UTC ICP HMP-03 Assembly instructions

INDIRECT OIL FIRED
SWIMMING POOL
HEATER
Printed in Canada 2006/05/24 X40020 Rev. E
Save these instructions for future reference
Caution : Do not tamper with
the unit or its controls.
Call a qualified service
technician.
Model:
HMP-03
DNS-0526RévA
Manufactured by:
UTC Canada Corporation
ICP Division
3400, Industrial Boulevard
Sherbrooke, Quebec
J1L 1V8

3
PART 1
INSTALLATION
1.1) DANGER, WARNING AND CAUTION
The signal words DANGER, WARNING and CAUTION are used to
identify levels of hazard seriousness. It is important that you understand
their meaning. You will find those words on the manual as followed :
DANGER
Immediate hazards which WILL result in death or
serious damage to body and/or property.
WARNING
Hazards or unsafe practices which CAN result in
death or damage to body and/or property.
CAUTION
Hazards or unsafe practices which CAN result in
damage to body and/or property.
A QUALIFIED TECHNICIAN MUST INSTALL THE
INDIRECT OIL - FIRED SWIMMING POOL HEATER.
IMPORTANT NOTICE
With the HMP-03 pool heater, ICP (Canada) is
redefining the pool heater concept by introducing a
simple and extra powerful unit. This extra power comes
from the uniquely designed heat exchanger, coupled
with a high efficiency oil burner. The pool water will
rapidly reach its desired temperature under any climatic
conditions. The HMP-03 need not be in operation if the
pool is not used. We suggest that the heater be used
based on need only, in order to avoid unnecessary
expenses.
To fully enjoy the power of your appliance, use it
only when required.
CAUTION
THE WARRANTY IS VOIDED IF CHEMICAL LEVELS ARE NOT MAINTAINED WITHIN THE
ACCEPTABLE LIMITS :
CHLORINE : 3.0 ppm MAX PH : 7.2 à 7.5
HARDNESS : 300 ppm MAX TOTAL ALKALINITY : 80 à 120 ppm
TOO ELEVATED A HARDNESS LEVEL IN THE PRESENCE OF HIGH ALKALINITY CAN CAUSE SCALE TO FORM
ON POOL WALLS AND IN THE POOL HEATER. IF THE HARDNESS LEVEL REACHES 300 ppm THE POOL
SHOULD BE DRAINED AND REFILLED WITH SOFT WATER UNTIL AN ACCEPTABLE HARDNESS LEVEL IS
REACHED. THE CALCIUM DOES NOT EVAPORATE AND, THEREFORE, BUILDS UP WITH EACH OF FILL-UP OF
THE POOL.
!
!

