Insnrg GI 160 Installation & Operating Manual Download Page 1

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INSTALLATION & OPERATING MANUAL
Gi Gas Heater

A GUIDE TO YOUR GAS

HEATER

Summary of Contents for GI 160

Page 1: ...INSTALLATION OPERATING MANUAL Gi Gas Heater A GUIDE TO YOUR GAS HEATER ...

Page 2: ...jor features of the unit The importance of maintenance If you have a problem what to trouble shoot before you contact your professional Finally your entitlements under your product warranty Insnrg have developed their product to provide you with the ultimate experience and are sure you will be delighted with your purchase Please note This equipment must be installed in a location that allows for r...

Page 3: ... delighted SECTION 3 Now to Have some Fun Local Code Safety Instructions Carbon Monoxide Important Tips for Hot Tubs Spas Maintenance Winter Operation Troubleshooting Replacement Parts Warranty Location Dimensions Indoor Outdoor Installations Gas Connections Water Connections Electrical Connections Operation 03 11 39 46 ...

Page 4: ...Heater If these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death This Appliance is not intended for use by young children or infirm persons without supervision Please ensure that young children are supervised so that they do not play with the appliance SECTION 1 ...

Page 5: ...L CODES AUSTRALIA Must be installed in accordance with the installation instructions local gas fitting regulations Standards Australia Installation Code AS NZ 5601 and any other relevant statutory authorities ...

Page 6: ...led and serviced by a contractor who is li censed 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 the instructions in t...

Page 7: ...n needs must be made by a qualified professional using approved parts The heater is available for use with natural gas or LP propane gas only It is not designed to operate with any other fuels Refer to the nameplate for the type of gas the heater is equipped to use Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or other volatile flammable liq...

Page 8: ...d with an integral venting system for outdoor installation Use the specified venting and only the specified venting when heater is installed in an enclosure or indoors Wiring errors can cause improper and dangerous operation and can also destroy the control board Label all wires prior to disconnection when servicing controls Connection in Australia is by supplied 3 Pin 10 Amp Plug and Lead only Ve...

Page 9: ...rbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces as an additional measure of safety WHAT TO DO IF YOU SMELL GAS 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...

Page 10: ...ended 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 102 F 38 5 C can cause fetal damage during the first three 3 months of pregnancy which could result in the birth of brain damaged or deformed child If pregnant wo...

Page 11: ... water can induce hyperthermia Hyperthermia occurs when the internal body temperature reaches a level of several degrees above the normal body temperature of 98 6 F 37 C 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 ...

Page 12: ... outline how to install your heater to get the best results To operate correctly your Gas Heater needs a reliable supply of Gas Water and Air By adhering to the following instructions you will ensure the best combination Insnrg highly recommend the use of qualified service technicians to ensure the best performance as well as the health and safety of your loved ones ...

Page 13: ...NS CLEARANCES OUTDOOR INSTALLATIONS INDOOR INSTALLATIONS VENTING REQUIREMENTS GAS CONNECTIONS WATER CONNECTIONS BELOW POOL WATER INSTALLATIONS WATER CHEMISTRY ELECTRICAL CONNECTIONS FOLLOW STEP BY STEP FOR THE BEST OUTCOME ...

Page 14: ...at does not leave the heater suspended by pipework or electrical connections allow movement through vibration and ensure no strain is put on connections or other equipment 3 Is accessible for disconnection and service 4 Within reach of the power supply 5 Complies with these instructions and all local codes and regulations DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUID IN THE VIC...

Page 15: ... m 23 8 437mm 17 2 472 mm 18 6 Electrical Connections Left Top A B C D E F 8 7 6 5 Right 161 mm 6 3 240 mm 9 4 239 mm 9 4 606 mm 23 9 470 mm 18 5 184 mm 7 2 Gas Connections 605 mm 23 8 SIDE CLEARANCE 300mm 12 SIDE CLEARANCE 300mm 12 FRONT CLEARANCE 300mm 12 REAR CLEARANCE 150mm 6 A B C D E F 4 4 3 3 2 2 1 1 DIMENSIONS A Front 470 m 18 5 605 mm 23 8 437mm 17 2 72 mm 18 6 Electrical Connections Left...

