Insnrg GI 160 Installation instructions

INSTALLATION & OPERATING MANUAL
Gi Gas Heater
A GUIDE TO YOUR GAS
HEATER

1
CONGRATULATIONS
ON YOUR PURCHASE
OF THIS PRODUCT.
THIS MANUAL HAS BEEN CAREFULLY DEVELOPED TO
GIVE YOU ALL THE INFORMATION YOU NEED TO GET THE
BEST VALUE FROM YOUR PURCHASE.
It is important that you read through the manual to identify the
key areas you need to understand, particularly the following:
• Health and Safety Concerns
• Installation requirements
• How to operate the major 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 regular maintenance and service by the pool owner and service
technicians. Insnrg will not put service technicians at risk of injury by
servicing difficult to access appliances.

2
THE IMPORTANT BITS
SECTION 1:
We care about your safety
SECTION 4:
Oops, something not right?
SECTION 2:
We want you to be 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

3
WE CARE
ABOUT YOUR
SAFETY
IMPORTANT WARNINGS
Please read this manual carefully
BEFORE installing, operating or
servicing the Gas 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

4
LOCAL 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.

5
NOTICE TO INSTALLERS
This appliance must be installed by an authorized person.
This appliance must be installed in accordance with the installation in-
struction, local gas fitting regulations, any local regulatory standards and
any other relevant statutory authorities.
Refer to date plate for details of gas type, gas consumption and burner
pressure.
This product must be installed 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
this manual can be followed exactly.
Electrical maintenance and repairs of this equipment must only be done
by qualified persons in accordance with national and local regulations.

6
SAFETY
INSTRUCTIONS
Risk of fire or explosion from incorrect fuel use or faulty fuel conversion.
Do not try to run a heater set up for natural gas on propane gas or vice versa.
Only qualified service technicians should attempt to convert heater from one
fuel to the other. Do not attempt to alter the rated input or type of gas by
changing the orifice. If it is necessary to convert to a different type of gas,
discuss with your Insnrg supplier and purchase the appropriate conversion
kits. Serious malfunction of the burner can occur which may result in loss of
life. Any additions, changes, or conversions required in order for the appliance
to satisfactorily meet the application 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 liquids near heater or in the same room with heater.
Risk of explosion if unit is installed near propane gas storage.
Propane (LP) gas is heavier than air. Consult local codes and fire protection
authorities about specific installation requirements and restrictions. Locate the
heater away from propane gas storage and filling equipment as specified by the
Standard for the Storage and Handling of Liquefied Petroleum Gases, CAN/CSA
B149.2 (latest edition) or ANSI/NFPA 58 (latest edition).

7
Risk of fire, carbon monoxide poisoning, or asphyxiation if
exhaust venting system leaks. Only qualified service technicians
should attempt to service the heater, as leakage of exhaust products
or flammable gas may result from incorrect servicing.
Risk of asphyxiation if exhaust is not correctly vented. Follow
venting instructions exactly when installing heater. Do not use
a drafthood with this heater, as the exhaust is under pressure from
the burner blower and a draft hood will allow exhaust fumes to blow
into the room housing the heater. The heater is supplied 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. Verify proper operation after servicing.
Ensure wiring into heater is properly restrained and not touching hot
surfaces.
Do not allow children to play on or around heater or associated
equipment.Never allow children to use the pool or spa without adult
supervision.
Read and follow other safety information contained in this
manual prior to operating this pool heater.

8
CARBON MONOXIDE
Improper installation or maintenance can result in
carbon monoxide in flue gases, this can cause nausea
or asphyxiation which could result in severe injury or
death.
For indoor installations, it is highly recommend the
installation of suitable Carbon 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.
• If you cannot reach your gas supplier,
call the fire department.

9
IMPORTANT TIPS FOR
HOT TUB & SPA
INSTALLATIONS:
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
104°F (40°C). One hundred degrees Fahrenheit (100°F[38°C])
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 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 women are going to use a spa or hot
tub, they should make sure the water temperature is below 100°F
(38°C) 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 1°F/ 1°C.

