installation and Operation Manual English Installation and Operation Manual Legacy™ Pool and Spa Heater Model LRZ Millivolt Natural Gas or LPG 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 gas safe registered and HWB1 certified.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater ENGLISH Page 3 Table of Contents Section 1. General Information..................... 5 Section 5. Water Connections....................... 14 1.1 Introduction..................................................... 5 1.2 Consumer Information and Safety.................. 5 1.2.1 Spa/Hot Tub Safety Rules......................... 5 1.2.2 Swimming Pool Energy Saving Tips............................................................ 6 1.
Page 4 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Table of Contents (Continued) Section 11. Professional Maintenance and Service......... 30 11.1 General Information........................................ 30 11.2 Natural-Draft Combustion System.................. 30 11.3 Heater Components and Their Operation...... 30 11.4 Electrical Troubleshooting.............................. 31 11.4.1 Gas Valve.................................................. 31 11.4.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Section 1. General Information NOTE “Fresh water swimming pools and spas” include systems that utilize saltwater chlorine generator units, such as the Jandy AquaPure® Electronic Chlorine Generator. Please ensure that the salt content of the pool/spa does not exceed 4000 ppm and water flow rate is within 110-470 lpm. 1.2 Spa or hot tub water temperature should never exceed 40°C (104°F).
Page 6 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual 1.2.2 Swimming Pool Energy Saving Tips Zodiac Pool Systems, Inc., ("Zodiac") offers the following recommendations to help conserve fuel and minimize the cost of operating your pool heater without sacrificing comfort. 1. The American Red Cross recommends a maximum water temperature of 25°C (78°F). Use an accurate pool thermometer.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 3. 4. A noncombustible platform for installation on combustible surfaces (see Section 2.5.3). Noncombustible bases are available from your Zodiac distributor. A factory approved vent cap for all outdoor installations where wind conditions may cause downdrafting. Approved vent caps are available from your Zodiac distributor. See Section 12.2, "Parts List", of this manual for the correct part number. 1.7 Specifications 1.7.
Page 8 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual H A 194 mm 406 mm 1041 mm 127 mm 1000 mm 264 mm 203 mm 724 mm 333 mm Outdoor Flueless Heater Configuration 95 mm Figure 1. 5. 6.
ENGLISH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Page 9 Table 2. LRZ M Performance Specifications LRZ M Size (In BTU Input) 125 BTU 175 BTU 250 BTU 325 BTU 400 BTU Nat. Gas LPG Nat. Gas LPG Nat. Gas LPG Nat. Gas LPG Nat.
Page 10 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual At least 457 mm access must be available in front of the heater for burner removal and access to the igniter. If the heater is to be installed in a garage, or similar structure, all burners and burner ignition devices must have a minimum 457 mm clearance above the floor. This heater must be installed at least 1.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater If the heater is installed close to a structure, protect it from rain water runoff with rain gutters on the roof or other measures. Do not locate the heater near irrigation sprinkler systems that could spray water on it. Water from sprinklers may cause damage to controls and electronic components. Avoid locations where wind deflection off nearby structures might cause downdraft conditions.
Page 12 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual vermiculite or perlite granules between the liner and the inner skin of the chimney body. Liners should be sealed at both top and bottom. Drainage points should be provided at the bottom of all vertical flue sections. Drain pipes should be: 1. No less than 25 mm inside diameter. 2. Made from acid condensate resistant material (e.g., stainless steel). 3.
ENGLISH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater The draft hood outlet is to be connected to an unobstructed vent pipe of the same diameter, terminating outside the building. The vent must terminate at least 0.6 m above the highest point of the roof or other object that is within 3.05 m of the vent termination. The vent pipe must have a listed vent cap which allows a full equivalent opening for flue products (see Figure 4).
Page 14 4.2 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Burner Pressure Confirm that gas supply pressure is correct. If the gas supply pressure is less than required, check for undersized pipe between the meter and the heater, a restrictive fitting, or an undersized gas meter. Gas inlet pressures to the heater, when it is operating, are listed in Table 2.
