JXi 370Mj - Heating ZODIAC - Free user manual and instructions

Product Type	Gas Pool Heater
Model	JXi 370Mj
Brand	Zodiac
BTU Input	370,000 BTU/hr
Fuel Type	Natural Gas or Propane
Dimensions (L x W x H)	38 x 30 x 36 inches
Weight	Approximately 180 lbs
Power Supply	120V, 60Hz
Water Flow Rate	40 GPM maximum
Heat Exchanger Material	Copper and Bronze
Ignition System	Electronic Hot Surface Ignition
Control Panel	Digital display with touchpad
Safety Features	High limit switch, flame roll-out sensor, pressure switch
Efficiency	Up to 84% thermal efficiency
Installation Type	Outdoor only
Warranty	5 years on heat exchanger, 1 year on parts

Frequently Asked Questions - JXi 370Mj ZODIAC

What is the BTU rating of the Zodiac JXi 370Mj?

The Zodiac JXi 370Mj has an input of 370,000 BTU/hr.

Can I use propane with this heater?

Yes, the JXi 370Mj can be converted to propane using a conversion kit.

What is the recommended water flow rate?

The recommended flow rate is 40 GPM maximum to ensure proper operation.

How do I clean the heat exchanger?

Regularly inspect and clean the heat exchanger with a soft brush or compressed air to remove debris.

What does the error code 'E01' mean?

Error code E01 indicates a high limit switch fault. Check water flow and temperature settings.

Is the heater suitable for indoor installation?

No, the JXi 370Mj is designed for outdoor installation only.

How often should I perform maintenance?

Annual maintenance is recommended, including cleaning the burner and checking safety devices.

What type of gas connection is needed?

Use a standard 1/2-inch NPT gas line for natural gas or propane.

Can I use a timer to control the heater?

Yes, you can connect an external timer, but ensure it is rated for the heater's electrical load.

Where can I find replacement parts?

Contact Zodiac customer service or an authorized dealer for genuine replacement parts.

USER MANUAL JXi 370Mj ZODIAC

Technical line drawing of a portable industrial device with ventilation slots and mounting flanges (no text or symbols)

Zodiac JXi™

Gas-Fired Pool and Spa Heater

Models 200, 370

WARNING

IF THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

FOR YOUR SAFETY: This product must be installed and serviced by a contractor who is licensed and qualified in pool equipment by the jurisdiction in which the product will be installed where such state or local requirements exists. In the event no such state or local requirement exists, the installer or maintainer must be a professional with sufficient experience in pool equipment installation and maintenance so that all of the instructions in this manual can be followed exactly. Before installing this product, read and follow all warning notices and instructions that accompany this product. Failure to follow warning notices and instructions may result in property damage, personal injury, or death. Improper installation and/or operation can create carbon monoxide gas and flue gases which can cause serious injury, property damage, or death. For indoor installations, as an additional measure of safety, Zodiac Group Australia Pty, Ltd. strongly recommends installation of suitable carbon monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces. Improper installation and/or operation will void the warranty.

• DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
• DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE
• DO NOT USE OR STORE FLAMMABLE MATERIALS NEAR THIS APPLIANCE
• DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION
- Immediately switch off main gas supply.
- 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.

WHAT TO DO IF YOU SMELL GAS

For full warranty terms and conditions and to register your warranty, simply visit www.zodiac.com.au/warranty and complete your details. Or scan the QR code and be taken directly to the registration page

Record your Equipment details here for quick reference:

Model No.:

Serial No.:

Refer to the following websites for information on warranty and service in your country:

• Australia, NZ, Asia and Sth Pacific go to www.zodiac.com.au

EQUIPMENT INFORMATION RECORD

DATE OF INSTALLATION

INSTALLER INFORMATION

INITIAL PRESSURE GAUGE READING (WITH CLEAN FILTER)

PUMP MODEL HORSEPOWER

FILTER MODEL

CONTROL PANEL MODEL SERIAL NUMBER

NOTES:

Table of Contents

Section 1. General Information .... 4

1.1 Technical Assistance 4
1.2 Warranty....4
1.3 Consumer Information and Safety......4
1.4 General Operation Description....4
1.5 Specifications 5
1.6 Dimensions.... 5
1.7 Certification Codes and Standards......6
1.8 Heater Components ...... 6

Section 2. Getting Started....7

2.1 Package Contents....7
2.2 Required Equipment....8

Section 3. Location Requirements......9

3.1 Clearances 9
3.2 Outdoor Installation 10
3.3 Indoor and Outdoor Shelter Installation......11

Section 4. Gas Connections....15

4.1 Supply Gas Requirements 15
4.2 Inlet Gas Pressure Test 15
4.3 Special Precautions for LP Gas.... 16

Section 5. Water Connections....17

5.1 Pump Sizing 17
5.2 Plumbing Connections 18
5.3 Water Pressure Switch Adjustment. 20
5.4 Check Valve Installation 21
5.5 Pressure Relief Valve (PRV) Installation ..... 21
5.6 Auxiliary Components, Chlorinators, Ozone Generators and Sanitizing Chemicals....22

Section 6. Electrical Connections......23

6.1 Service Access 24
6.2 Bonding 24
6.3 Input Voltage and Conversion 25

Section 7. Optional Remote Controls......26

7.1 Connecting to a Remote Pool-Off-Spa Selector (3-Wire Connection) 26
7.2 Connecting to a Remote TSTAT (2-Wire Connection)....26
7.3 Connect to an AquaLink® or "Smart" Communication via RS-485 27

Section 8. Final Installation Check ...... 29

8.1 Operating Instructions 29
8.2 Important Safety Information 29
8.3 First-Time Start-Up Procedure 29
8.4 To Turn Off Gas To The Heater 31
8.5 Normal Operation....31
8.6 Operating the Controller....31
8.7 Shutting Down the Heater 33

Section 9. Maintenance....34

9.1 Water Chemistry....34
9.2 Swimming Pool Energy Saving Tips......35
9.3 Winterizing.... 36
9.4 Spring Start-up 36
9.5 Inspection and Service 36

Section 10. Troubleshooting .... 38

10.1 Common Problems....38
10.2 Service Diagnostic Messages 39
10.3 Ignition Control LED Service Codes....39

Section 11. Professional Service and Maintenance....40

11.1 Header Bypass Reassembly Recommendations 40

Section 12. Spare Parts....41

12.1 Major Components 41
12.2 Cabinet Assembly Spare Parts List and Exploded Parts Diagram 42
12.3 Heat System Spare Parts List and Exploded Parts Diagrams....43
12.4 Water System Spare Parts List and Exploded Parts Diagrams....45
12.5 Electrical System Spare Parts List and Exploded Parts Diagrams ....46

Section 1. General Information

This manual provides installation and operation instructions for the Zodiac JXi pool and spa gas heater product line.

Read the installation and operation instructions completely before proceeding with the installation.

1.1 Technical Assistance

Web: www.zodiac.com.au

Phone: [phone]

1.2 Warranty

This heater is sold with a limited factory warranty. Details are included with this heater or for full terms and conditions please go to www.zodiac.com.au.

All warranty issues should be resolved with your Zodiac dealer or place of purchase. Claims must include the heater serial number and model (this information can be found on the rating plate), installation date, and name of the installer. Shipping costs are not included in the warranty coverage.

The warranty does NOT cover damage caused by improper assembly, installation, operation or field modification. Also, any damage to the heat exchanger caused by improper water chemistry will NOT be covered by the warranty.

NOTE: Keep this manual in a safe place for future reference when inspecting or servicing the heater.

1.3 Consumer Information and Safety

The heater is designed and manufactured to provide many years of safe and reliable service when installed, operated, and maintained according to

the information in this manual and the installation codes referred to throughout. Be sure to read and comply with all warnings and cautions.

WARNING

Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death. For indoor installations, as an additional measure of safety, Zodiac Group Australia Pty, Ltd. strongly recommends the installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.

WARNING

The following “Safety Rules for Hot Tubs,” recommended by the U.S. Consumer Product Safety Commission, should be observed when using the spa. Consult heater operation and installation instructions for water temperature guidelines before setting temperature.

• Spa or hot tub water temperature should never exceed 40°C (104°F). 38°C (100°F) is considered safe for a healthy adult. Special caution is recommended for young children.

• The 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.

• Pregnant women take note! Soaking in water above 38.5^ (102°F) can cause fetal damage during the first three (3) months of pregnancy (which could result in the birth of a brain-damaged or deformed child). If pregnant women are going to use a spa or hot tub, they should make sure the water temperature is below 38^ (100°F) maximum.

• The water temperature should always be checked with an accurate thermometer before entering a spa or hot tub. Temperature controls may vary by as much as 1C^ / 1F^ .
• Persons with a medical history of heart disease, diabetes, circulatory or blood pressure problems should consult their physician before using a hot tub or spa.
• Persons taking any medication which induces drowsiness (e.g., tranquilizers, antihistamines, or anticoagulants) should not use spas or hot tubs.
• Prolonged immersion in hot water can induce hyperthermia.
• Hyperthermia occurs when the internal body temperature reaches a level several degrees above the normal body temperature of 37^ (98.6^) . Symptoms include dizziness, fainting, drowsiness, lethargy, and an increase in the internal body temperature. The effects of hyperthermia include:
• Lack of awareness of impending hazard
• Failure to perceive heat
• Failure to recognize need to leave spa
  • Physical inability to leave spa
  • Fetal damage in pregnant women
  • Unconsciousness resulting in a danger of drowning

1.4 General Operation Description

The blower draws air and fuel through specially designed orifices, delivering a precise mixture to the burner, located inside the sealed combustion chamber. Water flows through the heat exchanger, which surrounds the

burner transferring the heat to the water. Exhaust gases are then directed through a duct where it is vented to the atmosphere.

1.5 Specifications

	SUPPLY GAS	APPLIANCE RATINGSPlease also refer to the appliance data plate
INSTALLATION LOCATION	NATURAL GAS (NG)	CERTIFIED INDOOR/OUTDOOR
	LIQUID PROPANE (LP)*	CERTIFIED INDOOR / OUTDOOR / COVERED SHELTER
GAS PIPE HEATER GAS VALVE CONNECTION†	NATURAL GAS (NG)	20 mm (3/4") NPT
	LIQUID PROPANE (LP)	20 mm (3/4") NPT
INLET GAS SUPPLY PRESSURE		Min Max
	NATURAL GAS (NG)	1.13 kPa (4.5" WC) 2.6 kPa (10.5" WC)
	LIQUID PROPANE (LP)	1.0 kPa (4.0" WC) 3.5 kPa (14.0" WC)
GAS VALVE OFFSET PRESSURE‡	NATURAL GAS (NG)	-.05 kPa (-.2" WC) -.05 kPa (-.2" WC)
	LIQUID PROPANE (LP)
WATER PIPE/HEATER CONNECTION	NATURAL GAS (NG)	• PVC/CPVC 50mm (2") unthreaded• Zodiac threaded union
	LIQUID PROPANE (LP)
WATER FLOW RATE		Min Max
	NATURAL GAS (NG)	113 lpm(30 gpm)	378 lpm(100 gpm)
	LIQUID PROPANE (LP)
WORKING WATER PRESSURE		Min Max
	NATURAL GAS (NG)	13.8 kPa(2 psi)	344.7 kPa(50 psi)
	LIQUID PROPANE (LP)
EXHAUST VENT CONNECTION SIZE§	NATURAL GAS (NG)	• Model 200: 150 mm (6")• Model 370: 200 mm (8")
	LIQUID PROPANE (LP)
ELECTRICAL SUPPLY	NATURAL GAS (NG)	• 230 VAC, 50Hz
	LIQUID PROPANE (LP)
HIGH ALTITUDE	NATURAL GAS (NG)	• The JXi heater has a special venturi-type combustion system which self compensates for changes in barometric pressure up to 1372 m (4500') above sea level. At elevations above 1372 m (4500'), the heater MJ output can be expected to be reduced by 4% for every 305 m (1000') over 1372 m (4500') above sea level.
	LIQUID PROPANE (LP)

* Indoor installation is not recommended for liquid propane heaters. Review Special Precautions for liquid propane heaters (Section 4.3).
†For gas pipe size requirements see Section 4
‡ All readings must be taken while the heater is operating
§ Use type B double-wall gas vent.
Any changes to the heater, gas controls, air orifice, gas orifices, wiring, or improper installation may void the warranty. If change is required to any of the above; contact your local Zodiac distributor visit www.zodiac.com.au or call technical support at 1300 763 021.