4
1.2) DELIVERY
Check the SWIMMING POOL HEATER carefully upon delivery for any
evidence of damage that may have occurred during shipping and
handling. Any claims for damages or lost parts must be made with the
transport company.
1.3) INSTALLATION
The unit must be installed according to regulations set out by
competent authorities. Refer to the CSA B139 Installation Code and the
CSA C22.10 Canadian Electrical Code.
This swimming pool heater can be installed any of the following ways:
a) outside;
b) inside, vented through a chimney.
1.3.1) Outside installation
1.3.2) Location
The swimming pool heater should be located where water will not
accumulate at any time of the year. It should be installed on a solid,
stable and level concrete base having the following minimum
dimensions: 0.6 m x 0.8 m x 50.8 mm (24" x 32" x 2") thick. The
consequences of the heater going off level due to frost heaving must be
addressed. The installer is responsible for taking appropriate steps to
prevent water from accumulating at the appliance location, at any time
of the year, by means of adequate drainage and/or heightened ground
level at its base location and/or any other required precaution.
1.3.3) Clearances
The following are minimum clearances and should be respected:
a) The vent hood of the swimming pool heater shall be no less than
1.8 m (6') from any :
- air supply inlet of any building;
- door;
- window;
- gas regulator;
- property line.
b) The vent hood of the swimming pool heater shall be no less than
0.9 m (3') from an oil tank vent or fill inlet;
c) The vent hood of the swimming pool heater shall not terminate
underneath a veranda, porch, deck or any combustible material.
Clearances from the exterior heater cabinet
Left side and front: 0.6 m (24")
Right side and back 228.6 mm (9")
Floor non-combustible
From nearest swimming pool wall 3.0 m (10')
Flue pipe 228.6 mm (9")
1.3.4) Installation of the Outdoor Diffuser Kit
The HMP-03 swimming pool heater must be installed with the Outdoor
Diffuser Kit model "GDK", manufactured by ICP (Canada), according to
the following instructions (also see Figure 2, p.10) :
1. Remove the top flue pipe cover (part F) and the top casing panel
(part G);
2. Insert the 6 inch diameter exhaust pipe in the smoke box collar,
align the pre-drilled holes of the exhaust pipe with the flue collar
and secure with the four screws supplied in the kit (part B);
3. Re-install the top casing panel (part G);
4. Slide the outside liner (part C) over the exhaust pipe (part A) and
make sure it is well seated all around and outside the top cover
collar (part G);
5. Install the diffuser (part D) on the outside liner with the eight legs
on the inside and align its top hole with the exhaust pipe top disk
hole;
6. With the screw supplied in the kit (part E) complete the assembly
of the kit.
1.4) Inside installation vented through a chimney
1.4.1) Location
The swimming pool heater must be installed in a clean area, as close
as possible to the chimney.
CAUTION
Chemical products such as chlorine, bromine or
any other volatile and corrosive chemical products
must be stored in an area removed from the pool
heater, since they can result in the oxidization of
the heat exchanger, causing the warranty to
become null and void.
1.5) WIRING AND REGULATORS
The installer must wire the swimming pool heater according to the
appropriate electrical diagram. All wiring must be done in accordance
with the CSA C22.10 standard, particularly Section #68.
CAUTION
If there is no fence or wall separating the heater
from the pool, a Class A ground fault current
interrupter must be installed on the power supply
circuit.
1.5.1) Inside or outside installation
with chimney venting
All controls, safety devices and the oil burner on the swimming pool
heater are factory wired and checked. An power supply suitable for 115
volts, 60 Hertz, single phase of less than 12 Amps should be provided
according to the applicable codes and regulations. For connections,
follow the instruction in Figure 4 (p. 12).

