Astral Pool ICI Series User manual

ICI
Gas pool heater
INST 471
INSTALLATION MANUAL
FOR YOUR SAFETY - This product must be installed and serviced by a licensed electrician in accordance with
AS/NZ 3000 and any other local applicable regulations. 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 will void the warranty.
Improper installation and/or operation can create unwanted electrical hazard which can cause serious injury,
property damage, or death.
WARNING
(all models)

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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

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Table of Contents
Section 1. Important Safety Instructions ...........4
Section 2. General Information.............................. 6
2.1 Technical Assistance................................................................6
2.2 Warranty ......................................................................................6
2.3 Consumer Information and Safety.....................................6
2.4 General Operation Description...........................................6
2.5 Specifications.............................................................................7
2.6 Dimensions.................................................................................7
2.7 Certification Codes and Standards ....................................8
Section 3. Getting Started ....................................... 8
3.1 Contents ......................................................................................8
3.2 Required Equipment...............................................................9
Section 4. Location Requirements......................10
4.1 Clearances................................................................................ 10
4.2 Outdoor Installation............................................................. 10
4.3 Indoor Installation................................................................. 10
Section 5. Gas Connections ..................................14
5.1 Supply Gas Requirements.................................................. 14
5.2 Inlet Gas Pressure Test ......................................................... 14
5.3 Special Precautions for LP Gas.......................................... 14
5.4 Gas Pipe Sizing Tables.......................................................... 15
5.5 Check Burner Performance................................................ 15
Section 6. Water Connections..............................16
6.1 Pump Sizing ............................................................................ 16
6.2 Plumbing Connections ....................................................... 16
6.3 Water Pressure Switch Adjustment................................. 17
6.4 Check Valve Installation ...................................................... 17
6.5 Pressure Relief Valve Installation ..................................... 17
6.6 Condensate Drain ................................................................. 18
Section 7. Electrical Connections........................19
7.1 Electronic Flow Response................................................... 19
Section 8. Final Installation Check......................21
8.1 Important Safety Information........................................... 21
8.2 What To Do If You Smell Gas.............................................. 21
8.3 First Time Start-up Procedure ........................................... 21
8.4 Lighting Instructions............................................................ 21
8.5 To Turn Off Gas To Heater................................................... 21
8.6 Shutting Down the Heater................................................. 21
Section 9. Operation................................................22
9.1 Normal Operation................................................................. 22
9.2 Digital Thermostat Operation........................................... 22
9.3 ICI User Controls .................................................................... 22
Section 10. Maintenance..........................................24
10.1 Water Chemistry.................................................................... 24
10.2 Winterizing .............................................................................. 24
10.3 Corrosion Prevention In Heaters...................................... 24
10.4 Maintenance Schedule........................................................ 25
10.5 Service Notification .............................................................. 25
Section 11. Troubleshooting...................................27
11.1 Display Symbol Indicators.................................................. 27
Section 12. Spare Parts..............................................28
12.1 Model ICI 200.......................................................................... 28
12.2 Model ICI 200 Spare Parts List........................................... 29
12.3 Model ICI 400.......................................................................... 30
12.4 Model ICI 400 Spare Parts List........................................... 31

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Section 1. Important Safety Instructions
READ AND FOLLOW ALL INSTRUCTIONS
All electrical work must be performed by a licensed electrician and conform to all national, state, and local
codes. When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following:
WARNING
Prolonged immersion in hot water may induce hyperthermia. Hyperthermia occurs when the internal temperature of
the body reaches a level several degrees above the normal body temperature of 37°C. The symptoms of hyperthermia
include dizziness, fainting, drowsiness, lethargy, and an increase in the internal temperature of the body. The effects of
hyperthermia include: 1) unawareness of impending danger; 2) failure to perceive heat; 3) failure to recognize the need to
exit spa; 4) physical inability to exit spa; 5) fetal damage in pregnant women; 6) unconsciousness resulting in a danger of
drowning.
DANGER
To reduce the risk of severe injury or death, do not remove the suction fittings of your spa or hot tub. Never operate a spa
or hot tub if the suction fittings are broken or missing. Never replace a suction fitting with one rated less than the flow rate
marked on the equipment assembly.
WARNING
To Reduce the Risk of Injury -
a) The water in a spa should never exceed 40°C. Water temperatures should remain between 38°C and 40°C. The water in
a spa should never exceed 40°C. Water temperatures between 38°C and 40°C are considered safe for a healthy adult.
Lower water temperatures are recommended for young children and when spa use exceeds 10 minutes.
b) Since excessive water temperatures have a high potential for causing fetal damage during the early months of
pregnancy, pregnant or possibly pregnant women should limit spa water temperatures to 38°C. Before entering a spa
or hot tub, the user should measure the water temperature with an accurate thermometer since the tolerance of water
temperature-regulating devices varies.
d) The use of alcohol, drugs, or medication before or during spa or hot tub use may lead to unconsciousness with the
possibility of drowning.
e) Obese persons and persons with a history of heart disease, low or high blood pressure, circulatory system problems,
or diabetes should consult a physician before using a spa.
f) Persons using medication should consult a physician before using a spa or hot tub since some medication may induce
drowsiness while other medication may affect heart rate, blood pressure, and circulation.
WARNING
Risk of electric shock - Install the controller at least 3.5 metres from the inside wall of the pool and/or hot tub using non-
metallic plumbing.
Children should not use spas or hot tubs without adult supervision.
Do not use spas or hot tubs unless all suction guards are installed to prevent body and hair entrapment.
People using medications and/or having an adverse medical history should consult a physician before using a spa or hot
tub.
WARNING
To avoid injury ensure that you use this control system to control only packaged pool/spa heaters which have built-in
operating and high limit controls to limit water temperature for pool/spa applications. This device should not be relied
upon as a safety limit control.