Page 16: ...he heater on carpet 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...

Page 17: ...4 606 mm 23 9 m 184 mm 7 2 Gas Connections SIDE CLEARANCE 300mm 12 SIDE CLEARANCE 300mm 12 FRONT CLEARANCE 300mm 12 REAR CLEARANCE 150mm 6 A B C D E F 4 4 3 3 2 2 1 1 150mm 6 150mm 6 150mm 6 150mm 6 6 5 4 3 INDOOR CLEARANCE OUTDOOR CLEARANCE ...

Page 18: ...ot under a deck or other structure Away from doors windows or louvers 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 1000mm below any overhang k So that the top surface of the heater is at least 1000mm above any forced air inlet within 1000mm k ...

Page 19: ... c 300mm k 1000mm f 75mm d e 1000mm Exhaust Grill Vent b note Maximum distance from the ground floor surface is 300mm 7 7 6 6 5 5 4 4 3 3 Date By cription of changes 19 01 2018 Aaron Marshall WEIGHT MATERIAL DATE SIGNATURE NAME FINISH Q A MFG APPV D DRAWN ...

Page 20: ...S FOR FOLDED PARTS TAKEN FROM OUTSIDE OF FOLD Aus Man Natural Ventilation direct from Outside Two permanent openings shall be provided directly to outside The openings shall be located to ensure the distance between the top of the upper opening and the ceiling of the plant room and the distance between the bottom of the lower opening and the floor of the plant room does not exceed 5 of the height ...

Page 21: ...20 Minimum Free Ventilation for each opening Model Direct Outside Via Adjacent Room Square inch Square cm Square inch Square cm GI 160 74 480 149 960 GI 265 123 795 246 1 590 GI 420 186 1 200 372 2 400 ...

Page 22: ...ndard code AS NZ 5601 The gas line from the meter will usually be of a larger size than the gas inlet connection REFER TO BELOW TABLE FOR CORRECT GAS INLET PIPING LENGTH FROM THE GAS METER TO THE HEATER 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 Install a manual gas ...

Page 23: ...ssure drop of 0 25kPa Note Gas Pipe Sizing Tables are indicative only All pipe sizing should be calculated by an authorised installer and according to local regulations MODEL NAME Gi 160 Gi 265 Gi420 NUMBER 21315 213157 21325 213257 21340 213407 GAS TYPE NATURAL PROPANE NATURAL PROPANE NATURAL PROPANE GAS INLET RATE MJ h 160 160 265 265 400 400 TTP kPa 0 1 INLET OPERATING MIN 1 1 2 75 1 1 2 75 1 1...

Page 24: ...n and closed 13 Turn gas analyser on ready to test combustion 14 Start pool pump 15 Turn heater on 16 Allow heater to start 17 Check outlet gas pressure on manometer as per table 1 18 Place gas analyser probe in the flue outlet in direct contact with combustion gas 19 Adjust outlet gas pressure if required 20 Adjust CO2 if required 21 Look through site glass to ensure no yellow flames are visible ...

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Page 26: ...tor needs to be installed downstream of the heater Ideally install a chemical resistant one way check valve between the heater and the chemical feeder to prevent back siphoning through the heater when the pump is off Failure to follow these recommendations can potentially cause the Heat Exchanger to corrode and void any manufacturing warranty WATER CONNECTIONS Equipment installation To Pool To Spa...

Page 27: ...ceptable range Then remove the valve handle to lock into place and avoid any tampering Make sure to keep handle in a safe area should you need for future adjustments Model Min Max GI 160 120 lpm 350 lpm GI 265 150 lpm 400 lpm GI 420 150 lpm 500 lpm The table below outlines the minimum and maximum flow rates for the optimal performance of the heater Installation of a manual bypass valve is required...