5
1.6) OIL TANK INSTALLATION AND HOOK-UP
The oil tank must be installed in accordance with local codes and
regulations and CSA Code B139. The burner can be hooked up with a
one-pipe or a two pipes system. We recommend using a two pipes
system when the burner level is higher than the bottom of the oil
storage tank. The burner is set-up at the factory for a one-pipe system.
Refer to the oil pump manufacturer instructions for a two pipe system.
Oil supply hookup must include a certified oil tank, vent, gage, fill
whistle, shut-off valve and oil filter with a 10 micron removal capacity.
Make sure the piping has no leaks or blockages. Never use
compression fittings. Use the same diameter piping for both the suction
and the return lines and set them at the same depth in the oil tank
when using a two pipe system. Additional information is found in the
burner and oil pump installation brochure that comes with the
swimming pool heater oil burner.
At the beginning of each heating season or once annually, check the
complete oil distribution system for leaks.
1.7) VENTING
The chimney draft must be strong enough to ensure the safe and
reliable operation of the unit.
1.7.1) Chimney
The recommended minimum draft is 0.02" W.C. The maximum and
minimum dimensions for the vent pipe (chimney or chimney liner) are
respectively 5" and 7". The connecting pipe between the pool heater
and the vent pipe must be 6" in diameter. (Refer to the CSA B 139
Code)
The diameter of the connecting pipe should never exceed that of the
chimney. The use of a damper in the connecting pipe is strictly
prohibited. If more than one pipe is to be connected to the same
chimney, the sectional area of the chimney must be equal to the
total of the individual sectional areas. The use of a 6" diameter draft
control is compulsory with the swimming pool heater when
connected to a chimney. Failure to comply with this condition
constitutes grounds for voiding the warranty.
1.7.2) Outdoor diffuser kit model GDK
With the outdoor-diffuser kit no draft regulator is needed and the
maximum over fire draft should be +0.045" W.C. after 5 minutes of
operation.
1.8) BURNER INFORMATION
The oil burner of the swimming pool heater is factory installed and
wired. The nozzle is also installed but the technician must do the final
air adjustment. The burner is factory set up for a one-pipe system.
Refer to section 1.6 for a two pipes system.
1.9) COMBUSTION AIR SUPPLY
Any oil-fired unit, if it is to operate properly, must have an adequate,
functional air supply. If the swimming pool heater is installed in an
enclosed area, two permanent air supply openings must be provided.
One should be located near the ceiling, the other near the floor. Each of
these openings should allow 1 square inch per 1000 BTU/h of output.
1.10) PIPING
The "HMP-03" swimming pool heater is designed so that its total flow
restriction is not more than the equivalent of 10 feet of 1½" pipe. The
total water flow from the swimming pool pump and filter system will
pass easily into the pool heater. A bypass with a balancing valve is not
needed. You must use a 1½" plastic pipe suitable for 60°C (140°F)
between the swimming pool heater outlet and the pool water inlet. The
water inlet and outlet connections of the heater are suitable for 1½"
NPT male fittings. Refer to figure 3 (p. 11) to locate the inlet and outlet
connections on the pool heater and the position of other equipment. An
automatic chemical product distributor must be located between the
pool heater water outlet and the pool.
We recommend the installation of a full flow valve on the inlet and outlet
water piping for maintenance. Those valves are needed if the water
heater is below the top of the swimming pool water level. All piping,
fitting and accessories used in the installation should be corrosion
protected. We recommend using two stainless steel hose clamps on
each joint.
TABLE 1
Burner characteristics
Model Input
(BTU/h) Output (BTU/h) Input (USGPH) Beckett Burner Nozzle Pressure (PSI)
HMP-03 198,000 168,000 1.42 AFG-MD-V1 1.20-60°B 140