1.6 Dimensions

67 cm (26.5") 63 cm (24.9") 40.6 cm (16") 56 cm (22.1") 13 cm (5.1") 55 cm (21.6") 90 cm (35.4") Versa Plumb Inlet Inlet 47 cm (18.5") 26 cm (10.13") 14 cm (5.6)

Figure 1. GeneralDimensions

1.7 Certifi cation Codes and Standards

CERTIFIED	IAPMO R&T Oceana
COMPLIANT	Standard for ‘Gas Pool Heaters’, AS 4560
APPLICABLE NATIONAL INSTALLATION AND COMMISSIONING CODE(S)	Standard for Gas Installations, AS/NZS 5601Pay particular attention to the chapter addressing Venting of Equipment
All Zodiac Gas heaters must be installed in accordance with the local building and installation codes as per the utility or Authority Having Jurisdiction (AHJ). In the absence of local codes, please refer to the latest edition of the national codes for installation:JXi pool and spa heaters meet or exceed the requirements of energy conservation regulations such as those in regions that have disallowed the use of continuously lit pilot type ignition sources.

1.8 HeaterComponents

Front Rear Header Type "A" Header Type "B" a b c i g h j e d a b c f g h i e scales a safety control equipped to protect internal components and extend the life of the heater.

Indicates a safety control equipped to protect internal components and extend the life of the heater.
a Flue Temperature Sensor Monitors temperature at the exhaust flue. If excessive temperatures are detected, combustion will stop and a fault will be displayed.
b Hot Surface Igniter When current is passed through the ceramic material of the igniter it will achieve temperatures great enough to initiate combustion of the air/fuel mixture.
C Ignition Control Provides energy for ignition, monitors flame quality and controls the gas valve. Upon call for heat, the blower is activated to purge the combustion chamber. Electrical power is then applied to the hot surface igniter. When ignition temperature is attained, the gas valve opens and ignition occurs. If stable flame is detected the igniter will power down. If stable flame is not detected the control system will close the valve to prevent further gas release. If a total of 3 ignition attempts fail an ignition fault is displayed.
d High Limit Switches Rated at 43°C (109°F), 52°C (126°F) and 66°C (151°F) will prevent water of excessive temperatures from being discharged from the heater. If the switch at the header inlet, or if either switch at the heat exchanger outlet senses excessive temperature, the gas valve will close and combustion will stop.
Pool/Spa Water Temperature Control Senses water temperature by means of a thermistor. Heater will operate to attain and maintain the water temperature according to the heater settings. Two separate thermostat settings are supported, typically used to set pool and spa temperatures.

f Water Pressure Switch Senses whether or not water is available to the heater by measuring back pressure at the header inlet. If insufficient pressure is detected, the display will indicate a "Check Flow" fault and combustion will stop.

⑨ Gas Valve Controls gas flow into the burner. Enables flow when the temperature control calls for heat and all safety controls enable operation. It also regulates gas pressure to -.05 kPa (-2" Water Column) below the air pressure at the blower inlet. Necessary pressure regulation cannot be accomplished with common (positive pressure) gas valves.

Combustion Blower and Air Orifice Draws in air and fuel gas creating an air/fuel mixture that is passed through the burner for combustion. The fan will operate for several seconds before flame initiation and after the flame is extinguished to purge the combustion chamber for a clean burn and to expel any residual exhaust gas.

Air Pressure Switch Monitors the vacuum (negative pressure) within the blower housing. This switch verifies that air is flowing through the combustion system by sensing pressure. If air flow is inadequate, combustion will stop and a fault will be displayed.

j VersaFlo™ Integrated Bypass The VersaFlo Integrated Bypass allows for increased hydraulic efficiency when the heater is not firing. When the JXi heater is not firing, a flow gate in the bypass assembly is moved to the bypass position, allowing the water flow within the heater header to bypass the heat exchanger and return directly to the pool.

Section 2. Getting Started

Install the JXi in accordance with the procedures in this manual, local codes and ordinances, and in accordance with the latest edition of the appropriate national code. See Section 1.7.

If the heater is to be operated in below freezing conditions it should be installed in a protected outdoor shelter. See Section 3.3

All gas-fi red products require correct installation to ensure safe operation. The requirements for pool heaters include the following:

• Field assembly (if required)
• Appropriate site location, clearances and fl ooring see Section 3
- Suffi cient combustion and ventilation air
• Properly sized gas meter and piping
• Proper electrical wiring
- Suffi cient water flow

This manual provides the information needed to meet these requirements. Review all applications and installation procedures before continuing the installation.

2.1 Package Contents

Before completely unpacking the unit please inspect carton for damage. In addition please check the carton label to ensure that you have the correct specifications for your application.

Item	Description Qty.
1 JXi	Heater 1
2 Versa	PlumbTM Sweep Elbow 1
3 50 mm (2") Universal Union Tailpiece 2
4 50 mm (2") Universal Union Cap 1
5 50 mm (2") Universal Union O-ring 3
6 50 mm (2") Universal Union Nut	3

NOTE: 1 EA of item 4, item 5 and item 6 will come pre-installed at the horizontal manifold inlet. 1 2 3 4 5 6

2.2 Required Equipment

Please ensure that the following equipment is available to the installer at the time of installation.

2.2.1 Tools

Simple icon of a pair of safety glasses inside a gray circle (no text or symbols)

Illustration of two gloves inside a circular frame (no text or symbols)

Simple icon of a screwdriver with a plus sign, no text or symbols present

Simple illustration of a screwdriver and a rectangular tool inside a gray circle (no text or symbols)

Simple line drawing of a mechanical tool inside a circular frame (no text or symbols)

Flathead Screwdriver
Pipe Wrench

Safety Eye Wear Gloves Phillips
Screwdriver

Simple line drawing of an adjustable wrench inside a gray circle (no text or symbols)

Adjustable Wrench

Simple line drawing of a pole with a hexagon nearby (no text or symbols)

5 mm (3/16") Hex Key

Illustration of a pair of pliers inside a circular frame (no text or symbols)

Multi Grips Digital

Simple line drawing of a handheld electronic device with two leads and a display screen (no text or symbols)

Differential Manometer

Illustration of a multimeter with two probes and a screen, enclosed in a circular frame (no text or symbols)

Simple line drawing of a mechanical joint or clamp (no text or symbols)

Simple line drawing of a drill bit with a plus sign, no text or symbols present

Simple icon of a measuring tape inside a circle (no text or symbols)

Voltage Meter PVC Pipe Cutter Power Drill Tape Measure

2.2.2 Materials Supplied by Installer

Please ensure that all materials used during the installation are in accordance with local codes or the authority having jurisdiction (AHJ) requirements. If you have any questions regarding the materials that need to be used during this installation please call the Zodiac customer service center at 1300 763 021.

Indoor installations will require additional venting and exhaust conversion materials which are outlined in detail in Section 3.3

NOTE: Required materials may differ from the materials listed. Be sure to confirm with all local and national codes before beginning the installation.

GAS SUPPLIES ELECTRICALSUPPLIES		PLUMBINGSUPPLIES
Appropriately sizedGas Piping	230 VAC, 50 Hz PVC	Piping
Manual Gas Shut OffValve		PVC Cement
Gas Union Teflon	Tape
Cap Red RTV	300°C (600°F)	rated silicone adhesive
Leak Solution
1.6 mm (1/16")Hose "T"
3.18 mm (1/8") -1.6 mm (1/16")Barbed Adapter
1.6 mm (1/16")Flexible Hose

Section 3. LocationRequirements

The JXi heater is shipped from the factory with an exhaust vent configured for outdoor installation. The heater is designed and certified, per AS 4560 for both outdoor and indoor installation in Australia and for indoor and outdoor installation of natural gas only heaters in New Zealand. It is shipped from the factory configured for outdoor use only, and is intended for use with permanently installed, swimming pools only. It should be installed on a level, stationary, non-mobile location and should not be subjected to intentional movement, vibration, etc. which could negatively affect the plumbing, wiring, and venting of the heater. For installation indoors, be sure to follow all the instructions provided in this instruction manual. See

Section 3.3 for details.

Location of the heater below or above the pool water level affects operation of its water pressure switch. See Section 5.3 for more information.

NOTE: If the heater is to be operated in below freezing conditions it should be installed in a protected outdoor shelter.

CAUTION

When pool equipment is located below the pool surface, a leak from any component can cause large scale water loss or fl ooding. Zodiac Group Australia Pty, Ltd., cannot be responsible for such water loss or fl ooding or resulting damage.

3.1 Clearances

The heater must be installed in a location that allows clearances for maintenance and inspection. Minimum distances from combustible surfaces must also be maintained. All criteria given in the following sections reflect minimum clearances as stated in the national standards. However, each installation must also be evaluated, taking into account prevailing local conditions such as wind speed and direction, proximity and height of obstructions that may block ventilation, and proximity to public access areas.

Service Clearance: 91 cm (36") from top of heater for removal of top panel.

61 cm (24") from one of either the front or rear panels.

Combustible Surfaces: Each heater face requires a 15 cm (6") clearance from combustible surfaces. Although not preferred, the heater is design certified for installation on combustible surfaces for operation. However, do not install the heater on carpet.

Combustible Surface 150 mm (6") Service Clearance TOP: 915 mm (36") FRONT OR REAR: 610 mm (24") *Clearance distance from exhaust vent *See Figure 3 for details NOTE: Clearances are manufacturer's tested values. These are given as minimum values. Where local and national codes apply, and if the clearance values specified in the applicable codes are different than those listed in this manual, use the greater value to ensure safest operation. Service clearance required at front or rear main panel Figure 2. Clearances

Figure 2. Clearances

3.2 Outdoor Installation

Locate the heater:

• On a level solid surface.
• 3.5 m (12') from inner pool edge unless separated by a permanent solid barrier, i.e. a wall or fence.
• In an open area, not under a deck or other structure.
• Away from doors windows or louvres that connect in any way to occupied or inhabited areas of the building.
• Away from rainwater runoff.

• Away from potential sprinkler water intrusion.

• So that the top of the heater is at least 1m (3') below any overhang.

• So that the top surface of the heater is at least 1 m (3') above any forced air inlet within 3 m (10').

WARNING

Do not install the heater with the top of the vent assembly within 1.22 m (4') horizontally, 1.22 m (4') below or less than 300 mm (1') above any opening into a building. Local codes and installation requirements may vary.

Do not locate the heater below or adjacent to any doors, windows, louvres, grills, etc., which connect in any way with an inhabited area of a building, even though the access might be through another structure (e.g., a garage or utility room). The area under an overhang must be open on three sides to prevent combustion gases from being diverted into living areas through doors, windows, or gravity inlets If the heater is installed close to a structure, protect it from rain water runoff with rain gutters on the roof or other measures. Be sure to divert rain water runoff away from heater Install the heater so that there is at least 500 mm (1.5') of clearance between the bottom of the overhang to the top of the heater exhaust vent. Install the heater so that the top of the vent is at least 1.5 m (5') from any building opening including windows, doors, air inlets including pool spa blowers or any other opening into the building with the exception of sub-floor ventilation. The top surface of the heater must be at least 1.0 m (3') above any forced air inlet, or intake ducts located within 3.0 m (10') horizontally. Required exhaust distance: •500 mm (1.5') from any return wall, building surface or external corner. •150 mm (6") from all other combustible surfaces. Locate the heater on a level surface in an open, unroofed area at least 1.0 m (3') from gas meter, 500 mm (1.5') from an electrical meter or fuse box (prohibited area extends to the ground below meter or fuse box), and 150 mm (6") from any drain pipe or soil pipe. Keep the area surrounding the heater free from mulch, pine needles and other flammable material. Do not install the heater under a deck. min. 3.5 m (12') unless the heater is separated from the pool by a solid fence, wall or other permanent solid barrier. Do not locate the heater near sprinkler systems that could spray water on it. Water from sprinklers can damage controls and electronic components. The heater must be installed on a level, solid, and firm surface or platform. This heater is not intended for any mobile installations. Although it is always preferable to install the heater on a non-combustible surface, the JXi-series has been certified by IAPMO-R&T Oceana to applicable national standards for installation on solid, firm, and level combustible surfaces. DO NOT INSTALL ON CARPET.

Figure 3. Location Requirements

3.3 Indoor and Outdoor Shelter Installation

Zodiac does not encourage installation of LP (liquid propane) gas heaters indoors. Always consult with the authority having jurisdiction (AHJ) along with all applicable national and local codes before installing a LP heater indoors. Please be sure to refer to Section 4.2.

The heater is Certified by IAPMO-R&T Oceana for indoor installations. Please keep in mind the clearances from Section 3.1 when selecting an installation location. You will also need to make considerations for intake combustion air see Section 3.3.1 and exhaust venting

see Section 3.3.3. In addition, when pool equipment is installed indoors, appropriate containment measures and drains should be considered for the prevention of property damage in the event of an equipment leak.

NOTE: An outdoor shelter is an unoccupied enclosure which does not communicate directly with occupied areas.

If the outdoor shelter is a completely closed structure, air openings in accordance with the size recommendations described in Section 3.3.1 must be maintained. If the structure does not have outside air openings then air must be provided for combustion by using our fresh air vent kit.