Page 28: ...pumps will not develop enough pressure on the lowest set speeds to operate the heater For two speed pumps correct by running the pump at high speed only to operate the heater Variable Speed Pumps can be tuned to exactly the speed required for optimal performance Ask your pool professional for more information Automatic Pool Cleaners significantly affect the flow rate of water through the heater We...

Page 29: ...eater TO CHECK THE OPERATION OF THE SWITCH 1 Pressure switch should only be checked and adjusted with clean skimmer pump basket and filter Ensure Pump Basket Skimmer and Filters have been cleaned prior to adjusting Pressure Switch 2 Connect the heater to mains power supply and turn power on The thermostat SHOULD Not have a light above the Flow indication 3 Turn on pump A light should now appear ab...

Page 30: ...s and disappears when pump turns on and off 10 When the pressure switch is correctly set slide the toggle down to lock the knurled wheel in position 11 If pressure switch cannot be made to activate heater when pump is turned on and off a flow switch may need to be purchased and fitted Contact your local authorised professional WARNING If the pressure switch cannot be adjusted correctly DO NOT OPER...

Page 31: ...e heat exchanger voids warranty Your local pool shop specialist or spa retailer can advise correct chemical balance Your water should be checked and maintained regularly by a pool water professional As a guide the following parameters may be used You should test your water chemical balance at least on a weekly basis Excessive sanitiser can damage your heater Chlorine should not exceed 4 ppm and br...

Page 32: ... with local codes 3 Electrical power circuits to the pool heater must follow local codes 4 All wiring between the heater and devices not attached to it or between seperate devices which are installed in the field must be Type T wire rated for 35 degrees Celcius rise 5 All line voltage wiring shall be en closed in approved flexible conduit and shall be securely attached to the field A Front 470 mm ...

Page 33: ... Any switches in the pump circuit in cluding circuit breakers that can disconnect the pump must also disconnect the heater 7 Do not wire single pole switches including protective devices into a grounded line The heater is sensitive to polarity Connect the L1 of the power supply to the black wire the L2 or neutral lead to the red wire and the ground wire to the green wire A time clock controlling t...

Page 34: ...33 Wiring Diagram Insnrg Gas Heater GI 160 GI 265 GI 420 Australia ...

Page 35: ...34 NOW TO HAVE SOME FUN Let s get the most out of your gas heater SECTION 3 ...

Page 36: ...mance unit and therefore we have designed it s features to replicate the latest trends in high performance vehicles even down to the on off switch Once your unit is installed simply press the Start Stop button to start operation of your heater START HEAT STOP ...

Page 37: ...epending on Gas supplier and location of the heater If symbol doesn t appear check your supply of gas Could be empty gas bottles a valve has been turned off your supply has been stopped for some reason If heater has not been used for a few weeks the gas may need to charge up the lines again Check system and try again 4 When the unit is operating correctly a symbol will appear above the OPERATING m...

Page 38: ...renheit Your Insnrg heater has a digital display to enable you to set to exactly what temperature you desire HOW TO SET TEMPERATURE Simply look at the screen which will tell you the current temperature of the water then adjust the Set Point by pressing the UP or DOWN buttons as you require Once the Gas Heater reaches the Set Point the Heater will turn off but continuously monitor the water tempera...

Page 39: ... your desired swimming temperature 3 Now press MODE again to select Spa Temperature Press UP or DOWN to select your desired spa temperature 4 Once completed there is no need to adjust the up or down temperature to change between pool or spa settings Simply press MODE to select Pool or Spa OTHER FEATURES MODE BUTTON ...

Page 40: ...rg Automation Application with the purchase of an Insnrg Portal unit The Insnrg Portal will provide a connection between the Gas Heater and your household Internet router This enables full control of pool and spa modes and temperatures from your smart phone tablet or computer anywhere in the world Just as long as you have a internet connection WI FI CONNECTION ...