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WARNING
To minimize possibility of fire or electric shock, which could result in property damage, and/or serious injury, including loss
of life, power to the Viron Connect should be supplied by an isolating switch or through a residual current device (RCD)
with a rated residual operating current not exceeding 30mA.
SAVE THESE INSTRUCTIONS
WARNING
People with infectious diseases should not use a spa or hot tub.
To avoid injury, exercise care when entering or exiting the spa or hot tub.
Do not use drugs or alcohol before or during the use of a spa or hot tub to avoid unconsciousness and possible drowning.
Before entering a spa or hot tub, measure the water temperature with an accurate thermometer.
Do not use a spa or hot tub immediately following strenuous exercise.
Prolonged immersion in a spa or hot tub may be injurious to your health.
Do not permit any electric appliance (such as a light, telephone, radio, or television) within 3.5 metres of a spa or hot tub.
The use of alcohol, drugs or medication can greatly increase the risk of fatal hyperthermia in hot tubs and spas.
Water temperature in excess of 38°C may be hazardous to your health.
Attention Installer: Install to provide drainage of compartment for electrical
components.
WARNING
A terminal bar marked "GROUND" is provided within the controller. To reduce the risk of electrical shock which can cause
serious injury or death, connect this terminal bar to the grounding terminal of your electric service or supply panel with a
continuous copper conductor having green insulation and one that is equivalent in size to the circuit conductors supplying
this equipment in accordance with AS/NZ 3000. In addition, where required, bonding should be extended in accordance
with AS/NZ 3000 to any metal ladders, water pipes, or other metal within 3.5 m of the pool/spa.

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Section 2. General Information
This manual provides installation and operation
instructions for the AstralPool ICI pool and spa gas
heater.
Read the installation and operation instructions
completely before proceeding with the
installation.
2.1 Technical Assistance
Web: www.astralpool.com.au Phone: [phone]
2.2 Warranty
This heater is sold with a limited factory warranty.
Details are included with this heater. For warranty
terms and conditions, please visit:
www.astralpool.com.au.
All warranty issues should be resolved with your
AstralPool 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.
2.3 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 ue
gases which could result in severe injury, or death. For
indoor installations, as an additional measure of safety,
AstralPool 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°C (102°F) can cause fetal damage during
the rst 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°C (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 anti-
coagulants) 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°C (98.6°F). Symptoms
include dizziness, fainting, drowsiness, lethargy, and
an increase in the internal body temperature. The ef-
fects 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
2.4 General Operation Description
The ICI GAS POOL HEATER can safely be connected to
PVC pipe. It accepts high water flow rates which help
the heater run cooler, giving greater efficiency and
long life. In addition, it is equipped with electronic
start up and an accurate electronic thermostat to
ensure ease of use and accurate temperature control.
The electronic display tells at a glance the operational
status of the heater.
The ICI GAS POOL HEATER requires a minimum of 120
litres per minute flow for the ICI 200 and 200 litres
per minute for the ICI 400 models. The maximum
permissible flow rate is 500 litres per minute. For flow
rates in excess of 500 litres per minute, an external by-
pass valve must be fitted.

