Legacy Combustion Chamber Replacement Kit

Transcription

1 H Replacement Kit Instructions WARNING FOR YOUR SAFETY - This product must be installed and serviced by authorized personnel, qualifi ed in pool/spa heater installation. Improper installation and/or operation can create carbon monoxide gas and fl ue gases which can cause serious injury, property damage, or death. For indoor installations, as an additional measure of safety, Zodiac Pool Systems, Inc. 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. These instructions are to be used with the following Replacement Kits: R through Legacy Model LRZE Combustion Chamber Replacement Kit R through Legacy Model LRZM Combustion Chamber Replacement Kit This document gives instructions for replacing the Combustion Chamber on all Jandy Legacy Models LRZE and LRZM Natural and Propane model pool/spa heaters. The instructions were written with safety as the priority and must be followed exactly. Not following the written procedure or taking shortcuts may increase the risk of personal injury. Read through the instructions completely before starting the procedure. Before starting the procedure, use the parts list at the back of these instructions to identify the parts that are in your kit. If any parts are missing from the kit please call your local Jandy distributor for assistance. For technical assistance, please contact our Technical Support Department at Removing the Heat Exchanger To remove the existing combustion chamber, the top of the heater and the heat exchanger must be removed first. Use the following procedure to remove these items. WARNING SHOCK HAZARD! Turn off all switches and the main breaker in the pool/spa heater electrical circuit before starting the replacement procedure. Failure to comply may cause a shock hazard resulting in severe personal injury or death. Legacy Combustion Chamber Replacement Kit WARNING If the information in this manual is not followed exactly, a fi re or explosion may result causing property damage, personal injury or death. 2. Be sure that the filter pump is OFF and that it will remain off during the entire procedure. 3. If the heater is below the surface level of the water in the pool, be sure to completely close shut-off valves leading to and coming from the pool. 4. Disconnect the water supply and return from the header. 5. Remove heater door. 6. If there is a vent cap or drafthood (indoor) on top of the heater, remove it. 7. Remove all hex head screws fastening the top and lift the rear of the top assembly up. Slide the top forward to remove the lip from the panel. See Figure Remove all hex head screws that secure the back panel. Remove the back panel and set it aside. 9. Remove all hex head screws that secure the rainshield assembly and pull it straight up and off of the flue collector and set it aside. 10. Remove screws that secure the side panels and put them aside. See Figure Remove the screws securing the flue collector to the heat exchanger assembly. Remove flue collector and set aside. 12. Remove the nuts and the retaining rings that secure the limit switches and lay them on the side of the cabinet. See Figure Turn off the electrical power to the heater. Turn off the main gas supply to the heater at the meter or the manual gas cock outside the heater.

2 Page 2 Top Assembly Rain Shield Slide Forward Up the combustion chamber. It may be necessary to have help lifting the heat exchanger out of the heater. 16. Lift out the heat exchanger assembly and set it aside. Front Refractory Channel (Rear Not Shown) Front Panel Lip Heat Exchanger Assembly 2. Removing the Burner Tray To remove the combustion chamber, the burner tray must be removed first. Please use the following procedure to remove the burner tray. Side Panel Brass Nut Front Panel Lip Nut Door Figure 1. Heat Exchanger Removal Bulb Retaining Ring Pressure Switch 150 F Sensor (Red Dot on the Face) Figure 2. In/Out Heat Exchanger Assembly Retaining Ring Do not kink the tubing. Kinking the tubing may result in poor heater operation. 13. Unscrew the brass nut securing the pressure switch to the inlet/outlet header. Remove tube from header and gently bend it out of the way. 14. Remove the nut and the retaining ring that secure the temperature sensing bulb. Remove the bulb from the header and lay it on the side of the cabinet. See Figure Remove the screws securing the heat exchanger to Nut Brass Nut Side Panel 130 F Sensor Nut Burners have sharp edges. Wear heavy leather gloves to protect hands while handling burners. Failure to wear gloves can cause serious injury to hands. 1. Shut off the main gas valve located outside the heater. Disconnect the gas line at the gas valve inside the heater. 2. Disconnect the burner tray wiring (for model LRZM only): a. Tag and remove the white wire from terminal PP/TH leading to the fusible link from the gas valve. b. Tag and remove the yellow wire from terminal PP and the black wire from terminal TH leading to the temperature control from the gas valve. c. Tag and remove the orange spark ignition wire from the piezo ignition button. 3. Disconnect the burner tray wiring (for model LRZE only): a. Tag and remove the brown wire and the yellow wire from the gas valve. b. Unplug the igniter wires from the ignition control and disconnect the flame sensor from the ignition control. 4. Remove the two (2) screws holding the anti-rotation bracket to the inner panel. Remove the anti-rotation bracket holding the gas valve in place (see Figure 3). 5. Remove the three (3) nuts and washers securing the igniter box assembly. Remove the igniter box assembly with the igniter and flame sensor attached and set aside. NOTE Use care when removing the igniter, it is very brittle and will break easily. 6. Remove the three (3) screws holding the manifold bracket to the inner panel. Slide the burner tray assembly out of the combustion chamber being careful not to damage the igniter, the flame sensor or pilot during removal. (An igniter and flame sensor