10
• Person with a medical history of heart disease, diabetes, circulatory or
blood pressure problems should consult their physician before using a
hot tub or spa.
• Person taking any medication which induces drowsiness
(e.g., tranquillizers, antihistamines, or anticoagulants) 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 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 to leave spa
• Physical inability to leave spa
• Fetal Damage in pregnant women
• Unconsciousness resulting in a danger of drowning

11
SECTION 2
WE WANT YOU TO BE
DELIGHTED WITH YOUR
PURCHASE, CORRECT
INSTALLATION WILL PROLONG
LIFE AND MAXIMISE THE
PERFORMANCE OF THIS UNIT.
The following section will 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.

12
LOCATION & DIMENSIONS
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:

13
LOCATION OF HEATER
PLAN THE POSITION OF THE
HEATER SO THAT IT WILL BE:
1. Free of water, flooding and
sprinklers. Avoid installation in
sumps, below roof lines without
gutters, or at the bottom of a
run off
2. On a stable fireproof base
that 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
VICINITY OF THIS
OR ANY OTHER
APPLIANCE.

14
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
DIMENSIONS
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
GI 160
GI 265
GI 420

15
SERVICE CLEARANCE:
A minimum of 300mm (12”)
is required on both the Front
and Top Panels for any service
requirements.
COMBUSTIBLE SURFACES:
Each heater face requires a
150mm (6”) clearance from
combustible surfaces.
Although it is not advisable,
the heater base can be placed
on a combustible surface for
operation.
However, do not install the
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 such as wind speed
and direction, proximity and height of obstructions that may
block ventilation, and proximity to public access areas.

16
A
Front
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"
437mm
17.2"
472 mm
18.6"
Electrical
Connections
SIDE CLEARANCE
300mm
12"'
SIDE CLEARANCE
300mm
12"
FRONT CLEARANCE
300mm
12"
REAR CLEARANCE
150mm
6"
Left
Top
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
150mm
6"
150mm
6"
150mm
6"
150mm
6"
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
DRAWN
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR: X=
0.5
X.X= 0.1
X.XX= 0.05
ANGULAR: X= 1
X= 0.5
FINISH:
DEBURR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A3
WEIGHT:
Toby Lawson
24/01/2018
insnrg techne pty. ltd.
Revision No.
Description of changes
By Date
PROJECT:
ALL DIMENSIONS FOR FOLDED PARTS
TAKEN FROM OUTSIDE OF FOLD
Manual Drawings
Indoor Clearances
INDOOR CLEARANCE
OUTDOOR CLEARANCE

17
OUTDOOR
INSTALLATIONS 
Locate the heater:
• On a level Solid Surface
• 3500mm from inner pool edge unless separated by a
permanent solid barrier, i.e. a wall or fence (l)
• In an open area, not 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)

18
(1)
3500mm
(a)
300mm
(g)500mm
(n)
1500mm
(i)1500mm
(k)
1000mm
(c)
300mm
(k)1000mm
(f)
75mm
(d/e)
1000mm
Exhaust Grill (Vent)
(b)
note. Maximum distance
from the ground/floor surface
is 300mm
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
Australia Outdoor Clearances
PROJECT:
Date By
Description of changes
Revision No.
insnrg techne pty. ltd.
19/01/2018
Aaron Marshall
WEIGHT:
A3
SHEET 1 OF 1
DWG NO.
TITLE:
REVISION
DO NOT SCALE DRAWING
MATERIAL:
DATE
SIGNATURE
NAME
FINISH:
Q.A
MFG
APPV'D
DRAWN
Manual Drawings

19
INDOOR INSTALLATIONS 
VENTING REQUIREMENTS
500mm
min.
1500mm
min.
Al Flue Pipe with
GAL Sheathing
125mm Al
Flue Pipe
125mm Certified Gas Cowl
Lower Vent
Upper Vent
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
DRAWN
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR: X=
0.5
X.X= 0.1
X.XX= 0.05
ANGULAR: X= 1
X= 0.5
FINISH:
DEBURR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE: 1:25 SHEET 1 OF 1
A3
WEIGHT:
Toby Lawson
17/01/2018
insnrg techne pty. ltd.
Revision No.
Description of changes
By Date
PROJECT:
ALL DIMENSIONS FOR FOLDED PARTS
TAKEN FROM OUTSIDE OF FOLD
Australia Flue Venting
Manual Drawings
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 of the plant room.
Natural Ventilation can be sourced from a non-habitable adjacent room
provided the adjacent room has the same ventilation as the direct outside
requirement.
The minimum free ventilation area provided by each opening is as per
the following table:
NOTE: MAXIMUM VERTICAL FLUE LENGTH IS 16m