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2.5 Specifications
Model ICI 200 ICI 400
Gas Inlet Rate 215 MJ/hr 400 MJ/hr
Gas Connection AS/NZ 5601 AS/NZ 5601
Gas Usage Rate of
Nominal Rate
(must be within %)
+/- 5 +/- 5
NG Inlet Static Gas
Pressure (kPa)
1.13 - 5 1.13 - 5
LPG Inlet Static Gas
Pressure (kPa)
2.75 - 5 2.75 - 5
NG Gas Inlet
Operating Pressure-
High Fire (kPa)
1.13 1.13
LPG Gas Inlet
Operating Pressure-
High Fire (kPa)
2.75 2.75
Water Flow Rate 120 - 500 200 - 500
Water pH 7.6 - 7.8 7.6 - 7.8
Water Total Alkalinity
(ppm)
80 -120 80 -120
Water Calcium
Hardness (ppm)
150 - 350 150 - 350
Water Salinity (ppm) 5000 maximum 5000 maximum
Chlorine Maximum
Content (ppm)
3 3
Bromine Maximum
Content (ppm)
5 5
Air-Free NG - CO
Level (ppm)
30 - 60 30 - 60
Air-Free LPG - CO
Level (ppm)
50 - 150 50 - 150
2.6 Dimensions
Figure 1. Front Dimensions
Figure 2. Side Dimensions
Figure 3. Header Height

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2.7 Certification Codes and Standards
Certied IAPMO R&T Oceana
COMPLIANT Standard for ‘Gas Pool Heaters’, AS 4560
Applicable National
Installation and Com-
missioning code(s)
Standard for Gas Installations, AS/NZS
5601
Pay particular attention to the chapter ad-
dressing Venting of Equipment
All AstralPool 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:
The ICI 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.
Section 3. Getting Started
Install the ICI 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 Section 4.
If the heater is to be operated in below freezing
conditions it should be installed in a protected
outdoor shelter. See Section 4.3.
All gas-fired 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 ooring see
Section Section 4.
• Sucient combustion and ventilation air
• Properly sized gas meter and piping
• Proper electrical wiring
• Sucient water ow
This manual provides the information needed to meet
these requirements. Review all applications and
installation procedures before continuing the
installation.
3.1 Contents
Before starting, check that you have the correct parts as
indicated in Table 1. If any parts are missing or incorrect,
please call your local distributor or technical support at
1300 186 875 for assistance.
1
23
4
Figure 4. ICI Gas Heater Contents

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Item Description Quantity
1 ICI Gas Heater 1
2 50mm Universal Union Nut 2
3 50mm Universal Union Tail 2
4 50mm Universal Union O-ring 2
Table 1. ICI Gas Heater Parts
3.2 Required Equipment
Please ensure that the following equipment is
available to the installer at the time of installation.
3.2.1 Required Tools
Safety Eye Wear Gloves Philips
Screwdriver
Flathead
Screwdriver
Pipe Wrench Adjustable
Wrench
5mm (3/16”)
Hex Key
Multi Grips Digital Dierential
Manometer
Voltage Meter PVC Pipe Cutter
Tape Measure
Power Drill
Figure 5. Required Tools
3.2.2 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
AstralPool customer service center at 1300 186 875.
Indoor installations will require additional venting and
exhaust conversion materials which are outlined in
detail in Section Section 4.
NOTE: Required materials may dier from the materials
listed. Be sure to conrm with all local and national
codes before beginning the installation.
Gas Supplies Electrical
Supplies
Plumbing
Supplies
Appropriately sized
Gas Piping
230 VAC, 50 Hz PVC Piping
Manual Gas Shut Off
Valve
PVC Cement
Gas Union Te on 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

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Section 4. Location Requirements
WARNING
Improper installation or maintenance can cause nausea or
asphyxiation from carbon monoxide in ue gases which
could result in severe injury or death. For indoor instal-
lations, as an added measure of safety, Zodiac strongly
recommends installation of suitable
carbon monoxide detectors in the vicinity of this appli-
ance 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 qualied professional service technician.
The ICI 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 4.3 for details.
Location of the heater below or above the pool water
level affects operation of its water pressure switch. See
Section 6.3 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 ooding. AstralPool cannot be responsible for
such water loss or ooding or resulting damage.
4.1 Clearances
Installation clearances must comply with AS/NZ 5601.
The heater is approved for installation at reduced
clearances as below.
Outdoor
Clearances From
Combustible
Surfaces
Non-
combustible
Surfaces
Front 300mm 300mm
Both Sides 300mm 300mm
Rear 300mm 50mm
Above 1000mm 1000mm
Indoor
Clearances From
Combustible
Surfaces
Non-
combustible
Surfaces
Front 300mm 300mm
Both Sides 300mm 50mm
Rear 300mm 50mm
Above 500mm 500mm
4.2 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 runo.
• Away from potential sprinkler water intrusion.
• So that the top of the heater is at least 1 m (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.
4.3 Indoor Installation
AstralPool 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 5.3.
The heater is Certified by IAPMO-R&T Oceana for
indoor installations. Please keep in mind the
clearances from Section 4.1 when selecting an
installation location. You will also need to make
considerations for ventilation, see Section 4.3.1. 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.
AstralPool does not recommend outdoor shelter
installations that depend on internal air for combustion.
4.3.1 Ventilation
When installing the heater indoors, it is imperative
that an adequate supply of fresh air is provided for
combustion. Failure to provide adequate ventilation
voids all warranties and may be a danger to persons or
property.