3 Page 3 Heat Guard Deflector Screws (Qty 4-2 each side) Anti-Rotation Bracket Igniter (LRZE only) Igniter Nuts and Washers Sensor (LRZE only) Igniter Box Assembly Screw (Wind Shield) Figure 4. Heater Top View, LRZE Shown Burner Tray Figure 3. Burner Tray Removal on model LRZE and a pilot on model LRZM.) See Figure 3. NOTE On model LRZE only, the heating element of the igniter is very brittle and will break easily if hit. An extra igniter has been included in this replacement kit in case the original one gets broken or damaged. Screw (Side Wind Shield) Combustion Chamber 3. Removing the Combustion Chamber Wear heavy leather gloves to protect hands while handling the combustion chamber panels. Failure to wear gloves can cause serious injury to hands. Heater 1. Remove the hex head screws securing the heat guard deflectors. See Figure 3. One (1) heat guard deflector is located in the front of the combustion chamber and the other one (1) is located at the rear of the combustion chamber. 2. Remove one (1) hex head screw securing the wind shield to the combustion chamber from each side of the combustion chamber. See Figures 3 and Remove the two (2) screws from each side panel that hold the combustion chamber to the base of the heater. Use a socket with a long extension to remove the screws. See Figure Pull the entire combustion chamber out of the heater. See Figure 5. Figure 5. Removing the Combustion Chamber Screw (Qty 8 Non-Painted) Side Panel Back Panel Screw (Qty 8 Non-Painted) 4. Installing the Combustion Chamber 1. Assemble the front panel onto the sides and secure with the eight (8) screws supplied in the kit. (NOTE: Use non-painted screws.) See Figure 6. Front Panel (LRZE shown, LRZM-No cutout) Combustion Chamber Kick Panel Figure 6. Combustion Chamber Side Panel Screw (Qty 6 Non-Painted)

4 Page 4 2. Assemble the back panel onto the sides and secure with the eight (8) screws supplied in the kit. (NOTE: Use non-painted screws.) 3. Assemble the combustion chamber kick panel to the back bottom of the sides and secure using six (6) screws supplied in the kit. (NOTE: Use non-painted screws.) 4. Place the combustion panel assembly inside the heater and align mounting holes on the side panels to the base mounting holes. Secure using four (4) screws supplied in the kit, two (2) on each side. (NOTE: Use non-painted screws.) See Figures 7 and Install the side refractory boards. Make sure the refractory board is in the support channel on the bottom of the sides. See Figures 9 and 10 for proper orientation of side boards. 6. Install the front 1.50" thick refractory board into the front support channel. Refer to Figure 8 and 10 for proper board orientation. 7. Install the back refractory board into the back support channel. See Figure Install new heat deflector guards included in this kit onto the front and rear of the combustion chamber. 9. Reconnect the side wind shields to the sides of the combustion chamber using one (1) screw on each side. 5. Replacing the Burner Tray 1. Position the burner tray in the combustion chamber. Slide the burner tray assembly into the combustion chamber. Be careful not to damage the pilot, igniter or flame sensor on the way in. Replace the three (3) screws holding the burner tray to the inner panel. 2. Position the anti-rotation bracket holding the gas valve in place and replace the two (2) screws holding the anti-rotation bracket to the inner panel. 3. Reconnect the burner tray wiring. Refer to the wiring diagram on the back of the heater door. Front Refractory Board Orientation Detail Combustion Panel Assembly Figure 8. Side View Cross Section Installing the Front Refractory Board Align Side Mounting Holes to Base Mounting Holes on Both Sides Side Refractory Board Orientation Detail Figure 7. Combustion Chamber Installation Figure 9. Front View Cross Section Installing Side Refractory Boards

