Correct Gas Pool & Spa Heater Installations

The most common issues with gas pool and spa heaters arise from incorrect installations and water chemistry problems. Incorrect installations, failure to adhere to manufacturer's requirements, as well as regulations such as AS/NZS 5601, can result in damage to the heater, equipment, and pose harmful or even fatal risks.

One crucial aspect of gas pool heater installations is ensuring correct combustion, flow, and pressure. Proper setup of flow and pressure is of utmost importance to prevent issues such as heat exchanger damage, burner issues, or sooting. Modern heaters often require the use of a combustion analyzer to set the combustion rate within the manufacturer's specified tolerance. Incorrect gas settings can also lead to high levels of carbon monoxide (CO), which can be harmful or fatal. Skillful gas fitters possess a range of tools, perform calculations, and adhere to regulations when installing gas heaters to ensure optimal performance and safety.

Another significant consideration is the sizing of gas lines and meters to accommodate the gas heater and other appliances. It is common for domestic gas meters to be insufficient for pool heaters, necessitating an upgrade, which is typically arranged by your gas company at no additional cost.

Meeting clearance requirements outlined in AS/NZS 5601 and other regulations, along with manufacturer's specifications, is crucial. Poor clearances can result in improper combustion, increased fire risk, and damage to the heater. Moreover, inadequate clearances can lead to dangerous levels of carbon monoxide.

Regarding the water side and plumbing of the heater, proper installation is paramount to prevent equipment damage or injury. Plumbing for the heater should be done using minimum PVC Class 12 or above, never Class 9 or lower. In some cases, CPVC with a higher heat rating may be necessary. Correct water flow after the filter is essential, and installers should utilize flow meters during installation. It is crucial to incorporate check valves and isolation valves where necessary. In cases where the heater is located below water level or pressure may cause the valve to remain open, a flow switch should be used instead of relying solely on the in-built pressure switch.

When using chemical dosing systems, including chlorinators, it is imperative to have a working check valve between them and the heater. Failure to do so can result in significant damage to the heat exchanger. Additionally, poor water flow can lead to tripped high-limits or melted pipes. Regularly checking and cleaning filters and using a flow meter to ensure the heater receives the required flow of water at all times is essential.

Switching off a heater without allowing it to cool down can result in collapsed or melted pipes. It is recommended to ensure the installation is 100% correct and let the pump run for a period after switching off the heater to cool it down. This practice, commonly referred to as a "cool-down" period, is often integrated into control systems like Aqualink, Connect 10, Halo, Aquatek, and others. Standalone run-on timers are also available.

There are common installation issues that arise, such as chemical corrosion, clearance problems, damaged heat exchangers, poor fluing and exhaust gases, melted pipes, and damage to other parts. Chemical corrosion is typically caused by low pH and poor water chemistry, especially when using bromine tablets or stabilized chlorine. Clearances that do not meet the standards outlined in AS/NZS 5601 and other regulations can lead to poor combustion or fire hazards. Damaged heat exchangers are usually the result of improper combustion, gas pressure, or inadequate water chemistry. Poor fluing or insufficient exhaust ventilation can result in improper combustion and the release of harmful gases such as carbon monoxide. Melted pipes indicate issues with equipment and installation, often caused by incorrect piping, plumbing, or inadequate cooling time for the heater. Other parts like burners, igniters, pilot assemblies, flame sensors, and flues can also suffer damage due to improper combustion or lack of servicing.