3.3.1 Combustion Intake Air Supply

Listed Vent Cap End of flue shall be: • At least 500 mm (20") from the nearest part of the roof. • 300 mm (12") from the nearest part of any chimney. • If the roof is to be used for personal or public use i.e. roof top patio/bar etc., flue shall be adequately supported and At least 2 m (6.5') above the roof level and 500 mm (20") above any surrounding parapet. Storm Collar Use Approved Rook Jack Single wall flue clearance to combustible per AS/NZS 5601. 75 mm (3") from unprotected surfaces, 50 mm (2") protected combustible surfaces or ensure that temp rise limit does not exceed 50°C (122°F) above ambient, typically 25°C (77°F). = "A" / 20 if air passes through: Multiply opening by Horizontal Duct 2 1.5 Screens or Metal Lou Wood Louvers 4 Minimum Net Free Open Area* Combustion Openings MODEL 200 370 Gas appliance in a room or enclosure other than a plant room. Direct to outside** 600 cm² 1110 cm² Via an adjacent room 1200 cm² 2220 cm² Gas appliance in a plant room. Direct to outside 300 cm² 555 cm² Via an adjacent room 600 cm² 1110 cm² = "A" / 20 For garage installation, heater base must be 46 cm (18") above the floor and vent directly outside. * AS5601 indicates two permanent openings, each with the minimum free ventilation area indicated in the table. ** Direct to outside means any of the following options, provided the ventilation path is unobstructed by building material or insulation. • Directly through an outside wall (preferred option). • Through an outside wall but offset. • into a cavity ventilated to outside. • into an underfloor vent space ventilated to outside. • Into a roof space ventilated to outside.

Figure 4. Indoor and Outdoor Shelter Installation

As outlined in the latest edition of ANSI standard Z223.1 (NFPA 54), the heater location must be properly vented to provide sufficient air supply for proper combustion. Please also consult Australian standards, AS4560 and AS/NZS 5601.

When combustion air is supplied directly through an outside wall, each opening should have a minimum free area of 25.4 mm square (1 in ^2 ) per 1.2 kW input of the total input rating of all appliances in the enclosed area. If combustion air must pass through horizontal ducts, each opening should have a minimum free area of 25.4 mm square (1 in ^2 ) per 1.2 kW input of the total input rating of all appliances in the enclosed area. Details can be found in Figure 4.

The “Minimum Net Free Open Area” information from Figure 4 is not applicable in installations where exhaust fans or blowers of any type are used. Any equipment which exhausts air from the room where the heater is installed can deplete the combustion air supply or reverse the natural draft action of the venting system. This could cause flue products to accumulate in the room. Additional air must be supplied to compensate for such exhaust. Consult a professional engineer to ensure that installations where exhaust fans or blowers are used are designed and installed in accordance with all applicable local and national installation codes.

In addition, the heater must be completely isolated and protected from any source of corrosive chemical fumes or corrosive vapors (i.e chlorine or hydrochloric acid).

WARNING

Do not store any chemicals, cleaners, or other corrosive material near combustion air openings or in the room. Avoid locating appliance vents in the vicinity of combustion air openings. Failure to prevent corrosive materials from mixing with combustion air can result in reduced heater life and unsafe heater operation.

3.3.2 Direct Air Intake

In certain applications it may be necessary to supply intake air directly to the heater. You will need to order and install the direct air conversion R-Kit R0724600.

A total

equivalent length of

15 m (50')

of 75 mm

(3") PVC

tubing can be used to

bring the intake air

directly to the blower input. Please be aware that each elbow used will account for 3.6 m (12') of length.

Gas Valve Hose Port Air Pressure Switch Hose Port Air Orifice Air Orifice Screen b a make air e blower input. are that each will account for f length.

- For ease of access, remove the rear and top panels.

a Loosen the two screws securing the air orifice and screen in place. Remove the air pressure switch and gas valve hose from the air orifice.
b Remove the air orifice, separate and dispose of the orifice screen.

C Align the orifice adapter with the orifice tabs and secure with four screws.
d Dry fit the 75 mm (3") PVC tubing into the orifice adapter. Mark screw hole locations with a pen. Remove and drill pilot holes in the
PVC. Fit the PVC into the orifice adapter, align the holes and secure with four screws
e Reinstall the air orifice and air hoses.
f Install the new rear panel over the PVC and secure with four screws.

Air Orifice Air Orifice Adapter 75 mm (3") PVC f d e

3.3.3 ExhaustVenting

When the JXi heater is installed indoors or in an outdoor shelter the vent pipe sizing must be in accordance with the specifications listed in Table 1.

CODES*	US	National Fuel Gas code ANSI Z223.1 (NFPA 54)
	AUS	IAPMO Oceana Standard for Gas Pool Heaters, AS4560, AS5601 and/or Authority Having Jurisdiction (AHJ)
STATIC PRESS.	STACK TEMP.	TERMINATION LOCATION	PIPE SIZING		MAX RUN LENGTH†	MATERIAL
			MODEL	PIPE SIZE
Negative High		Roof(Vertical Termination)	200	150 mm(6")	11 m (35')	Aluminum inner pipe.Galvanized outer pipe.
			370	200 mm(8")
*Ensure that you are referencing the latest edition and pay special attention to the chapter addressing "venting of equipment"†For each elbow installed, reduce the run length by 3.7 m (12'). If a vent run is required that will exceed a total equivalent length of 11 metres (35'), a draft inducer or external fan will need to be added to the system.If a vent run is required that will exceed a total equivalent length of 11 metres (35 ft), seek the assistance of a Registered Professional Engineer for proper design of indoor venting systems.

Table 1. Vent Pipe sizing Requirements

WARNING

Vent pipe materials, sizing, and installation must be as required by the National Fuel Gas Code NFPA 54/ANSI Z223.1 or Australia Standard for Gas Pool Heaters, AS4560, AS/NZS 5601 Gas Installations as applicable by local code. Undersized pipe can result in inadequate venting and oversize pipe can result in vent condensation. Improper selection of vent pipe material, incorrect sizing of the pipe, and incorrect installation of vent piping can result in release of combustion products to the indoors. This can cause serious injury or death by Carbon Monoxide poisoning or asphyxiation.

WARNING

Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury or death. For indoor installations, as an added measure of safety, Zodiac strongly recommends installation of suitable carbon monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.

Incorrect design and installation of heater vents and ducts can result in personal injury, damage to property, or death. To avoid such hazards, the heater must be installed only by a qualified professional service technician.

• STATIC PRESSURE - NEGATIVE: Appliance operates with a negative vent static pressure, a vent gas temperature that avoids excessive condensate production and will vent vertically terminating at the roof. Termination must pass through a properly installed and approved roof jack, a properly sized storm collar and a listed vent cap. See Figure 4.
• Do not terminate heater vents near air conditioning or air supply fans which could pick up exhaust flue products, such as carbon monoxide and other hazardous effluent, and return them inside the building.
• Vent pipe type and material must be carefully selected and depends on the type of installation.

• Do not locate the vent terminal where exhaust flue products could strike against building materials and cause degradation.

• Vent opening should be well away from landscaping or other obstructions that would prevent free air flow to and from vent terminal.

• Do not terminate vent under decks, stairs, or car ports.
• Do not use the appliance to support the vent pipe.
• Vent piping must be supported with no low spots or sagging which could allow condensate to collect.
  • Install the vent pipe so it can expand and contract freely with temperature changes.

• Do not run the heater vent into a common vent with any other appliance.

• It is recommended that vent runs over 5.5 m (18') be insulated to reduce condensation. Use a condensate trap in the vent run close to the heater, especially in cold climate installations.

• Do Not install the heater in a sidewall terminated confi guration or run exhaust venting in a primarily horizontal confi guration. This heater is intended for vertical vented applications only.
• Horizontal runs of vent piping may be used but must not exceed 4.9 m (16 ft.) in length and must always maintain the minimum pitch/slope for any horizontal runs, as specified in Figure 4.

3.3.4 Indoor and Outdoor Shelter Exhaust Conversion

WARNING

Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury or death. For indoor installations, as an added measure of safety, Zodiac strongly recommends installation of suitable carbon monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.

Incorrect design and installation of heater vents and ducts can result in personal injury, damage to property, or death. To avoid such hazards, the heater must be installed only by a qualified professional service technician.

The heater can be fully converted to indoor exhaust type. In order to complete the conversion you will need to install the appropriate vent adapter. If connecting this heater to empirical (non-metric) venting, use R0731100 to adapt to empirical venting material.

150 mm (5.86°) WJXI150IN200 mm (7.86°) WJXI200IN a HOT CHAUD a

a Remove two screws securing the exhaust grill to the exhaust grill backplate.
b Remove exhaust grill.
C Remove the two screws securing the rain shield to the exhaust backplate.
d Remove the rain shield.
e Remove the remaining two screws securing the exhaust backplate to the exhaust outlet.

Exhaust Outlet Exhaust Grill Backplate Rain Shield Exhaust Grill Remove the exhaust backplate. Using two #10 thread cutting screws secure the vent adapter to the exhaust outlet.

h Using red RTV 300°C (600°F) rated silicone adhesive run a bead of sealant around the interior joint of the adapter and the exhaust outlet.

When using parts or materials from other manufacturers please be sure to follow the manufacturers instructions completely to ensure harmonious function.

or er h

3.3.5 Precautions Against Common Venting

Seek the assistance of a Registered Professional Engineer for proper design of a common venting system.

Zodiac does not recommend using a common vent to vent multiple appliances through a common duct. However, if no other option is deemed available by the installer, each appliance must have its own vent temperature limit switch. All vent limit switches must be wired in series so as to prevent any appliance from firing in the event of a

blocked vent. An outside draft inducer must be installed to pull and create negative pressure in the vent system. Refer to ANSI Z223.1 or Australian standards applicable to Gas Pool Heaters, AS4560, AS/NZS 5601 for more information on common venting multiple appliances. Do not connect vent systems of different categories to the same venting system.

3.3.6 Inspection and Replacement of Existing Vent System with New Components

When replacing an existing pool heater with the JXi, it is recommended that a new appropriate venting system is installed with the new heater. However, if the existing venting system must be used, be sure to carefully inspect the existing system to ensure that it is in good condition and appropriate for the JXi heater. Replace any parts that are not in serviceable condition before completing the installation.

Section 4. GasConnections

Gas piping installation must be in accordance with the latest edition of ANSI Z223.1 and the Australia standard installations, AS/NZS 5601.1 along with all local codes.

- Pressure Testing : The heater must be isolated from the gas supply piping system by closing the individual manual shut off valve during any pressure testing of the gas supply piping system at test pressure greater than or equal to 3.5 kPa (.5 psi).

4.1 Supply Gas Requirements

• Refer to AS/NZS 5601.1 for correct gas inlet piping length from the gas meter to the heater.
• Confirm correct supply pipe size and supply pressure before proceeding with the installation.
• Check the gas meter to make sure it will supply enough gas to the heater and any other appliances using the same gas supply. If unsure, contact your local gas utility to confirm.
• It is critical that the incoming gas supply pressure at the heater is within the maximum and minimum pressure requirements as outlined in Table 2. If the range of acceptable supply pressure is not provided, the gas supply system to the heater must be modified to meet pressure requirements.
• Consider pipe fittings when determining gas pipe sizing. For every elbow used add 900 mm (3') to straight pipe length.
• Install a manual gas shutoff valve outside the heater body for service and safety. Never install the shutoff valve inside the body of the heater.
• Where required by local code, install a sediment trap/condensate fall and gas union in accordance with Australia standard 5601. See Figure 5
• Do not use a restrictive gas cock.

4.2 Inlet Gas Pressure Test

Before the heater can be put into service it is necessary to test the input gas pressure to ensure that it falls within the required range as outlined in Table 2.

INLET GAS PRESSURE	NG (NATURAL GAS)		LP (LIQUID PROPANE)
	KPA	INCHES W.C.	KPA	INCHES W.C.
MAX	2.6	10.5	3.5	14
MIN	1.13	4.5	1.0	4.0

• All readings must be made while heater is operating.
- Relying on any reading taken while heater is off may result in poor performance and difficulty in operation.

Table 2. Supply Gas Input Pressure Requirements

CAUTION

Permanent damage to the gas valve will occur if the installation procedures are not followed correctly.

WARNING

CONVERTING THIS HEATER FOR USE WITH ANY OTHER FUEL TYPE IS NOT RECOMMENDED BUT, WHEN NECESSARY, SHOULD ONLY BE PERFORMED BY A LICENSED AND QUALIFIED PROFESSIONAL, AND ONLY AFTER CONTACTING ZODIAC GROUP AUSTRALIA FOR THE PROPER INSTRUCTIONS AND CONVERSION KIT.

All questions should be directed to the Zodiac customer service center at 1300 763 021

ATTENTION

Do not use fl exible appliance connectors on any gas connections unless the connector is AGA approved for outdoor installation, and is marked with the BTUH capacity (which must be equal to or greater than the heater rated input) and the type of gas (Natural or LP). Also, any fl exible connectors, such as CSST buried underground must be certified for underground installation and meet all applicable codes. Please note, use of fl exible connector still requires the installation of a sediment trap. See Figure 5.

NOTE: The gas line from the meter is usually larger than the gas valve. Therefore, you will need to reduce connecting pipe as necessary. Make this reduction as close to the heater as possible.