6
PART 2
MAINTENANCE AND OPERATION
We recommend that a qualified technician
start-up and service the swimming pool heater.
Ensure that the heater and the system are
always full of water and air has been bled using
the air vent before starting the burner.
2.1) FUEL
Use only #2 fuel oil. Never attempt to use a heavier fuel oil, gasoline,
motor oil or any other fuel for this pool heater.
2.2) START-UP
The oil burner of the HMP-03 swimming pool heater is factory
assembled (including nozzle) and wired. The pump pressure is factory
adjusted to 140 psi, the air adjustment is set at 2 for the coarse air band
and 8 for the fine air adjustment. The nozzle assembly is permanently
set at 0 .The start-up must be performed in accordance with the
following steps (See figure 1, p. 8) :
1. Make sure that the tank contains fuel oil and that the fuel valve is
open;
2. Make sure that the pool water-circulating pump is ON and the
water circulates through the pool heater. Turn the pool heater
electric power supply switch on;
3. Remove the front access door and adjust the pool thermostat (C)
to its minimum setting. Select the ON position of the operating
switch (D) located below the pool thermostat (C). If the pool heater
is filled with water, the low water cut-off (F) green light (E) should
be ON. If the low water cut-off red light (F) is ON it means that the
swimming pool heater is not properly air bled. On the initial start-
up allow 15 to 20 minutes to fill the pool heater. We recommend
opening the swimming pool heater air bleeder (A) (white handle
located outside the right side panel) by turning one turn
counterclockwise until water comes out and turn clockwise until
the water flow stops. DO NOT OVER-TIGHTEN THE HANDLE
OF THE AIR BLEEDER;
4. Start the burner by setting the pool thermostat (C) located on the
top right portion of control compartment of the heater above the
pool water temperature. Air must be completely bled from oil lines
through the bleed port on the oil pump. If there is no ignition and
the red button of the combustion relay comes up, see section 2.3
below;
5. (INSIDE INSTALLATION ONLY). Adjust the chimney draft as
specified in section 1.7 (p. 5). Take this reading midway between
the draft-regulator and the flue outlet of the swimming pool heater;
6. Do a smoke test and a take a CO2reading after a minimum of 5
minutes of operation. The smoke test reading must be 0 and the
CO2reading must be between a minimum of 10.0% and a
maximum of 12.5%. If not, use the fine air adjustment to adjust
combustion air to reach the specified smoke and CO2reading. DO
NOT OPERATE THE SWIMMING POOL HEATER WITH A
SMOKE READING HIGHER THAN 0.
2.3) RESTARTING AFTER IGNITION FAILURE
1. Check the fuel level in the tank;
2. Make sure the fuel valve is open;
3. Make sure the oil filter is not clogged (check the vacuum reading
and make sure it is less than 6 in. hg for a one-pipe system and
12 in. hg for a two pipes system);
4. Check the electrical supply circuits (breakers);
5. Check the burner electrode adjustments (refer to the burner
instruction manual);
6. Check if the pool thermostat is calling for heat;
7. Check if the low water cut-off green light is on;
8. Check for air in the oil pump suction line.
If after following these procedures and pressing the red burner reset
button on the combustion relay (L), the burner (N) still does not light,
call a qualified service technician. Never attempt to restart the burner if
there is excess fuel oil or oil vapour in the combustion chamber.
2.4) OPERATION
The HMP-03 swimming pool heater is an indirect-fired appliance. The
primary water circuit in contact with the combustion product is a
pressurized closed system same as a domestic oil fired boiler with a
feed water regulator and check valve, (J), expansion tank (V),
operational and high limit temperature control (S), safety pressure relief
valve (U), low water cut-off (G), drain valve (O), air vent (A) and
thermomanometer (W). The water supply is effected by the pool water-
circulating pump and limited to 15 PSI by the pressure regulator.
The secondary water circuit is a copper integrated finned tube coil, in
which the pool water will circulate to be heated by the hot water of the
primary circuit. It is equipped with a pool thermostat (C) to adjust the
desired pool temperature with the knob located behind the front access
panel. The maximum temperature setting is 40°C (105°F). The sensor
of this controller is located at the inlet side of the heater to read the
water temperature. This control allows for a differential of -16°C (3°F)
on a continuous operating basis. A temperature safety device (B) on
the HMP-03 will limit the outlet temperature to a maximum of 54°C
(130°F). A difference between the temperature setting of the pool
thermostat and the reading of a submerged pool thermometer is
possible for the following reasons :
a. If the unit does not operate on a continuous basis one must wait a
period of time until it reaches the desired temperature;
b. The location of the submerged pool thermometer is not
representative of the temperature at the inlet of the circulating
pump;
c. The submerged thermometer is defective or it may not be properly
calibrated;
d. The submerged thermometer is too close to the heated water
inlet.
The swimming pool heater can be stopped and started with the ON-
OFF switch (D) located behind the front access door. A safety device
built into the HMP-03 (a low water cut-off (G)) will avoid operation of the
oil burner if the pool heater is not full of water. The pool heater should
be shut off 5 minutes in advance of draining, backwashing or
turning off the pool water circulating pump.
CAUTION
If the pool pump is equipped with an adjustable
timer, remember that the pool heater must be
turned off before the water circulating pump.

