIB) High Limits J16 J15 Fusible Link Vent Temp Limit J 6 J 3 Pressure Switch 24 VAC COMP/ IGN PUMP FAN/ LOUVER Power to PIB 24 VAC to Ignition Control Notes: 18

19 Fenwal Ignition Control Fenwal Ignition Control FENWAL IGNITION: 7 SEC. HEAT-UP: 40 SEC. PRE-PURGE: 15 SEC. INTERPURGE: 15 SEC. IGN/ FS W VAL GND Common To Gas Valve From PIB To Flame Sensor 24 VAC 24 VAC FC IGN/ 120 L1 L2 From Line IGN/ 240 To HSI From PIB

20 Hot Surface Igniter Flame Sensor

21 Gas Valve Supply Side Tap Manifold Side Tap Notes: 21

22 Troubleshooting Ignition Sequence White Black Black/Yellow HSI L1 Safety Loop Complete } 120 or 240 VAC W Terminal on Ignition Control VAC to Igniter - Igniter heats to 2600 F second heat-up V is sent on the Brown wire to Gas Valve Gas Valve Opens. 3. AC Micro Amp signal sent to Flame Sensor 4. Burners ignite, AC Micro Amp signal is rectified to a DC Micro Amp signal. 5. DC Micro Amp signal returns to the Ignition Control on the Ground wire seconds after Gas Valve gets power or when rectification is confirmed power to Igniter goes off. If rectification is not confirmed power to gas valve shuts off after 7 seconds. 2 additional tries (3 total) then shut down/lock out. Turn heater off, then back to pool or spa to reset. Notes: 22

23 Troubleshooting Testing J12 J 9 H2O J17 J16 Power Interface Board (PIB) IGNITION CONTROL GND VAL W J15 IGN/FS Fusible Link 305 F Vent Temp Limit 464 F Red Marking J 6 J 3 FC 24 VAC L2 L1 IGN/ 120 IGN/ /230 VAC Power Supply 24 VAC COMP/ PUMP FAN/ IGN LOUVER Notes: 23

24 Hot Surface Igniter Test DCV OFF 750 ACV 200 DCA Set Meter to W at 2 K µ µ 200m 20m 2000K 200K 20K 2K W 200 hfe 10A 200m NPN PNP Test Hot Surface Igniter at Ambient Temperature - range 40 to 75 Ohms- Hot Surface Igniter Test DCV 1000 OFF 750 ACV Set Meter to W at 2 K DCA µ µ 200m 20m 2000K 200m 200K 20K 2K W 200 hfe 10A NPN PNP Test Hot Surface Ignitor at Ambient Temperature - range 50 to 500 Ohms-

25 Thermistor Test DCV NPN m 2000K 200K PNP Set Meter to W at 20 K 77 F K Ohms Thermistor must be disconnected for test 20K W 2K Temp Resistance Temp Resistance 50 F K Ohms 78 F K Ohms OFF 750 ACV 51 F K Ohms 79 F K Ohms DCA 52 F 200µ K Ohms 80 F K Ohms 53 F 2000µ K Ohms 81 F K Ohms 54 F K Ohms 82 F K Ohms 20m 55 F 200m K Ohms 83 F K Ohms 56 F 10A K Ohms 84 F K Ohms hfe 57 F K Ohms 85 F K Ohms F K Ohms 86 F K Ohms 59 F K Ohms 87 F K Ohms 60 F K Ohms 88 F K Ohms 61 F K Ohms 89 F K Ohms 62 F K Ohms 90 F K Ohms 63 F K Ohms 91 F K Ohms 64 F K Ohms 92 F K Ohms 65 F K Ohms 93 F K Ohms 66 F K Ohms 94 F K Ohms 67 F K Ohms 95 F K Ohms 68 F K Ohms 96 F K Ohms 69 F K Ohms 97 F K Ohms 70 F K Ohms 98 F K Ohms 71 F K Ohms 99 F K Ohms 72 F K Ohms 100 F K Ohms 73 F K Ohms 101 F K Ohms 74 F K Ohms 102 F K Ohms 75 F K Ohms 103 F K Ohms 76 F K Ohms 104 F K Ohms Notes: 25

26 R Gas Pressure Test Gas Pressure Testing Manifold Regulated Gas Pressure 4 W.C. - Nat. Gas 9 W.C. - Propane Gas Testing Supply Line Gas Pressure 5.5 to 10 W.C. Nat. Gas 10 to 14 W.C. Propane Gas

27 Temperature Rise taken after first pass 8 tube two pass heat exchanger Notes: 27

28 Water Flow Test Legacy Model Temperature Rise Prior to Rev. F Minimum Temp Rise, F ( C) Maximum Temp Rise, F ( C) 3 (2) 7 (4) 5 (3) 10 (6) 7 (4) 15 (8) 9 (5) 17 (9) 11 (6) 20 (11) Minimum System Flow GPM (lps) 30 (1.9) 30 (1.9) 30 (1.9) 30 (1.9) 30 (1.9) Pete s Plug and Thermometer Water Flow Test Legacy Model Temperature Rise Prior to Rev. F Minimum Temp Rise, F ( C) Maximum Temp Rise, F ( C) 3 (2) 7 (4) 5 (3) 10 (6) 7 (4) 15 (8) 9 (5) 17 (9) 11 (6) 20 (11) Minimum System Flow GPM (lps) 30 (1.9) 30 (1.9) 30 (1.9) 30 (1.9) 30 (1.9) Pete s Plug and Thermometer

29 Notes:

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