MANUAL SHUT-OFF VALVE GAS SUPPLY INLET T-FITTING SEDIMENT TRAP MINIMUM 76mm PIPE NIPPLE REMOVABLE CAP GAS PIPE UNION TO HEATER INLET Image is for reference of a trap/fall assembly, the specifics and location of your trap/fall assembly may differ. Please ensure that your installation complies with local authorities and Australian standard 5601.

Figure 5. Manual Shut-off Valve and Sediment Trap

• Verify the manual gas shutoff valve is open.
  • Make sure the heater is off.
• Remove the heater rear panel to expose the gas valve.

NOTE: The rear panel is the main body panel closest to the gas inlet. This may appear to be the front panel if the user interface was moved to accommodate a left side water connection. For instructions on moving the user interface see 5.2.1.

a Locate the inlet pressure tap on the gas valve.
b Using a small flathead screwdriver (ideally .100" width or smaller), turn the tap plug 2-3 turns counter clockwise.

CAUTION

Do not back the tap screw entirely out of the inlet pressure tap. The screw is small and easily lost. A lost screw needs to be replaced before the heater can operated.

C Connect positive manometer lead to the inlet pressure tap.

• Turn the heater on.
• Inlet gas pressure must be taken while the heater, and if possible, all other gas burning appliances supplied by the same gas delivery system, are operating.
• If the gas supply pressure is less than required.
• Check for an undersized pipe between the meter and the heater, a restrictive fitting, or an undersized gas meter. Make adjustments and perform the test again.

If needed contact the local gas utility company for assistance.

• Once proper inlet pressure has been confirmed, turn off heater.
• Remove manometer.
• Tighten the tap plug securely. DO NOT OVERTIGHTEN.

WARNING

Failure to secure or replace the pressure tap plugs will allow gas to leak from the valve into the heater body which could result in property damage, severe injury, or death.

- Before operating the heater, test the gas supply system and all connections for leaks using a soap solution. Do not use an open flame to test for leaks.

MANOMETER HOSE (FROM POSITIVE PORT) INLET PRESSURE TAP OUTLET ELBOW a b c INLET PRESSURE TAP INLET ELBOWINLET ELBOW

4.3 Special Precautions for LP Gas

This appliance is approved for use with LP (Propane) and Natural Gas in Australia only. It is approved for use with Natural gas only in New Zealand. Under the same environmental conditions, liquid propane (LP) gas is more dense or heavier than air and will more readily collect or pool in enclosed areas if adequate ventilation is not provided. It is not recommended to install LP gas heaters in enclosed areas such as pits. Locate heaters a safe distance from LP gas cylinders and filling

equipment. Consult the Australian / New Zealand Standard AS/NZS 1596 and gas installation standard AS/NZS 5601, and any other local codes and fire protection authorities about specific installation restrictions in your area.

For ALL installations the combustion air openings requirements and AS/NZS 5601 MUST be followed for safe and proper operation.

Section 5. WaterConnections

Install pool system components with connections as illustrated in Figure 6. Any configuration other than as illustrated in Figure 6 can affect the operation of the water pressure switch. Locating the heater above or below the pool water surface can also affect operation of the water pressure switch.

NOTE: When pool equipment is located below the pool surface, Zodiac is not responsible for any large scale water loss, flooding or damage caused by a leak.

CAUTION

The pool equipment must be protected from back-siphoning of water. If there is any chance of back-siphoning, provide a check valve between the pool and the filter pump inlet.

FILTER HEATER a. POOL/SPA 3 WAY VALVE PUMP SKIMMER CHECK VALVE (Always install a corrosion resistant check valve when any sanitation equipment, including erosion feeders and salt chlorination systems are installed, see section 5.4 for more details) MAIN DRAINS* (Suction Outlet) SPA DRAIN* (Suction Outlet) SPA RETURN POOL RETURN *All pool suction outlets and plumbing must be properly installed in compliance with applicable entrapment protection standards such as AS2610.2 a. MANUAL BY-PASS VALVE USE WHEN FILTRATION RATE EXCEEDS 379 lpm (100 gpm). REFER TO THE MANUFACTURER'S RECOMMENDATIONS IF USING A DIFFERENT BRAND HEATER. * All pool suction outlets and plumbing must be properly installed in compliance with applicable entrapment protection standards such as AS2610.2

Figure 6. Typical Water Piping Configuration

5.1 PumpSizing

The flow bypass within the heater manifold will accommodate flows rates delivered to the heater from a minimum of 114 Litres per minute (lpm) (30 gpm) to a maximum flow of 379 lpm (100 gpm.)

CAUTION

The system water pump must be capable of providing no less than 114 lpm (30 gpm) of flow through the heater. Flow rates at less than 114 lpm (30 gpm) may cause nuisance operation causing the heater to turn off or damage to the heater.

MODEL MIN LPM (GPM) MAX LPM (GPM)
JXI 200	114 (30)	379 (100)
JXI 370	114 (30)	379 (100)

Table 3. Recommended Flow Rate Adjustment

JXi 200 MJ Heater JXi 370 MJ Heater JXi VersaFlo™ Bypass*

* This heater comes equipped with the VersaFlo™ Integrated Bypass. For details please review the included installation and operation manual.

Figure 7. Head Loss Chart

5.1.1 Manual Bypass Valve

A manual bypass valve is to be installed in any system in which the pump flow exceeds 378 lpm (100 gpm). Connect ball valve between water inlet and outlet. See inset “a.” in Figure 6.

5.1.2 Pump Sizing for New Pool Construction:

When sizing a pump for the system, the head loss for all system components must be added together when determining the design flow rate. Component “Head Loss at Flow” curves are available from equipment manufacturers.

• Adjust the valve to bring the flow rate within the acceptable range. See Table 3.
• Remove the valve handle to avoid tampering.

NOTE: In order to properly establish head loss at flow for a filter, remember that a "dirty" filter can typically add 69 kPa (10 psi) of additional head loss, 7 extra metres (22 ^-1 ) of head. This must be considered when sizing a pump for a new pool system.

5.1.3 Pump Sizing for Replacement in an Existing Pool:

If the JXi heater replaces a different model of heater, determine if the existing pump is capable of providing the minimum flow of 114 lpm (30 gpm). JXi heaters are high efficiency heaters. Heaters typical of this construction may have higher head loss characteristics than the one

being replaced.

CAUTION

Heater failure due to insufficient water flow is not covered under warranty. See measurements in the Head Loss Chart. See Figure 7.

5.2 Plumbing Connections

The heater has a standard 50 mm (2") water manifold and coupling design. With this feature, only nominal 50 mm (2") PVC or CPVC may be connected to the heater. Zodiac

Australia Pty Ltd recommend the use of 50mm (2") pipe with a minimum of 40mm (1.5") to be fitted to the heater.

5.2.1 Reversing Plumbing Connections

The JXi heater is shipped with the manifold on the right side by default. If necessary the water connections can be orientated to the left side by rotating the top panel of the appliance.

NOTE: The electrical raceway, transformer, PIB, Ignition control and voltage selector board are all accessed through the default front panel. Special considerations should be made for service clearance, see Figure 2, before a final location and orientation for the appliance is determined.

- Turn off all power to the heater at the breaker.

- Ensure that the pump is off and will remain off for the duration of the procedure.

a Remove the four black screws securing the heater top panel to the heater body.

b Lift heater top panel. Be careful not to damage or apply undue stress to the user interface wiring.

© Rotate the heater top panel 180°.

• Place heater top panel securely on heater body.
• Secure with the four screws removed in step "a".
• Restore power to the heater.
• Return heater to normal operation.

5.2.2 Water Inlet Piping

There are two options for water inlet connections on the JXi. Both configurations use the same water outlet to return heated water to the pool. Be sure to check flow rates as outlined in Section 5.1 and if necessary make provisions for and ensure sufficient space for the installation of a manual bypass valve as outlined in Section 5.1.1

The top inlet is intended for use with the Versa Plumb™ sweep elbow. Plumbing in this configuration can increase hydraulic efficiency particularly when used in a system with other Versa Plumb™ compatible Equipment.

See Figure 8.

The sweep elbow also provides the advantage of its exclusive interface with the AquaLink ^® RS temperature sensor.

The side inlet is positioned at a 26 cm (10.13") center height providing an ideal height for replacement or new construction plumbing.

• Turn off all power to the heater at the breaker.
• Turn off main gas supply to heater.
- Ensure that the pump is off and will remain off for the duration of the procedure.
- Do a dry fit test of cut pipe lengths in order to ensure proper seating of the union tailpiece and o-ring. Make adjustments to pipe length or positioning as needed.
- Clean all adhesion surfaces with an appropriate NSF approved all purpose cleaner/primer.
- Slide the union nut onto the cut pipe length. or sweep elbow. Ensure proper nut orientation with threads directed towards the heater manifold. See Figure 9.
- Use approved NSF adhesive to glue the tailpiece onto the cut pipe, or sweep elbow.

180° a b NOTE:Maintain 12"US/24"CAN service clearance at "rear" of heater when reversed.

Heater Sweep Elbow Inlet Filter Sweep Elbow Check Valve Outlet Pump

Figure 8. Versa Plumb Heater Inlet

• Align tailpiece and manifold orifice.
• Secure union nut over tailpiece hand tight only. Be sure that the o-ring is properly seated. Do not overtighten. Do not use pipe joint or tape.

Sweep Elbow/Union Nut Union Tailpiece O-Ring Top Inlet Manifold Orifice Side Inlet Manifold Orifice O-Ring Drain Cap Union Nut Cut Pipe Union Tailpiece O-Ring Manifold Outlet NOTE: Glue Union Tailpiece and Union Nut away from heater to prevent spillage that can affect the Versaflo gate operation. Remove excess glue.

Figure 9. InletPiping

• If using the sweep elbow. Use approved NSF adhesive to glue the sweep elbow into the tailpiece and onto the cut pipe.
• Repeat the above steps for the manifold outlet. Again paying special care to ensure proper seating of the union tailpiece o-ring.
  • Install the union nut and drain cap with o-ring at the unused inlet on the heater manifold. Be sure that the o-ring is properly seated. Secure hand tight only. Do not overtighten. Do not use pipe joint or tape.
• Return all valves to their operating positions.
• Restore power to the heater at the breaker.
  • Turn on pump and inspect carefully for leaks.

• Restore main gas supply.

• Start the system and check for proper flow.

• Return heater to normal operation.

WARNING

To avoid an electrical shock hazard, which can result in serious injury or death, ensure that all electrical power to the system is turned off before approaching, inspecting or troubleshooting any leaking valves or plumbing that may have caused other electrical devices in the surrounding area to get wet.

Follow all fi liter manufacturer's instructions. Never attempt to assemble, dis as sem ble or adjust the fi liter when there is pressurized air in the system. Starting the pump while there is any pressurized air in the system can cause the fi liter lid to be blown off, which can cause death, serious personal injury or property dam age.

5.3 Water Pressure Switch Adjustment.

The water pressure switch is located inside the heater jacket on the water connection side See Section 1.8, item "f".

The switch is preset at the factory for activation at 14 kPa (2 psi). The pressure switch setting must be adjusted. If the heater is installed:

• Below the surface level of the pool
• More than 600 mm (2') above the pool level
- Where the pressure is measured at 6.9 kPa (1 psi) or greater with the filter pump off

CAUTION

The water pressure switch should be adjusted to turn the heater off when the pump is off. Setting the switch to close at too low flow can damage the appliance. Adjust the switch to turn the heater off, not on.

NOTE: It is recommended that a Pressure Release Valve (PRV) be installed prior to taking any of the steps below.

Location of the heater above or below the pool water surface can also affect the operation of the switch. The factory installed switch can accommodate elevations of 1.8 m (6') above the pool water surface or 3.4 m (11') below pool water surface. If the heater water connections are outside this range, consult your local Zodiac representative for recommendations.

• Set the heater control to "OFF".
• Remove five screws securing the side panel to the heater body.
• Remove the side panel to gain access to the water pressure switch. See Figure 10.
• Turn the filter pump on.
• Confirm that the pressure switch closes with a voltmeter.
• If the switch does not close, check that all valves are open to the heater and that there are no restrictions in the line. You may also need to confirm flow rate from your pump as outlined in Section 5.1.

Leads Adjustment Sprocket Pressure Switch Rotate clockwise with fingers until heater turns off. Then rotate coute-rclockwise 1/4 turn to set.

Figure 10. Water Pressure Switch Adjustment

• Once an operational and correctly sized pressure switch has been confirmed, set the heater control to either POOL or SPA.
• With your fingers, turn the adjustment sprocket very slowly clockwise until the heater shuts off.
• Slowly turn the pressure switch adjustment sprocket counterclockwise one-quarter turn. The heater should come back on. See Figure 10.
• Check the adjustment by turning the filter pump OFF. The burner should shut off immediately.
• If it does not, restart the filter pump and repeat the preceding step.
• Check the adjustment again. If you are still unable to successfully set your water pressure switch please contact your local Zodiac distributor or call technical support at 1300 763 021. Additional information can be found at www.zodiac.com.au.
• Return the pool temperature control to the desired temperature.
• Return heater to normal operation.