7
WARNING
At 60°C (140°F) hot water can produce third
degree burns in 6 seconds; at 54°C (130°F) in 30
seconds. Maximum thermostat setting is 41°C
(106°F).
2.4.1) Precautions against freeze-ups
To avoid damage to the swimming pool heater, pump, filter, piping and
other accessories, make sure that the circulating pump is "ON" and that
there is adequate circulation of water through all these components to
prevent freeze-up when the outside temperature is below 0°C (32°F). If
the swimming pool heater is to be turned off at temperatures below the
freezing point, the water piping at the inlet and outlet of the swimming
pool heater must be disconnected. Also, it must be drained by opening
the drain valve at the bottom as well as the air vent, to allow the
introduction of air into the primary circuit of your pool heater. Then, the
feed water line must be bled by removing the 1/2’’ NPT plug (I) located
at the bottom of the T fitting located after the water feeder and regulator
device.
2.5) SHUT DOWN AT THE END OF THE
SWIMMING SEASON
2.5.1) Outside installation
1. Make sure that the HMP-03 ON-OFF switch (D) and the
circulating pump switch are OFF;
2. Make sure that power supply switch is OFF;
3. Disconnect the water inlet and outlet of the HMP-03 swimming
pool heater;
4. Open the drain valve (O) located on the bottom of the HMP-03
unit and drain it completely;
5. Removed the ½’’ plug (I) from the T fitting located on the right end
side of the water feeder & regulator device (J);
6. Leave the drain valve open during all shut down periods.
2.5.2) Inside installation
3. For inside installations protected from freezing, we suggest you
follow the same procedure than article 2.5.1 at the exception that
you can leave it full of water for the winter shutdown period. This
apply only for an installation protect against cool temperature.
2.5.3) Prolonged non-use or winterization
of the oil burner
When the oil burner will not be used for an extended period of time OR
the appliance is not used altogether, follow this procedure:
1) Close the valve located at the bottom of the oil tank that feeds the
burner;
2) Raise the thermostat to call for heat and cause the oil burner to
start;
3) Let the burner fire until there is no longer a flame and combustion
is cut by the safety (usually 30 to45 seconds after the flame
extinguishes)
4) Depress the red Re-start Button; the burner should start. If there is
still a flame, repeat the procedure until there is no more flame.
5) When you have assured yourself that steps 3) and 4) are
completed, shut-off the electrical power to the unit.
2.6) START-UP AT THE BEGINNING OF THE
SWIMMING SEASON
Have the chimney and the connecting pipes swept (INSIDE
INSTALLATION ONLY).
Have all heating surfaces cleaned if deemed necessary after a visual
check. To clean the tubes of the heat exchanger, remove the smoke
box and the flue baffles.
CAUTION
The HMP-03 being equipped with a sound trap,
make sure not to damage the acoustical material
when cleaning the boiler. The use of a flexible
cleaning brush is strongly recommended.
1. To clean the combustion chamber removes the burner;
2. Replace the oil filter and nozzle;
3. Have the burner electrodes cleaned along with the burner
retention head;
4. Close the drain valve (O), install the ½’’ plug (I) to the T fitting and
install the inlet and outlet water pipes as showed in figure 3;
5. Make sure that oil valve is open;
6. The power supply interrupter should be "ON";
7. Start the filter pump and wait until the air is completely bled
through the HMP-03 unit;
8. Select the "ON" position on the HMP-03 switch located on the
front panel;
9. Refer to section 2.2 for the burner start up.
2.6.1) Regular maintenance during
the heating season
2.6.2) Nozzle
3. A dirty or clogged nozzle can prevent ignition or cause odors
and smoke. It must be replaced.
2.6.3) Fuel tank
Regularly check the level tank. Should it run dry, the lines will have to
be bled before restarting the burner.
2.7) PRECAUTIONS
Never use your swimming pool heater as an incinerator. Never pile or
store paper or garbage near it.
!

8
FIGURE 1
A Automatic air vent M Junction electrical box
B Outlet water temperature control (setting, max. = 130oF,
diff = 10oF) N Oil burner
C Pool thermostat O Drain valve (at the back of the appliance)
D ON-OFF switch P Ground terminal
E Green light, correct water level Q Observation door
F Red light, low water level R Pool heater water outlet
G Low water cut-off S Operation and Hi-limit control (HI = 180-160o F, LOW =
170-150oF)
H Pool thermostat sensor location T Pool heater water inlet
I 1/2" NPT drain plug U Safety valve (at the back of the appliance)
J Feed water regulator and check valve device V Expansion tank
K Outlet water temperature sensor location W Thermomanometre
L Burner combustion relay
DNS-0527 Rev. B