ENGLISH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Page 15 AQUAPURE MANUAL BY-PASS DETAIL MANUAL BY-PASS IS USED WHEN FILTRATION RATE EXCEEDS 125 GPM Figure 6. Typical Piping Installation LRZ Pressure Drop vs Flow 5 4.5 LRZ400 Pressure Drop (m H2O) 4 LRZ325 LRZ175 3.5 LRZ250 LRZ125 3 2.5 2 1.5 1 0.5 0 0 100 200 300 400 500 Water Flow (LPM) Figure 7.
Page 16 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Water connection reversal is illustrated in Figures 8 and 9. Proceed as follows: 1. For an existing installation, drain the heater by removing the two (2) drain plugs on the inlet/ outlet header and the drain plug on the return header. 2. Remove the heater front panel (door). 3. Remove the I/O header side cover plates, top and bottom. See Figure 10. 4. Remove the return header side cover plates, top and bottom.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 12. Place the inlet/outlet header over the bolts and gasketed tubes on the left side of the tube assembly. Make sure the high limit devices are on the bottom. Refer to Figure 9. Align the bolt and tube holes in the header with the bolts and tubes in the header bar and slide the assembly together. 13. Thread on the 10 bolts and washers and hand tighten. 14.
page 18 enGlisH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Be sure to check any applicable installation codes in your area to determine whether a pressure relief valve is required. See Section 12.2 (Parts List) of this manual for the appropriate kit part number. The pressure rating of the valve should be at or below the lowest working pressure of any component in the system. The maximum working pressure of this heater is 5.1 bar.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Refer to your local installation codes for more detailed information. The valve setting should be at or below the maximum working pressure of any component in the filter system. The maximum working pressure of the Legacy Model LRZ millivolt heater is 5.1 bar. 5.
Page 20 ENGLISH TH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual TEMPERATURE CONTROL BK BK TP R BK W TP/TH GAS VALVE W W W W EARTH BONDING LUG PILOT GENERATOR PILOT BK BK W ROLL-OUT SWITCH (FUSIBLE LINK) W 240°C (464°F) VENT TEMPERATURE LIMIT PRESSURE SWITCH HIGH LIMIT HIGH LIMIT W BK BK 42°C (108°F) 52°C (126°F) FIREMAN SWITCH IGNITER ® R W BK - BLACK R - RED W - WHITE R H0321000 Rev E Figure 15.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Section 7. Commissioning 7.1 1. 2. Check the manifold (burner) pressure setting and adjust as necessary (see Table 1). 3. Start the adjustment procedure with the heater cold, on full load, and with the temperature control set at maximum. This will ensure, as far as possible, that thermostatic shutdown does not interfere while the pressure is being checked and adjusted. 4.
Page 22 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual the temperature control setting, an operating cycle is initiated by the automatic control. The temperature control circuit is closed, activating the gas valve and the gas valve is opened. Gas flows through the burners, is mixed with air in the combustion chamber, and is ignited by the pilot. Operation will continue until the temperature of the water entering the heater reaches the temperature control setting.
ENGLISH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater WARNING LP Gas Models: To avoid possible injury, fire and explosion, read and follow these precautions and all instructions on this appliance before starting the heater. LP (propane) gas is heavier than air and will remain at ground level if there is a leak. Before lighting, sniff at ground level. If you smell gas, follow these rules: 1. DO NOT light matches. DO NOT turn electric lights or switches on or off in area.
Page 24 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual 8.3.2 Relighting the Heater Control Knob with OFF, Pilot and ON Position Pilot Adjustment If the pilot goes out, repeat steps 5 through 7 in Section 8.3.1. 8.3.3 Shut-Down Procedure Regulator Figure 19. Natural Gas/Propane Control Valve 2. 3. 4. 5. 6. 7. 8. 9. Turn the gas control knob clockwise until it stops at the OFF position (see Figure 19). Wait five (5) minutes before lighting the pilot.
ENGLISH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater Once the pool/spa water temperature reaches the thermostat setting, the heater will automatically stop firing. As the pool/spa water temperature falls below the thermostat setting the heater will once again start the heating cycle. Rotate the thermostat dial clockwise to increase the temperature setting and counterclockwise to decrease the setting.
Page 26 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual 9.3 Inspection and Service The Legacy 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.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 9.3.2 Professional Inspection Inspections performed at least once a year by a qualified technician are required to maintain your heater's safe and efficient operation. The following basic safety checks must be performed. 1. Inspect the venting system for blockage, leakage, and corrosion. 2. Inspect burners and verify that they are clean. Clean with a wire brush if necessary to remove debris. 3.