5.4 Check Valve Installation

When any equipment is located below the surface of the pool or spa, back-siphoning can occur, which can draw water backwards through the circulation system. This can be particularly concerning if chemically treated water is allowed to flow back into equipment such as heaters, filters and pumps. Make sure any chemical feeder or chlorination system outlet lines are downstream of the heater. Install a positive seal noncorrosive check valve between the sanitation equipment and the heater. Always install a check valve if there is sanitation equipment

5.5 Pressure Relief Valve (PRV) Installation

A pressure relief valve (PRV) is recommended in all installations, and is mandatory in any installation in which the water flow can be shut off between the heater outlet and the pool/spa.

A pressure relief valve is not supplied with the JXi heater. However, it is recommended that a pressure relief valve be installed and may be required by local or national codes. Be sure to check any applicable installation codes in your area to determine whether a pressure relief valve is required. If one is required, it must meet the requirements below and must be provided and installed by the installer

The maximum working pressure of this heater is 345 kPa (50 psi). Be sure to take into consideration the maximum allowable pressure of the other components in the system when installing a PRV. Any pressure relief valve installed must comply with provisions of the standard.

Installation procedure will differ depending on which header type is installed on your heater. See Figure 11.

• The PRV must be compliant to AS1357.1 or ASME certified.
  • Relief pressure must be at 3.45 bars (50 PSI)
• Minimum rating of 7.77 Kilowatts or 125.8 kg/hr steam rating.
  • Install the PRV so that it is vertical. See Figure 12.
  • Install a drain pipe from the pressure relief valve outlet to a safe area. This is a precaution to prevent the possibility of personal injury or property damage

installed in the system. Do not install any shutoff valve in the piping between the heater outlet and the pool.

WARNING

A check valve can interfere with the proper operation of certain Suction Vacuum Release System (SVRS) products. To avoid possible entrapment hazard, serious injury, or death, make sure to review the operation/owners manual of your particular SVRS product before installing the check valve.

in the event scalding water is discharged from the pressure relief valve.

• Install the discharge pipe so that there is no trapped or standing water in the piping. Discharge piping must be facing down, terminating with a threadless nipple, no more than 6" and no less than twice the diameter of the discharge pipe from the floor.
  Discharge piping must be open with no reducers or shut-off valves or other restrictions.

NOTE: To ensure the continued proper operation of the pressure relief valve, the valve should be tested once a year. To test, lift the lever with the circulation system running to ensure that water will pass through. When the lever is down, there should be no leaks from the outlet.

Header Type "A" Header Type "B"

Technical diagram of a mechanical assembly with no visible text or symbols

Technical diagram of a mechanical assembly with no visible text or symbols

Figure 11. HeaderType

5.5.1 Header Type "A" PRV Installation

- Locate the water outlet port on the inlet/outlet header side of the heater. This is the bottom port which returns water to the pool and/or spa. See Figure 12.

NOTE: PVC and or brass fittings must be installed immediately after the outlet with no valves or other components in between. The pressure relief valve must be installed at the outlet port. Do not install at the header inlet port.

CAUTION

In order to prevent damage, do not tighten with a wrench. Hand tighten only and use caution not to overtighten. Overtightening may crack the header.

Use Tefl off tape only on threads mating brass components to the plastic reducer fi tting. Do not use any pipe compound or pipe dope on the threads or any part(s) that come(s) into contact with plastic. These compounds can damage plastic components over time.

- Using PVC or CPVC plastic pipe and fittings, install a 50 mm (2") tee. See Figure 12.

• Install an elbow and a reducer fi tting. Make sure the internal pipe thread on the reducer fi tting matches the thread on the pressure relief valve.

INLET OUTLET Discharge Pipe Assembly NOTE: Discharge piping must be open with no reducers, or shut-off valves, or other restrictions.

Figure 12. Pressure Relief Valve install

5.5.2 Header Type "B" PRV Installation (not supplied by Zodiac)

• Locate the threaded boss on the outlet port of the header, and find the dimple at the center. See Figure 13.
• Use the dimple to center the drill bit.
• Drill a 9.5 mm (3/8") diameter hole through the boss.
• Take care not to damage the surrounding plastic threads. Drilling a 3 mm (1/8") diameter hole first will help prevent thread damage.
• Install a 19 mm (3/4") threaded nipple, elbow and the pressure relief valve. Make sure to get a sung fi t. Do not overtighten.

CAUTION

In order to prevent damage, do not tighten with a wrench. Hand tighten only and use caution not to overtighten. Overtightening may crack the header.

Use Tefl on tape only on threads mating brass components to the plastic reducer fi tting. Do not use any pipe compound or pipe dope on the threads or any part(s) that come(s) into contact with plastic. These compounds can damage plastic components over time.

Discharge piping must be open with no reducers, or shut-off valves, or other restrictions.

Drill Using a 3/8" Bit * Pressure Relief Valve * Elbow * 19 mm (3/4") Threaded Nipple * Discharge Pipe Assembly * Not supplied by Zodiac

Figure 13. Pressure Relief Valve install

5.6 Auxiliary Components, Chlorinators, Ozone Generators and Sanitizing Chemicals

The JXi heater is manufactured with materials that are not compatible with high concentrations of ozone, chlorine, bromine, or other sanitizing chemicals. Heater damage caused by improper water chemistry or plumbing configurations are not covered by the Zodiac Group Australia Pty, Ltd., warranty. All questions should be directed to technical support at 1300 763 021. Additional information can be found at www.zodiac.com.au. Be sure to adhere to the following:

- All sanitation equipment is to be installed as the last piece of equipment in the circulation system.

• When ozone is used, install a mixing degas chamber, to prevent ozone and air from entering the heater.
• When chemical feeders are used install an in-line check valve between the heater and the feeder.
• Wire any electrical sanitation equipment so that it cannot operate unless the filter pump is running.
• Always follow pool chemical manufacturer's instructions when adding chemicals to pool.

Section 6. Electrical Connections

ALTERNATE 110 V WIRING 220-240 VAC Healer Power Supply WATER TEMP SENSOR 8K 8K JUNIVERSAL CONTROLLER POWER INTERFACE COILAIR TEMP BR Y GAS VALVE SAV LUXED H FL TEMP g) USER INTERFACE1 (f) (e) (d) HPRESSI LIMIT FOR AIR LOUVER STARTER (IF USED) BKK DBR R (c) W W GY V (c) WATER PRESS SPA POOL COM REV VALVE (a) BYPASS MOTOR FAN/LOUVER PUMP COMP/IGN 24VAC 3 CONNECTOR O Y9K R Y (a) BYPASS SWITCH (b) REV VALVE WATER PRESS SWITCH TRANSFORMER W R 24 VAC FUSE BL BK F1 F2 R FC + IGNITION CONTROL S10 L12 IGK PSW W BR NO GAS VALVE T GY6R BL C Y5K BR T GY HCT SURFACE IGNITER AIR FLOW SWITCH B/SK GBK PK PK TO PUMP RELAY CONTACTS (F USED) Factory Wired 24V Factory Wired 120V/240V VersaFlo Bypass Accessory Leads WK-BL BL-HOT BR G-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BLK-GY-BRK-O-ORANGE-R-RED-V-VIOLET-W-WHIT-Y-YELLOW-T-Y YELLOW-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWITCH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWICH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWCH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWACH-W-SWCH-F/W-K-PINK

Figure 14. JXi Connections/ Schematic Wiring Diagram

Wiring connections must be made exactly as shown in the wiring diagram found on the inside of the heater door. If local code also requires that the equipment and/or appliances associated with the pool water circulating system, including, but not limited to, pump motors and heaters, be bonded together as part of the equipotential bonding grid. Zodiac provides a special labeled bonding lug on the manifold side of the heater to accommodate this requirement.

All electrical connections and wiring must be done by a certified electrician only. Electrical wiring must also be in accordance with the latest edition of the AS/NZS 5601, AS/NZS 3000, along with all local codes.

The heater comes factory-wired for installation with 230 Volt, 50 Hz AC field electrical supply.

WARNING

ELECTRICAL SHOCK HAZARD. This heater contains wiring that carries high voltage. Contact with these wires may result in severe injury or death.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

6.1 ServiceAccess

- Remove the four screws holding the front heater panel in place to expose the raceway.

a Locate the raceway lock release on the interior of the heater raceway.
b Using a screwdriver or comparable tool; press into the raceway release orifice until the raceway latch releases, and the raceway swings free.
C Secure the raceway in place by lifting until the Locking latch engages.
d Push the tab on the locking latch to the left to release.

• Press raceway down and back until an audible click indicates that it is latched in position.
• Replace heater front panel.

NOTE: Before the raceway can be rotated for the first time a shipping zip tie must be cut. This zip tie is threaded at the raceway release point see item (a) below. While cutting this zip tie be sure not to damage or abrade any of the wires.

Technical diagram of a device interior with labeled components and views, showing internal compartments and assembly steps.

6.2 Bonding

Zodiac, requires that the appliance be connected to a "bonding loop" that includes all electrical equipment in the system and on the equipment pad. Bonding lugs must be connected with a solid copper wire at least 8 AWG (6 AWG in Canada) or larger. Failure to do so will void the warranty.

Additionally, in the United States the National Electrical Code (NEC) and the Australian Wiring Rules (AS/NZS 3000), require that all metallic components of a pool structure, including reinforcing steel, metal fittings and above ground components be bonded together (forming an “equipotential bonding grid”) with a solid copper conductor not smaller than an 8 AWG.

CAUTION

To prevent premature failure of the appliance resulting from stray voltages and voltage differentials, the heater must be bonded to other equipment which is part of the pool plumbing system with a solid copper wire not smaller in diameter than 8 AWG (6 AWG in Canada).

6.3 Input Voltage and Conversion

The heater comes factory-wired for installation with 230 Volt, 50 Hz AC fi eld electrical supply. If the use of 120 Volt, 60 Hz AC fi eld electrical supply is required, You must fi rst change the position of the voltage selector board on the power distribution board.

• Ensure that all electrical power is shut off to the heater at the breaker.
• Ensure that the filter pump is off and will stay off for the remainder of the procedure.
• Follow service access instructions from Section 6.1.

a Locate the power distribution board in the lower right hand section of the raceway.
b Using scissors, clip the zip tie securing the voltage selector board into the power distribution board.

Remove and rotate the voltage selector board 180°. The printed message "FOR 120 VAC" will be displayed above the card connection pins.

d Reinstall voltage selector board.

NOTE: The voltage selector board is keyed so that it will fit in only one direction for either selected voltage (either side of the board).

WARNING

ELECTRICAL SHOCK HAZARD. To avoid an electrical shock hazard, which can result in serious injury or death, ensure that all electrical power to the system is turned off before approaching, inspecting, or troubleshooting any leaking plumbing that may have caused electrical devices in the surrounding area to get wet.

Technical diagram of an electronic device showing internal components and a connected circuit breaker labeled 'FOR 120 VAC'.

Section 7. Optional Remote Controls

The JXi heater controls can be wired for remote operation. All Zodiac ^® AquaLink ^® Control Systems will permit the heater to be operated by remote control. The instructions in the following sections should be used as a general guideline only. Please follow the instructions that accompany your selected control system thoroughly.

Electrical wiring must be in accordance with the latest edition of the Australian Wiring Rules (AS/NZS 3000) and all other applicable installation codes.

Refer to Figure 14 for a complete diagram of wiring connections and terminals.

7.1 Connecting to a Remote Pool-Off-Spa Selector (3-Wire Connection)

• Turn off the power to both the pool/spa control system and the heater unit.
• Remove the front panel.

• Run the wires from the pool/spa control system through the low voltage knockout on the right or left hand side of the heater.

• Connect the wiring from the pool/spa control system to the heater remote control terminal. See Figure 14 item "b".

• Connect the three wires to Spa, Pool & Common terminals of the J6 terminal bar.
• Reinstall front panel.
• Restore power to the heater and the pool/spa control system.

7.1.1 Configure the Control Panel:

• Make sure the pool heater line voltage is ON.
• Pool and spa temperature control settings must be OFF.
• Press and hold MENU, then the POOL and SPA buttons for 5 seconds to access Service Setup mode.
• Press Up or Down to display REMOTE.

• Press MENU, REMOTE OFF (default remote) is displayed.

• Use Up or Down to scroll through the Remote options until HI-LO-COM is displayed, then press MENU to select.

• Press POOL or SPA to exit Service Setup mode.

NOTE: The display will revert back to OFF after 1 minute since the last key press.

7.2 Connecting to a Remote TSTAT (2-Wire Connection)

An interrupt (on/off-type) remote can be connected as a Remote TSTAT to turn the heater on or off but not perform any other function. When using this type of

connection, remember to set the heater control to "SPA" and set the thermostat control to maximum.