9
PART 3
INFORMATION
Date of installation of the HMP-03: Serial number:
Service telephone - Day: Night:
Dealer name and address:
START-UP TEST RESULTS
Nozzle: Pressure: lb/psi
Burner adjustments: Primary air
Fine air
Draw Assembly
CO2:
% Smoke scale: (Bacharach)
Gross stack temperature:
0F
Ambient temperature:
0F
Chimney draft: "W.C.
Overfire draft: "W.C.
Test performed by:

FIGURE 2
GDK-24 Installation
10
DNS-0524 Rev. A

FIGURE 3
Typical Piping Arrangement
11
DNS-0525 Rev. A

12
FIGURE 4
Wiring Diagram
DNS-0518 Rev. B

13
PARTS LIST
Model : HMP-03
ITEM DESCRIPTION NUMBER
1 Tankless coil ass'y B02125
2 Gasket, tankless coil B02113
3 Heat exchanger ass'y B02131
4 Combustion chamber bottom insulation B00618-04
5 Floor insulation B00619-03
6 Floor B02115
7 Left side panel ass'y B02147-02
8 Gasket, outside inlet/outlet B01520-01
9 Rear panel B02132
10 Gasket, outside inlet/outlet B01520-02
11 3/4" NPT x 2 3/4" drain faucet G11Z025
12 Overflow tube 3/4" x 18" B02159
13 Relief valve 30 Lbs G11F012
14 6" pipe adapter B01508
15 Top cabinet cover B02133
16 Top insulation B02160
17 Flange hex nut 3/8-16NC brass F07O001
18 Smoke outlet ass'y B01747
19 Gasket, outlet cover B00205
20 Sound trap ass'y B02144
21 Gasket, sound trap B02112
22 Sound trap box ass'y B02142
23 Sound trap box side insulation B01526-74
24 Gasket, extruded 1/2" x 1/8" J06L001
25 Flue baffle B00864-02
26 Aquastat, operation & hi-limit R02H004
27 Right side panel B02135-01
28A Top front panel ass'y (HMP-03-D only) B02148-01
ITEM DESCRIPTION NUMBER
28B Top front panel ass'y (HMP-03-T only) B02148-02
29 Front door ass'y B02151
30 Water leak pan B02117
31 Front underneath covert B02116
32 Observation door ass'y B01842
33 AFG-V1 burner ass'y B01532-01
34 Hex nut 3/8-16NC zinc F07F011
35 Oil inlet tube B01467
36 Gasket, fixed flange N04Z026
37 Drain line ass'y B02146
38 Automatic air vent G99Z027
39 Controle support B02136
40 Aquastat, water outlet temperature limit R02F012
41 Thermostat, pool water R02P020
42 SPST rocker switch L07F003
43 Low water cut-off R99H005
44 Boiler inlet tube ass'y B02145
45 1/2" flare x 1/2" NPT brass fitting G07F007
46 1/2" NPT galvanized tee G05J001
47 1/2" NPT x 1 1/2" NPT stainless std nipple G02I001
48 1/2" NPT galvanized square head plug G06K001
49 Water pressure regulator 1/2"NPT R99F025
50 Tridicator 0-60 PSI R02L001
51 1/2" NPT galvanized male-female 90 elbow G04M001
52 Well 3/4" NPT R02J003
53 Capillary clip R02J009
54 Expension tank G13F001-3
55 Hex nut 1/2-13NC zinc F07F019
DNS-0540 Rev. B

14
PARTS LIST
Model : GDK-24
DNS-0557 Rev. A
ITEM DESCRIPTION NUMBER COMMENTS
1 Hex washer head self-drilling screw #1/4-14 x 1" F03G010 Stainless steel
2 Diffuser ass'y B01504
3 Diffuser bracket ass'y B01506
4 Hex washer head self-drilling screw #8-18 x 1/2" F03G009 Quantity: 4, stainless steel
5 Flue pipe casing B01486
6 Stainless steel flue pipe B02118