5 Page 5 Front Refractory Board (1.50 Thick) (LRZE Shown, LRZM-No Cutout) Back Refractory Board 5. Reconnect the gas line at the gas valve inside the heater. 6. Open the gas valve on the line that leads into the heater. Side Refractory Board Side Refractory Board IMPORTANT Before proceeding, use a soap solution to check all gas connections for leaks. Some leak test solutions (including soap and water) may cause corrosion or stress cracking. Rinse the piping with water after testing. 6. Replacing the Heat Exchanger Side Support Channel (Both Sides) Back Support Channel (Note: Front Support Channel is not shown) Figure 10. Assembling the Rear and Side Panels a. For model LRZM only: 1. Reconnect the white wire leading from the fusible link to the PP/TH terminal of the gas valve. 2. Reconnect the yellow wire leading from the temperature control to the PP terminal of the gas valve and the black wire leading from the temperature control to the TH terminal of the gas valve. 3. Reconnect the red spark ignition wire from the pilot assembly to the piezo ignition button. b. For model LRZE only: 1. Carefully reinstall the igniter box assembly to the front of the combustion chamber and secure using hex head screws. NOTE Use care when installing the igniter, it is very brittle and will break easily. 2. Reconnect the brown wire and the yellow wire leading from the power distribution board to the terminals on the gas valve (brown wire closest to the valve control knob). 3. Plug the igniter wires into the ignition control and terminal block and reconnect the flame sensor wire to the ignition control. 1. Carefully place the heat exchanger back in the heater. Be sure that the heater refractory channel on each side of the heat exchanger rest on top of the refractory boards just placed on the side walls of the combustion chamber. See Figure 1. Be sure that no wires have been pinched under the heat exchanger. Secure using 10 screws provided in the kit. (NOTE: Use non-painted screws.) 2. Reinstall the temperature sensing bulb in the header and fasten it with the nut and retaining ring. See Figure 2. Do not kink the tubing. Kinking the tubing may result in poor heater operation. 3. Reinstall the compression fitting at the end of the pressure switch line into header. Be careful not to kink or bend the water pressure switch tubing. 4. Reinstall the high limit sensors into the heat exchanger header and secure using the retaining rings and nuts. Tighten hand tight only. See Figure 2. Do not use a wrench to tighten the high limit sensors. Overtightening may crush the sensors. 5. Install the flue collector assembly. Be sure the bottom flanges align to the front, sides and rear of the heat exchanger's top flanges. Secure using 10 screws provided in the kit. (NOTE: Use non-painted screws.) 6. Double-check to make sure the wiring is not pinched against sharp edges, or resting on the flue collector assembly. 7. Reinstall rainshield assembly and secure using six (6) screws provided in the kit. (NOTE: Use nonpainted screws.) 8. Replace the side panels and secure using 14 painted screws. 9. Replace the top assembly. Make sure the top fits over the outside of the heater jacket. Fasten the top

6 Page 6 assembly with the four (4) painted screws provided in the kit. 10. Install plastic tie wraps on wiring in the front compartment of the heater. 11. Reconnect the water supply and return to the header. 12. If any shut-off valves were closed earlier, open them now. 13. Turn on the filter pump and check the connections for leaks. 14. Turn on the power to the heater and test it's operation. 15. Install heater door. 16. Reinstall the vent cap or drafthood, if one was removed. D. Replacement Kit Lists The following table is for your reference. To order additional parts, please contact your local Jandy Distributor. Parts Lists for Replacement Kits Item # Component Description R R Combustion Chamber Front Panel Combustion Chamber Rear Panel Combustion Chamber Side Panel Combustion Chamber Kick Panel Front Refractory Tile Rear Refractory Tile Side Refractory Tile Heat Defl ector Guard Rear Heat Defl ector Guard Igniter 1-11 Screw Screw, Painted Gray Tag, Wire Identifi cation Instructions 1 1

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8 H Page 8 Zodiac Pool Systems, Inc Condor Drive, Moorpark, CA, USA FAX Litho in U.S.A. Zodiac Pool Systems, Inc. 0905