7.2.1 Install the Remote TSTAT:

• Turn off the power to both the pool/spa control system and the heater unit.
• Remove the front panel.
• Run the wires from the pool/spa control system through the low voltage knockout on the right or left hand side of the heater.
• Connect the wiring from the pool/spa control system to the heater remote control terminal.
• Connect the two wires to Pool and Common (not Spa) on the J6 terminal bar. See Figure 14 item “b”.
• Reinstall panel.
• Restore power to the heater and the pool/spa control system.

NOTE: If you install a time clock to control the filter pump operation, it is recommended that the time clock have its own low voltage (Fireman's) switch to turn off the heater before turning off the pump. The switch should shut off the heater about 15 minutes before the filter pump shuts off. This will allow for a more efficient operation by removing any residual heat contained in the heat exchanger back to the pool.

CAUTION

To avoid damage to the heater, do not connect the power supply of the heater to the output side of the clock if your time clock simply interrupts the high voltage power supply or has a high voltage output. Doing so will prevent the blower from purging the residual heat from the heater when the heater turns off. The blower must be allowed to run for 45 seconds after the heater shuts off.

7.2.2 Configure the Control Panel:

• Make sure the pool heater is OFF.
- Press and hold MENU, then the POOL and SPA buttons for 5 seconds to access Service Setup mode.

NOTE: The display will revert back to OFF after 1 minute since the last key press.

- Press MENU, REMOTE OFF (default remote) is displayed.

• Use Up or Down to scroll through the Remote options until REMOTE TSTAT is displayed, then press MENU to select.
• Press POOL or SPA to exit Service Setup mode.
• Press SPA to adjust the set point to the maximum 40^ .

7.3 Connect to an AquaLink® or "Smart" Communication via RS-485

To provide "smart" communication between the JXi and a power center board (PCB) (AquaLink® RS, AquaLink PDA, and AquaLink TRi) through a red four-pin RS485 connector, your PCB must have the appropriate firmware. To determine the REV of the AquaLink RS PCB firmware in your system, refer to Table 4.

COMPONENTS	REV MMM OR EARLIER	REV N OR LATER
RS485 CONNECTORS	One (1) set of four (4)	Two (2) sets of four (4)
JVA SOCKETS 24 VAC	Located on top of board	Located on bottom of board
RELAY SOCKETS 24 VDC	10 total sockets. Eight (8) located on bottom, two (2) on top of board	11 total sockets. All located on bottom of board.

Table 4. AquaLink RS Power Center Board Identifying Features

Indoor Controller JXi Control Green Yellow Black Red Green Yellow Black Red RS Control System Power Center Bezel Power Center 22 Gauge 4 Conductor Wire

Figure 15. Wiring the JXi to a Zodiac® Remote

If your PCB firmware is REV MMM or earlier:

Connect via a 2-wire connection. See Section 7.2 for details.

Do not connect more than two (2) wires to any of the terminals in the Control System when connecting peripheral devices. If connecting the heater to the control system creates this situation, then a Multiplex PCB Kit, which includes the Multiplex Board (part # W6584) must be used.

NOTE: Only an AquaLink® RS System with firmware revision "N", or higher, will support the heater interface. Refer to Table 4 along with Figure 16 and Figure 17 to determine the REV of your system's firmware. If it is "N" or higher, continue with these procedures. If it is MMM or lower, follow the procedures in Section 7.2 for connecting to a remote TSTAT.

NOTE: Only a PDA System with firmware revision 4.1, or higher, will support the heater interface.

Connection to Controller: RS485 Connectors Spa Side Switch Sensors and Heater JVA Sockets 24 VAC Intake Return Cleaner Solar Relay Sockets 24 VDC Solar Pump Elect Htr Filter Pump Aux 1 Aux 2 Aux 3 Aux 4 Aux 5 Aux 6 Aux 7 Relay Sockets 24 VDC

Figure 16. PCB with firmware REV MMM or lower

If your PCB firmware is REV N or higher:

• Turn off the power to both the heater and the controller.
• Open the power center enclosure and remove the front dead panel.

Connection to Controller: RS485 Connectors Spa Side Switch Sensors and Heater Filter Pump Aux 1 Aux 2 Aux 3 Aux 4 Aux 5 Aux 6 Aux 7 Relay Sockets 24 VDC JVA Sockets 24 VAC Relay Sockets 24 VDC Intake Return Cleaner Solar Elect. Htr. Spare

Figure 17. PCB with firmware REV N or higher

• Use 22 gauge 4-conductor wire to run between the heater and the RS control and match the wire color order. See Figure 15.
• The wires coming from the heater can be “doubled up” on the red terminal bar with the four wires from the indoor controller.
• Check all wiring, then apply power to both the heater and the control system. Verify operation in either Service or Auto mode. Refer to your Control System manual for operating instructions.

When the heater is connected to an external controller, all functionality of the heater control panel is disabled, therefore heater functions can be controlled only from the controller.

7.3.1 To Restore Heater Control Panel Functionality After Connecting to an External Controller

- Turn power to the heater ON. The heater display shows: JANDY REMOTE ONLINE PUSH MENU TO DISABLE.

- Press MENU to remove message and restore functionality to the heater control panel.

7.3.2 To Return Control Back to a Connected External Controller

• Turn power to the heater OFF then back ON.
• Press and hold MENU for 5 seconds to access Setup Mode.
• Choose JANDY REMOTE.

Section 8. Final Installation Check

In order to ensure proper function and successful installation it is required that the operation of the appliance be fully tested and confirmed. The following sections (8.1 - 8.7) address the initial start up and shut down of the heater. A successful initial startup test must be performed in order to complete the installation.

8.1 Operating Instructions

Follow the instructions outlined below to start the heater. Refer to the Lighting and Shutdown Instructions label on the inside lid panel of the heater. See Figure 18

All questions should be directed to technical support at 1300 763 021. Additional information can be found at www.zodiac.com.au.

WARNING

If you do not follow the instructions below exactly, a fire or explosion may result, causing property damage, personal injury or loss of life.

8.2 Important Safety Information

Read Before You Start:

- This appliance does not have a pilot light. It is equipped with an ignition device, which automatically lights the heater. Do NOT try to light the burners by hand.

- BEFORE OPERATING, smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

8.2.1 What To Do If You Smell Gas

• Do not try to light any appliance.
• Do not touch any electric 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.
• Use only your hand to switch on or off the gas control switch. Never use tools. If the switch appears

broken or will not move, don't try to repair it, call a qualified service technician. Force or attempted repair may result in fire or explosion.

- Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.

8.3 First-Time Start-Up Procedure

WARNING

Vent pipes and heater tops get hot! These surfaces can cause serious burns. Do not touch these surfaces while the heater is in operation.

Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water.

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater.

Do not attempt repairs on the gas controls or appliance. Tampering is dangerous and voids all warranties

• Confirm that pool water is flowing normally through the pool system and equipment.
• If it is a new pool or spa installation, operate the filter pump with the heater off long enough to completely clean the water. This will remove any installation residue from the water.
• Clean the filter before starting the heater.
• Start the heater in either Pool or Spa mode. See Figure 18.
• Start the heater. See Figure 18.

- When the heater starts, confirm there is adequate water flow. See Section 5 for details.

8.3.1 LIGHTING INSTRUCTIONS

If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury, or loss of life.

(A) This appliance does not have a pilot light. It is equipped with an ignition device which automatically lights the burners. Do NOT try to light the burners by hand.
(B) BEFORE OPERATING, smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electric 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.

(C) Use only your hand to activate the gas control. Never use tools. If the plug will not move by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in fire or explosion.

(D) Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.
   2.* Set the thermostat to lowest setting and turn appliance switch to OFF.
2. Turn off all electric power to the appliance.
3. This appliance is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.
4. Remove the top panel.
5. Unplug gas valve power supply.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to next step.

7. Plug in gas valve power supply.

8. Replace the top panel.

9. Turn on all electric power to appliance.
   11.* Set thermostat to desired setting and switch appliance from OFF to either POOL or SPA.

10. If the appliance will not operate, check that the filter pump is on, the filter is clean and water is flowing to the pool.

Otherwise, follow the instructions "To Turn Gas Off" and call your service technician Power Supply Plug

TO TURN GAS OFF

(1) Remove top panel
(2) * Set the thermostat to lowest setting and switch appliance to OFF.
(3) Turn off all electrical power to the appliance if service is to be performed.
(4) Unplug gas valve power supply.
(5) Replace top panel.

* See manual for details of operation and thermostat control.

Power Supply Plug

PARA APAGAR EL GAS

Figure 18. Lighting and Shutdown Instructions Label on Top Panel

H0577000 REVA

Refer to the Lighting and Shutdown Instructions. See Figure 18 located inside the top panel.

- STOP! Read IMPORTANT SAFETY INFORMATION in previous section.

• Set temperature thermostat controls to their lowest setting and turn off the controller. Make sure the display shows GAS HEATER IS OFF.
• Turn off all electrical power to the heater at the junction box.
• This appliance is equipped with an ignition device which automatically lights the heater. Do NOT try to light the burner by hand.
• Remove the heater rear or top panel.
• Unplug gas valve. See Figure 18.

• Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. IF YOU SMELL GAS, STOP! Follow instructions in Section 8.2.1.

• If no gas is detected, plug gas valve back in.

• Replace the rear panel and/or top.
• Turn on electrical power to the heater.
• Turn the controller ON by pressing POOL or SPA and set the temperatures as necessary.

NOTE: If the heater does not start, check that the filter pump is ON, the filter is clean and that water is flowing to the pool. If the heater still does not operate, follow the procedure in Section 8.4 to turn off gas supply to the heater.

WARNING

When the heater is fired for the first time, the combustion chamber refractory binder material is driven out by the heat of the flame. White smoke and/or sharp odors may be emitted from the vent during this period. Do not inhale combustion product fumes at any time, and especially when these fumes are being emitted. This "burn-in" period will last only a few minutes.

8.3.2 If Ignition Is Unsuccessful

If ignition is unsuccessful, or the flame fails during normal operation, the ignition control shuts off the gas valve. The heater will then go through a post purge process and attempt to establish stable combustion two additional times. If ignition is unsuccessful after three attempts, the system shuts down and will automatically

8.4 To Turn Off Gas To The Heater

• Set temperature thermostat controls to their lowest setting and turn off the controller. Make sure the display shows GAS HEATER IS OFF.
• Turn off all electrical power to the heater at the junction box.

Power Supply Plug

attempt to restart after one hour.

• To reset the heater to provide three (3) attempts to start:
• Turn OFF the control then turn it back ON.

• Access either the Pool or Spa mode.

• Remove the rear panel or top.

• Disconnect power connection to the gas valve by unplugging the power supply plug from the gas valve body.
• Shut off the external gas supply valve to the heater.
• Replace the rear panel or top.

8.5 Normal Operation

During normal operation, the control system measures the temperature of the water flowing through the heater and will begin the start-up process if the temperature is below the set point. If the blower pressure switch senses adequate airflow when the blower starts, the ignition

8.6 Operating the Controller

Unless the heater is connected to a remote controller, all operations are set up and programmed through the control panel on the top of the heater. See Figure 19.

NOTE: The display light reverts to OFF after two minutes of inactivity since the last key was pressed.

sequence begins. Following a pre purge, the igniter is energized, then the gas valve opens. As long as a flame is sensed at the burner, operation continues until the temperature of the water entering the heater reaches the temperature control setting.

GAS HEATER IS OFF PRESS POOL OR SPA POOL SPA MENU

Figure 19. Main Control Panel

8.6.1 Setting up Heater Options

Before using the heater for the first time, set up the following options:

• Languages: Set a display language
- Temperature Scale: Set temperatures to be displayed in either Celsius or Fahrenheit scale
- Display Light Timeout: Set the display light to turn off after a specific interval of inactivity

• To Program the Display Language Heater must be in OFF mode to begin.

graph TD
    A["MENU"] --> B["OR"]
    B --> C["SELECT USER SETUP LANGUAGE"]
    D["MENU"] --> E["OR"]
    E --> F["SELECT LANGUAGE ENGLISH"]
    G["MENU"] --> H["To Save"]
    H --> I["POOL or SPA"]
    I --> J["To Exit"]

To Program the Temperature Scale (F or C)

graph TD
    A["MENU"] --> B["Select USER SETUP TEMPERATURE SCALE"]
    C["or"] --> B
    D["MENU"] --> E["SELECT TEMP SCALE °F"]
    F["or"] --> G["to Toggle °F and °C"]
    H["MENU"] --> I["To Save"]
    J["POOL"] --> K["or To Exit"]
    L["→"] --> M["→"]
    N["→"] --> O["→"]
    P["→"] --> Q["→"]

• To Program Display Light to Turn Off Automatically Heater must be in OFF mode to begin.
  

graph TD
    A["MENU"] --> B["OR"]
    B --> C["SELECT USER SETUP DISPLAY LIGHT"]
    D["MENU"] --> E["OR"]
    E --> F["SELECT DISPLAY LIGHT 2 MIN TIMEOUT"]
    G["MENU"] --> H["To Save"]
    H --> I["POOL or To ISRR"]

8.6.2 Operating the Heater

• To Turn on Pool or Spa Heat

graph TD
    A["POOL or SPA"] --> B["SET: 80°F"]
    C["To Change Temperature Set Point"] --> D["SET: 80°F"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333

- To Maintain Pool or Spa Heat (optional Relay and Wiring Required)

graph TD
    A["POOL or SPA"] --> B["MENU"]
    B --> C["MAINTAIN POOL HEAT or MAINTAIN SPA HEAT"]
    C --> D["MENU"]
    D --> E["SET: 80°F"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333

If connected, the Maintain Heat mode monitors the pool water temperature 24 hours a day by turning the pool pump on and sampling the water temperature. When the water temperature drops below the programmed temperature set point, the controller automatically starts heating the pool.