Page 41: ...40 OOPS SOMETHING S NOT RIGHT Maintenance Trouble Shooting Replacement Parts Warranty Contact Section SECTION 4 ...

Page 42: ...tored in the vicinity of the heater The vapours from these chemicals if drawn through a heater can rapidly cause corrosion of the heat exchanger and other valuable components 3 Check the heater area for any garden refuse and debris Not only does it affect air flow and can be a potential fire hazard the garden waste can encourage insects to nest in the unit and affect the life and reliability of yo...

Page 43: ...ide the heater can cause significant and costly damage when it expands Therefore it is vital to drain the water from the heater anywhere where freezing is a possibility The easiest way to drain the heater is by loosening the inlet and or outlet barrel union and allowing the water to drain away If the heater is below water level remember to close the valves before and after the heater first to isol...

Page 44: ...enough Thermal regulator valve TRV is opening early or is permanently open Heater plumbed back wards 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 operat ing conditions Correct the plumbing HEATER POUNDING OR KNOCKING Insufficient water flow through heater Failed Therma...

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Page 46: ...45 REPLACEMENT PARTS GAS HEATER 6 5 4 3 11 1 4 5 9 10 6 12 18 17 14 8 19 13 3 2 16 7 15 21 20 ...

Page 47: ...00310060 Combustion Blower 1 211011513002 O ring Venturi to Blower 1 21C01602004 Blower Gasket 1 211011513001 Venturi PreMix Combustion 1 11 21214001 Top Assembly 160 Heater 1 11 21225002 Top Assembly 265 Heater 1 11 21240003 Top Assembly 420 Heater 1 12 21101401006 Rear Left Pillar 1 13 21101509 Thermostat PCB 1 14 21C01506002 Heater Control Module 1 15 21101401002 Lid Rail Left Side 1 16 21C0110...

Page 48: ...47 COMBUSTION CHAMBER 1 11 3 2 15 14 18 12 17 6 8 4 7 13 5 16 9 10 19 20 21 22 23 24 7 A B C D E F 8 8 7 7 6 6 5 5 4 4 ...

Page 49: ...ear 420 1 9 21C01601004 Refractory Right Side 160 1 10 21C01106002 Combustion Side Panel Inlet Side 1 11 8001403 Water Pressure Switch 1 12 21C01201002 Temperature Thermistor Well 2 13 211700 Inlet Header Assembly 1 14 21C01503001 Bypass Thermostat Element 1 15 21201010 Themostatic Bypass Valve Assembly 1 16 21C01513001 Hi Limit 52 DEG N C 1 17 15201001 Union Assembly 50mm 2 2 18 10101003 5 6 18UN...

Page 50: ...from an authorised Insnrg dealership in Australia New Zealand 2 This warranty is not assignable and applies to the original retail purchaser only and the original receipt invoice or any other proof of purchase must be retained and produced if requested by the Company 3 Nothing in this warranty shall apply to any defects caused by misuse or abuse neglect accident extremes of climate dampness humidi...

Page 51: ...e the defective product in secure packaging clearly label it with the IAN number allocated and send it to the address of the authorised service agent which will be advised by your dealership The Company will not be liable for any transportation costs or in the event that a poolside call is arranged with an authorised service technician costs of technician s travel time if the defect is found not t...

Page 52: ...rk undertaken will be performed during normal business hours The equipment must be installed in a location that allows for regular maintenance service and repair by authorised technicians Work will not be undertaken if a technician can be put at risk due to restricted access or working from heights The company manufactures and supplies products to installers and distributors Any advice or recommen...

Page 53: ...tinuously developing new products and ideas to make pool ownership easier and more enjoyable Should you wish to keep updated with our progress and hear first hand about our new products and developments please feel free to stay in touch by using any or all of the below methods MAIL 57 59 Nantilla Rd Clayton VIC 3168 LANDLINE 1800 INSNRG 1800 467674 WEBSITE www insnrg com ...

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Page 55: ...54 PRODUCTS IN PERFECT SYNERGY ...

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