Page 28 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Section 10. Troubleshooting 10.1 General Heater Troubleshooting Table 8 lists some of the more common problems, causes and solutions encountered when running the heater. Most problems occur when the heater is being started for the first time after installation or at spring start-up. Careful installation and maintenance will help ensure years of trouble free use from your Legacy heater.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater ENGLISH Page 29 Table 8. Legacy Troubleshooting Guide # Symptom Cause Remedy 1. Pump not operating A. B. C. No power. Pump defective. Incorrectly wired. A. B. C. Check circuit breakers and power source. Replace pump.* Recheck wiring.* 2. Pilot outage A. Inlet gas pressure too low. B. C. D. E. F. G. Inlet gas pressure too high causing an unstable blowing pilot. Weak or defective thermocouple or thermopile.
Page 30 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual Section 11. Professional Maintenance and Service WARNING SERVICING SAFETY Some of the servicing procedures for the Legacy heater are 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.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 4. 5. 6. 7. 8. broken at any time, the gas valve is immediately shut off and the heater stops firing. This voltage is also used to activate the gas valve's pilot coil which allows gas to flow to the pilot after the gas valve knob is released. Thermocouple - The thermocouple is a device that senses if the pilot flame is hot enough to ignite the gas fuel from the burner. If hot enough, the main gas valve is allowed to open.
Page 32 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual 17 TH TEMPERATURE CONTROL BK BK 1 TP R 16 15 W TP/TH 2 W W 4 3 ROLL-OUT SWITCH (FUSIBLE LINK) EARTH BONDING LUG PILOT GENERATOR PILOT W 5 W 6 7W BK W 240°C (464°F) VENT TEMPERATURE LIMIT 8 9 BK 52°C (126°F) PRESSURE SWITCH HIGH LIMIT HIGH LIMIT W GAS VALVE 10 11 BK 42°C (108°F) BK BK 12 13 14 FIREMAN SWITCH IGNITER ® R W R BK - BLACK R - RED W - WHITE H0321000 Rev E Figure 25
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater • Correct type of gas supplied • Correct gas supply pressure • Correct gas burner pressure • Correct orifice size • Air in the gas line If the main burners will not stay lit after checking the items listed above, the gas valve may be causing the fault. Replace the gas valve. 11.4.2 Pilot Generator The pilot generator generates a 700-750mVDC signal when heated by the pilot flame.
Page 34 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual 11.4.5 Limit Switches Since the limit switches are not easily accessible, you can check the voltage going into the component after the limit switches in the circuit. If voltage is detected there, then the limit switches are closed and are operational. Check the voltage going to the water pressure switch. Leave the red voltmeter lead in place at test point 1.
Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 3. 4. Slowly turn adjustment sprocket clockwise until heater goes off. 11.5 Adjusting the Water Pressure Switch 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 of a flow can damage the appliance. Adjust the switch to turn the heater off, not on. The pressure switch is preset at the factory for activation at 14 kPa.
Page 36 ENGLISH Legacy™ Model LRZM Pool/Spa Heater | Installation and Operation Manual For most installations, an external bypass valve is not needed in the heater water piping. This is due to the large size of the heater's internal bypass valve. If the pump flow rate is known to exceed 470 lpm, an external bypass may be needed to assure proper heater operation. Water flow should be confirmed upon start-up of the heater and in most servicing situations.
enGlisH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 12.2 page 37 parts list Key no. description Model no. order part no. 1 Pilot, Main Burner Assembly, Natural All R0522101 1 Pilot, Main Burner Assembly, LPG All Key no. description 44 45 * R0522102 pilot/igniter system Model no. order part no.
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enGlisH Installation and Operation Manual | Legacy™ Model LRZM Pool/Spa Heater 12.
Zodiac Pool Systems, Inc. 2620 Commerce Way, Vista, CA 92081 1.800.822.7933 | www.ZodiacPoolSystems.com ZODIAC ® is a registered trademark of Zodiac International, S.A.S.U., used under license. All trademarks referenced herein are the property of their respective owners. ©2012 Zodiac Pool Systems, Inc.