8.7 Shutting Down the Heater

Complete shutdown instructions are as follows. Refer to Figure 18.

- Set temperature thermostat controls to their lowest setting and turn off the controller. Make sure the display shows OFF.

• To Turn the Heater Off

POOL Press once to enter Pool Heat Mode. Press again to turn Pool Heat Mode Off SPA Press once to enter Spa Heat Mode. Press again to turn Spa Heat Mode Off

When the control panel is OFF, the screen displays: GAS HEATER IS OFF PRESS POOL OR SPA.

• Temperature Set Point Lock

Once you have programmed pool temperature and spa temperature set points, you can lock them so that they may not be changed inadvertently.

graph TD
    A["POOL or SPA"] --> B["SET: 80°F"]
    C["Press both Keys at same time.<br>Hold for 7 seconds"] --> D["SET POINT LOCKED SET POINT UNLOCKED"]
    E["Current temp displayed"] --> F["Current setting"]
    G["Lock or unlock depending on current setting."] --> H["End"]

• Turn off all electrical power to the heater at the junction box.
• Remove the top panel of the heater.
• Unplug the gas valve.
• Shut off the external gas supply valve to the heater.
• Replace the top panel.

Section 9. Maintenance

If the heater is not going to be used for an extended period of time and in colder climates, shut it down completely. See Section 8.7 and Figure 18.

IMPORTANT MAINTENANCE NOTE

We recommend that before each pool season, the Thermal Regulator Valve (TRV) be inspected for proper operation and replaced if there are signs of scaling or corrosion.

Corrosion and scaling are the result of improperly balanced water please see Section 9.1.1 for complete details on managing your water chemistry.

The TRV ensures the heater operates at it's optimal efficiency and if properly maintained will extend the life of the heater.

WARNING

Do not operate the heater if the water temperature is below 40 °F (4°C)

• Short term operation of heater when temps are below 40F can continue but continuous flow must be maintained.
• Prolonged operation with water below 50F can seriously damage the heater and is not covered by warranty.

9.1 Water Chemistry

Proper Water Balance is the key to the enjoyment of your pool or spa experience and to the long life of your heater.

The pH of your pool or spa's water is one of the factors that has the most impact on indicating how properly balanced the water is. The other factors are: temperature, total alkalinity, calcium hardness and total dissolved solids. Cold water is typically more acidic (corrosive), while hot water tends to lead to a scale forming (basic) condition. While the heater is in operation, if the PH is allowed to rise above 7.8 and the calcium hardness and

total alkalinity are not properly maintained; calcium in the water could lose solubility, coating the copper tubes inside the heat exchanger. This will restrict the flow of water resulting in reduced efficiency and possible damage to the heater.

If the pH is allowed to drop below 7.2, and the alkalinity is not properly maintained, the water will become more acidic. Acidic water has a tendency to dissolve metal components in the pool plumbing such as copper tubing in the heat exchanger.

Recommended Levels Fiberglass Pools Fiberglass Spas Other Pool and Spa Types
Water Temperature 66-88 °F (20-31 °C) 89-104 °F (31-40 °C) 68-104 °F (20-40 °C)
pH 7.3 - 7.4 7.3 - 7.4 7.6 - 7.8
Total Alkalinity (ppm)	120 - 150	120 - 150	80 - 120
Calcium Hardness (ppm)	200 - 300	150 - 200	200 - 400
Salt (ppm)	4500 Maximum	4500 Maximum	4500 Maximum
Free Chlorine (ppm)*	2 - 3	2 - 3	2 - 3
Total Dissolved Solids (ppm)	3000 Maximum**	3000 Maximum**	3000 Maximum**
*Free Chlorine MUST NOT EXCEED 5 ppm!.**In saltwater chlorinated pools, the total TDS can be as high as 6000 ppm.

Table 5. Pool Water Chemistry

9.1.1 Saturation Index

Saturation Index = pH + AF + CF + TF -12.1*A-Factor=(AF), C-Factor=(CF), T-Factor=(TF)
Total Alkalinity		Calcium Hardness Temperature
A-Factor C-Factor T-Factor
PPM	Factor Value	PPM	Factor Value	°C	Factor Value
5 = 0.7 5 = 0.9 0 = 0.0
25 = 1.4 25 = 1.0		3 = 0.1
50 = 1.7 50 = 1.3		8 = 0.2
75 = 1.9 75 = 1.5		12 = 0.3
100 = 2.0 100		= 1.6 16 = 0.4
150 = 2.2 150		= 1.8 19 = 0.5
200 = 2.3 200		= 1.9 24 = 0.6
300 = 2.5 300		= 2.1 29 = 0.7
400 = 2.6 400		= 2.2 34 = 0.8
800 = 2.9 800		= 2.5 41 = 0.9
A saturation index of 0 is perfectly balancedA negative saturation index has corrosive tendenciesA positive saturation index has scaling tendenciesA saturation index of +0.3 or -0.3 is ideal*-12.1 should be changed to -12.2 if Total Dissolved Solids (TDS)measure at 1,000 ppm or greater

Table 6. Water Saturation Index

PH, Total Alkalinity (TA), temperature, Calcium Hardness and Total Dissolved Solids (TDS) play a role in whether the water is either corrosive or scale forming. These factors are combined in the Langelier Saturation

Index, which is a method for determining whether or not water is properly balanced. See Table 6.

The practice of putting tablet-based sanitizer in the skimmer basket can produce heavily chlorinated water with very low pH. If this comes in contact with metal parts of the heater it can cause serious damage. Practices like this should be discontinued.

If acidic conditions are present, there could be signs of metal in the pool water that could cause staining on the floor of your pool. This might manifest itself in the form of brown stains on the finish of your pool bottom or pool water discoloration. Your local pool dealer can test for metals in your water or can provide you with a test kit.

Every effort should be made to maintain the water balance of your pool or spa in the proper range. Ignoring this very important component of your pool's water chemistry can make the water less enjoyable to bathe in and result in permanent damage to your heater and/or complete failure of individual components.

Zodiac Group Australia Pty, Ltd. does not warrant heat exchangers damaged by corrosive water issues or from the build-up of calcium in the heater's heat exchanger. Any questions regarding proper water balance can be directed to our product support line at Zodiac ^ or to your local pool dealer.

NOTE: The Thermal Regulator Valve (TRV) is an indicator of how well the water balance is being maintained. The TRV should be inspected before each pool season to ensure it is clean and operating properly. If you see signs of calcium buildup (scale-forming or base water) or corrosion (acidic water) the TRV should be replaced and your water balanced.

9.2 Swimming Pool Energy Saving Tips

Please review the following recommendations to help conserve fuel and minimize the cost of operating your pool heater without sacrificing comfort.

• The recommended maximum water temperature is 26 °C (79 °F). Use an accurate pool thermometer. A difference of 2 °C (3 °F), between 26 °C (79 °F) and 28 °C (82 °F), will use as much as 40% more gas.
• Carefully monitor the water temperature of your pool in the summertime. You can reduce heater usage due to warmer air temperatures.
• Find the proper setting on the pool heater temperature control and use the Set Point Lockout feature to discourage further adjustments.
• Set the pump time clock to start the pump no earlier than 6:00 AM. This is the time when nightly heat loss balances.
• If the pool is only going to be used on weekends, reduce the heater temperature control setting by 4 or 6

degrees during the week. Reset it to the 26^ C ( 79^ F) level a day or so before you plan to use the pool.

• During the winter or when on vacation for longer than a week, shut down the heater by following the shutdown instructions found in Section 8.7 and Figure 18. and on the inside of the heater.
• Where possible, shelter the pool from prevailing winds with well-trimmed hedges or other landscaping, cabanas, or fencing.
• The greatest source of heat loss in a swimming pool is through evaporation. It can accounts for 50% of pool systems total heat loss. The use of solar blankets, automatic covers or anything that limits the air's access to the surface of the water will help reduce this heat loss and minimize evaporation.

9.3 Winterizing

In areas where freezing temperatures occur in winter and the pool or spa will not be used, the pool should be winterized by a qualified pool service technician:

• Turn off the electrical supply and the main gas supply to the heater.
• Remove the heater access panel.
• Turn off gas supply to the heater following the shut-down instructions.

See Section 8.7 and Figure 18.

• Remove the drain plug from the inlet/outlet header and completely drain the heater before the first frost.
• Inspect the gasket on the drain plug. Store the drain plug in a safe place for winter.
• Cover the exhaust vent grill with plastic so that snow will not accumulate and freeze on top of the combustion chamber.

- Remove and drain the copper tubing for the water pressure switch.

PRESSURE SWITCH COPPER TUBING DISCONNECT HERE (WINTERIZING)

Figure 20. Water Pressure Switch Copper Tubing (Siphon Loop)

9.4 Spring Start-up

When winterized, the heater should be reassembled by a qualified professional technician in the Spring.

• Reinstall the drain plug.
  • Uncover the vent grill.

• Reattach copper tubing to water pressure switch.
  • Make sure power is supplied to the pump.

• Turn on the filter pump and circulate water through the heater for 5 minutes. Check for leaks while circulating.

• Turn on the main gas supply to the heater at the gas cock outside the heater jacket.
• Turn on the heater according to Section 8.7 and Figure 18.

9.5 Inspection and Service

WARNING

Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death.

The heater is designed and constructed to provide long performance life when installed and operated properly under normal conditions. Periodic inspections, especially at spring start-up, are important to keep your heater running safely and efficiently through the years. Zodiac

recommends that the homeowner inspect the heater on a regular basis (especially after abnormal weather conditions), and arrange to have a professional inspection at least once a year by a qualified service technician.

WARNING

For your safety, when starting the heater, keep your head and face away from the exhaust grill opening and blower inlet grill to prevent any risk of personal injury. Make sure all doors/panels are securely in place and stand back from the heater.

9.5.1 Guidelines for Homeowner Inspection:

WARNING

Do not store or use gasoline or other fl ammable vapors, liquids or chemicals in the vicinity of this or any other appliance.

WARNING

Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water.

• Keep the top of the heater, under the heater, and surrounding area clear of all debris and combustible materials such as paper, leaves, etc.
• If there is a pressure relief valve, check for corrosion in and around the valve. If there is corrosion, turn off the filter pump and replace the pressure relief valve.
• Once a year check that water is running freely through the pressure relief valve. To check, turn on the filter pump and lift the release lever on the top of the valve.
• Be sure combustion air and ventilation openings are not blocked.

9.5.2 Guidelines for Professional Inspection:

The following inspections should be made once a year or as needed. Routine inspections are a critical to the safety and long life of your Zodiac pool equipment.

• Check for loose or broken wires and terminal connections.
• Check the water pressure switch by turning the filter pump off and on several times. The burner should go off immediately after the pump stops. The fan run for 45 seconds after the burner shuts down.

CAUTION

If the heater is wired serially to or on the same relay as the filter pump, there is a chance that power will be disconnected to the heater before the fan is able to fully purge the combustion chamber. It is inadvisable to install the heater in a manner which would prevent this combustion chamber purge from taking place.

- An ignition sequence should start shortly after the pump is turned back on.

• Inspection the thermal regulator valve (TRV).

- Inspect the electrical controls, specifically:

- An ignition sequence should start shortly after the pump is turned back on. - Inspection the thermal regulator valve (TRV). - Inspect the electrical controls, specifically:

a. High limit switches.
b. Water pressure switch.
c. Automatic gas valve.
d. Power interface/Temperature control.
e. Flue temperature sensor.
f. Control circuit fuse.
g. Ignition control.
h. Air pressure switch.

- Inspect the inlet grill at the blower for blockage, leakage, and corrosion.

- Inspect the combustion blower for damage.

• Conduct a normal operating cycle and observe that the sequence proceeds as intended.
• If the heater is equipped with a pressure relief valve, clean any accumulated corrosion and make sure that water runs freely when lever is lifted.
• Inspect the outside of the combustion chamber and blower for corrosion and indication of improper operation.
• Inspect electrical controls for deterioration. Repair and replace as necessary.
• Visually check the main burner flame. Remove the top of the heater to inspect the sight glass. See Figure 21

View With Heater Top Panel Removed Sight Galss Sight Galss

Figure 21. Remove Heater Top to View Sight Glass

Section 10. Troubleshooting

10.1 Common Problems

Zodiac Group Australia strongly recommends that you call a qualified service technician to perform all service and repairs on the heater. To locate a licensed or qualified technician service company, call Zodiac, 1300 763 021, or visit www.zodiac.com.au.

The following table lists some of the most common problems when running the heater. Most problems occur when the heater is started for the first time after installation or at spring start-up.

Symptom Possible Cause Remedy
Pump not operating • No power.		• Check circuit breakers and power source.• Replace the pump.• Recheck wiring.• Check time clock setting.
	• Pump defective.• Incorrectly wired.• Time clock settings not synchronized with actual time.
Unstable combustion-(1) heater turns off and on(2) heater ignites slowly(3) flame lifts and goes out(4) short yellow streaked flame	• Wrong gas.• Lean fuel/air mixture— low supply pressure.• Lean fuel/air mixture— too much combustion air.• Rich fuel/air mixture— high manifold pressure.• Rich fuel/air mixture— too little combustion air.	• Make sure the gas supply matches the gas type indicated on the rating plate.• Correct gas supply inlet pressure to:- NATURAL GAS - 1.13 kPa (4.5" W.C.) min - 2.6 kPa (10.5" W.C.) max- PROPANE - 1.13 kPa (4.5" W.C.) min - 3.5 kPa (14.0" W.C.) max• Offset pressure should be -.05 kPa (-0.2" W.C.) Use a digital differential manometer to verify correct offset pressure. Adjust offset pressure as needed.See Section• Connect a digital differential manometer to blower throat and gas valve port to obtain differential. Make sure the differential value falls within the specified range for the heater size. See Section• Gas meter too small.• Gas line from meter to heater too small.• Check blower inlet grill for obstruction.
Not enough heat(1) heater is slow to heat up(2) heater not maintaining set temperature(3) Low temperature rise	• Heater size inadequate.• Filter pump not running long enough.• Thermal regulator valve (TRV) is opening early or is permanently open.• Heater plumbed backwards.	• Replace with heater of higher output.• Replace TRV.• Heater is condensing. Flue product moisture will condense at the start-up until the heater water temperature reaches the normal operating conditions.• Correct the plumbing.
Heater pounding or knocking •	Water flow through heater too low.• Failed Thermal Regulating Valve (TRV).	• Look for obstruction or closed valve in system.• Check for damaged internal bypass.• Variable speed pump set too low.• Dirty filter or baskets.
Igniter lights but heater does not fire	• Gas valve is not ON.• Air in gas line.• No power to gas valve.• Low gas pressure/volume.• High burner throat pressure.• Gas valve failed.	• Cycle ignition sequence until air is out of the gas line.• Check controls for proper operation.• Check supply pressure/volume and verify proper gas supply pipe size.• Replace gas valve.NOTE: Gas valve failures are extremely rare. Please confirm this as the root problem before replacing.

10.2 Service Diagnostic Messages

The controller monitors several functions of the heater. In the event of a malfunction, the controller will display a FAULT message. The following table lists the Heater

Service Messages along with potential causes and remedies.

Fault Message Possible Cause Remedy
CHECK FLOW	Pump is not running.Low pump pressure.Pressure switch fault.Variable speed pump set too low.	Check breakers and power source, recheck wiring, set time clock and current time.Clean filter or clear blockage, check position of valve in plumbing system.Make sure return eyeball fittings are installed on the wall of the poolAdjust or replace pressure switch.Adjust variable speed pump.Refer to qualified service personnel.
FAULT-HIGH LIMIT	Water temperature in heater exceeds the internal limit.Limit switch fault.	Inspect vent for obstructions or blockages.Indoor installations, check vent pipe for bird, insect or rodent activity that could cause a blockage.Replace switches.Refer to qualified service personnel.
FAULT - HIGH FLUE TEMPERATURE	Flue temp limit fault·Identify and correct loose connections.	Replace flue sensor.Refer to qualified service personnel.
FAULT-CHECK IGN CONTROL	Broken, split, pinched or disconnected air pressure switch tubing.Fan not operating.Fan running slow or premature fan failure.Air flow restricted at intake or discharge.Broken igniter.Low gas supply pressure/volume.No flame at burner.	Check tubing and replace if necessary.Correct fault or replace fan.Replace igniter.Verify proper wiring for 230 VAC.Check for proper clearances around heater and for adequate room ventilation if enclosed. Inspect for blockage or restriction at discharge of flue.Check ignition control LED codes (see Section 9.3, Ignition Control LED Service Codes).Verify that the size, length and number of elbows on the gas supply line meet national codes.Identify and correct loose wiring connections, or problems with igniter, gas valve, or ignition control.Refer to qualified service personnel.
FAULT-SHORTED H2O SENSOR or FAULT-OPEN WATER SENSOR	Faulty wiring or connection.Failured water temperature sensor.	Inspect water temperature sensor wiring.Ensure sensor is connected correctly into the power interface board (PIB).Replace water temperature sensor.Refer to qualified service personnel.
FAULT-PUMP	Status message indicating the filter pump is currently turned OFF when the heater system programmed in Maintain Temp mode.	No Service Required. This is normal when the control is in a Maintain Temp mode.

10.3 Ignition Control LED Service Codes

In addition to service diagnostic messages, the ignition controller has an LED light that flashes to indicate various ignition control faults. The following table lists the LED codes and the corresponding fault description. To diagnose possible cause and remedy, refer to Section 10.2, Service Diagnostic Messages.

LED Code Fault	Description
The LED light is on continuously.	Ignition Control Fault. Refer to qualified service personnel.
LED single flash. Air flow fault.
LED double flash. Flame exists when there is NO call for heat. Refer to qualified service personnel.
LED triple flash. Ignition lockout (heater has made three (3) unsuccessful attempts to fire and is in a soft lockout condition).

Section 11. Professional Service and Maintenance

Zodiac strongly recommends that you call a qualified service technician to perform all service and repairs on the heater. To locate a licensed or qualified technician or independent service company in your area, contact Zodiac Technical Support at:

1300 763 021

www.zodiac.com.au

Before servicing the heater:

• Confirm that the heater control is set to either POOL or SPA
• Confirm the temperature set point for either Pool or Spa is set high enough to make the heater operate given the current water temperature.

WARNING

SERVICING SAFETY

Service procedures can be hazardous because they involve fuel gas, electricity, moving parts and procedures which require testing or temporary bypass of safety controls. For this reason, the heater must be serviced only by a qualified professional service technician.

IMPROPER SERVICE HAZARD

The heater incorporates unique design features. Incorrect service of this heater can result in personal injury or damage to property. To avoid such hazards, the heater must be serviced only by a qualified professional service technician.

11.1 Header Bypass Reassembly Recommendations

If you need to remove the access cover or the VersaFlo housing from the header, use the following torque process to re-install them to the header. Start each screw by hand and then follow the torque pattern detailed below.

Technical diagram of a mechanical device with numbered components and labeled parts

Figure 22. Header Bypass Reassembly Torque Pattern

Section 12. Spare Parts

Using genuine Zodiac factory replacement parts helps to ensure the ongoing quality and reliability of our products.

Unauthentic parts might seem okay on the surface, but they often fall short of factory standards, and they typically lack the backing you get from an established, global manufacturer like Zodiac. Plus, the use of unauthentic parts voids all factory warranties.

Zodiac does not sell parts directly to pool owners, so when it's time for maintenance, please see your local Zodiac stockist for genuine parts. You can find a dealer here at www.zodiac.com.au/find-a-dealer.

NOTE: To identify the correct part, you will need to know the model number, serial number and type of gas when applicable. This information can be found on the rating plate sticker, which is located inside the heater on the outside of the combustion chamber.

12.1 Major Components

Cabinet See Section 12.2 Water System See Section 12.4 Electrical System See Section 12.5 Heat System See Section 12.3

12.2 Cabinet Assembly Spare Parts List and Exploded Parts Diagram

Key No Description model 200 model 370
1 Heater Jacket Top Kit (no User Interface) R0592400 R0592400
2 Corner Post Kit, Left/Right (set of 2) R0592500 R0592500
3 Heater Base Kit R0592600 R0592600
4 Front or Back Panel Kit R0592701 R0592701
5 Side Panel Kit R0592901 R0592901
6 Vent Terminal Housing Kit R0593100 R0593100
7 Jacket Hardware Kit(speed nuts, screws, jacket clips)		R0593300 R0593300
8 Anchor Brackets Kit (set of 4) R0593400 R0593400
9 Jacket Hole Plug Kit		R0591800 R0591800
10*	Complete Replacement BoxPackaging Kit	R0593601 R0593601

* Not Shown

Exploded view diagram of a device's internal components with numbered parts for identification

12.3 Heat System Spare Parts List and Exploded Parts Diagrams

12.3.1 Combustion Chamber Assembly

Key No* Description model 200 model 370
1 Exhaust Elbow Assembly Kit R0590200 R0590200
2 Band Clamp Kit R0590400 R0590400
3 Refractory Kit, Internal R0590500 R0590500
4 Combustion Chamber Shelf R0590701 N/A
5 Combustion Chamber Lid Kit R0590800 R0590800
6 Gasket Kit R0590901 R0590901
7 Sight Glass Kit		R0305400 R0305400
8 Ignitor Kit		R0457502 R0457502
9 Insulation Kit, External R0591000 R0591000
10	Isolator Kit (Thermal)	R0593200 R0593200
11	Heat Exchange Assembly	R0589402	R0589405

Technical diagram of a mechanical assembly with numbered components for identification

12.3.2 Burner Assembly

Key No	Description model 200 model	370
		*N **LP	N LP
1	Blower Assembly Kit	R0591100 R0591100	R0591100 R0591100	R0591100
2	Air Intake Grate Kit	R0591200 R0591200	R0591200 R0591200	R0591200
3	Blower Intake Orifice Kit	R0734101 R0734101	R0734101 R0734102	R0734102
4	Gas Valve	R0739300 R0739300	R0739300 R0739300	R0739300
5	Burner Kit	R0591702 R0591702	R0591702 R0591705	R0591705
6	Direct Air Intake Kit	R0724600 R0724600	R0724600 R0724600	R0724600
7	Capacitor Kit	R0614500 R0614500	R0614500 R0614500	R0614500

* N - Natural Gas; **LP - Liquid Propane

Exploded view diagram of a mechanical device with numbered parts for identification

12.4 Water System Spare Parts List and Exploded Parts Diagrams

Key No Description model 200 model 370
1 VersaFlo ^TM Integrated Bypass WG000016 WG000016
2 Thermal Regulator Valve Kit (TRV) R0589700 R0589700
3 Bypass Kit R0589800 R0589800
4 Drain Plug Kit R0446000 R0446000
5 Gasket and Seals Kit R0589500 R0589500
6 Manifold Backplate Kit R0590002 R0590005
7 Manifold, 3 Port (no backplate included; must order separately) R0590101 R0590101
8 Water Pressure Switch Kit R0457002 R0457002
9 Goody Bag Kit ^		R0593500 R0593500
10	Universal Half Union Kit (1 Ea, requires 2 kits for full unit replacement)	R0522900	R0522900
11	Sweep Elbow Aqualink ^ Temp Sensor	SEAQL1001	SEAQL1001
12	Drain Cap Assembly Kit	R0523000 R0523000
13	Flow Plate Assembly	R0725201 R0725203

† Goody Bag Kit Also Includes the Installation and Operation Manual and the Universal Controller Quick Guide

Header Type "A" (Discontinued)

12.5 Electrical System Spare Parts List and Exploded Parts Diagrams

Key No Description model 200 model 370
1 Ignition Control Kit R0456901 R0456901
2 Transformer Kit R0456301 R0456301
3 User Interface Kit R0591901 R0591901
4 User Interface Lid Kit R0592001 R0592001
5 Wiring Harness Kit R0592102 R0592102
6 Air Pressure Switch Kit R0456400 R0456400
7 Flue Temp Sensor R0719401 R0719401
8 7 PSI Water Pressure Switch Kit R0013204 R0013204
9 Power Interface Board (PIB)		R0719503 R0719503
10	Power Distribution Board (PDB)	R0458101 R0458101
11	Temperature Sensor Kit	R0456500	R0456500
12a	High Limit Temperature Sensors Kit (For Header Type “A”)	R0592301	R0592301
12b	High Limit Temperature Sensors Kit (For Header Type “B”)	R0592302	R0592302
13	Igniter Kit	R0457502 R0457502
14	Power Interface Harness	R0457702 R0457702

1 2 3 4 5* 6 7 8 9 10 11 12 13 14 * Items not shown in illustration: • Power interface, controller harness w/bypass • Universal controller main reset, rollout switch harness • User interface, universal controller harness 4'

* Items not shown in illustration:
• Power interface, controller harness w/bypass
• Universal controller main reset, rollout switch harness
- User interface, universal controller harness 4'

NOTES

IAPMO-R&T OCEANA TM

GasMark

Fluidra Group Australia Pty, Ltd.

219 Woodpark Rd.

Smithfield NSW2164, Australia

1300 763 021 | www.zodiac.com.au

© 2021 Zodiac Pool Systems LLC. All rights reserved.

ZODIAC is a registered trademark of Zodiac International S.A.S.U., used under license. All other trademarks are the property of their respective owners.

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