Pentair 400K BTU-HR, 300K BTU-HR, 200K BTU-HR, 250K BTU-HR User Manual

POOL AND SPA HEATER
120/240 VAC NATURAL
GAS/LP GAS

INSTALLATION
and
USER’S GUIDE

MODELS Natural Propane
200K BTU/HR 460730 460731

250K BTU/HR 460732 460733
300K BTU/HR 460734 460735
400K BTU/HR 460736 460737

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

If the information in these instructions is not followed exactly, a fire
or explosion may result causing property damage, personal injury or death.
Call [phone] for additional free copies of these instructions.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.

WHAT TO DO IF YOU SMELL GAS

• 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.

Installation and service must be performed by a qualified installer, service agency or the gas
supplier.

SPECIAL INSTRUCTIONS TO OWNER

Retain this manual for future reference.
This manual supplies information for the installation, operation,

and servicing of the appliance. READ AND REVIEW THIS
MANUAL COMPLETELY before proceeding with an installation.
Its use will reduce service calls and chance of injury and will
lengthen product life.

®

MasterTemp

TM

WARNING

472592 Rev. A (04/04/06)

CERTIFIED

®

INSTALLATION, OPERATION
AND SERVICE MANUAL

TO INSTALLER:
Affix these instructions adjacent to the

heater.

TO CONSUMER:

Retain these instructions for future reference.
FOR YOUR SAFETY - This product must be installed

and serviced by a professional service technician,
qualified in pool heater installation. Improper installation
and/or operation could create carbon monoxide gas and
flue gases which could cause serious injury or death.
Improper installation and/or operation will void the
warranty.

FIGURE 1

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Specifications, Requirements . . . . . . . . . 3

Description of the Heater . . . . . . . . . . . . . . . . . . . 4

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . 4

Owner’s Operating Instructions . . . . . . . . . . . . . . 4

Before Startup. . . . . . . . . . . . . . . . . . . . . . . . . . 4

What To Do If You Smell Gas . . . . . . . . . . . . . . . 4

Spa Temperature Caution . . . . . . . . . . . . . . . . . . 5

Operating Instructions . . . . . . . . . . . . . . . . . . . . 5

To Switch Off Gas To the Appliance . . . . . . . . . . . 6

Operating Control . . . . . . . . . . . . . . . . . . . . . . . 6

After Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Care/Maintenance/Winterizing. . . . . . . . . . . . . . . 8

Installation Instructions . . . . . . . . . . . . . . . . . . . . 8

Pre-Existing Vent Systems . . . . . . . . . . . . . . . . . 8

Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . 9

Outdoor Shelter/Indoor Installation . . . . . . . . 10-15

Water Connections . . . . . . . . . . . . . . . . . . . 15-18

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . 18

Checking Combination Gas Control Valve . . . . . . 19

Gas Connections . . . . . . . . . . . . . . . . . . . . . . . 20

Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . 20

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . 20-22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 23-30

Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 31-35

Wiring Diagrams/External Control Interface 36-37

SAFETY INSTRUCTIONS

FOR YOUR SAFETY - This product must be installed
and serviced by a professional service technician,
qualified in pool heater installation.

Some jurisdictions require that installers be licensed.
Check with your local building authority about contractor
licensing requirements. Improper installation and/or
operation could create carbon monoxide gas and flue
gases which could cause serious injury or death.
Improper installation and/or operation will void the
warranty.

CODES AND STANDARDS: Installation must be in
accordance with all local codes and/or the latest edition
of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and
the National Electrical Code, ANSI/NFPA70 (U.S.), or
standards CSA B149 – INSTALLATION CODES FOR GAS­BURNING APPLIANCES AND EQUIPMENT and/or local
codes and Standard CSA C22.1 – Canadian Electrical
Code, Part 1 (Canada). The heater, when installed, must
be electrically grounded and bonded in accordance with
local codes, or, in absence of local codes, with the
Canadian Electrical Code or the National Electrical Code,
ANSI/NFPA70, as applicable.

2

For instructions on checking the gas pressure

through the Combination Gas Control Valve,

See the sidebar on Page 19.

SAFETY INSTRUCTIONS (Continued)

This appliance is equipped with an
unconventional gas control valve that is factory
set with a manifold pressure of -.2 inches wc.
Improper installation, adjustment, alteration, ser­vice or maintenance can cause property damage,
personal injury or loss of life. Installation or service

must be performed by a qualified installer, service agency
or the gas supplier. If this control is replaced, it must be
replaced with an identical control.

Do not attempt to adjust the gas flow by adjusting
the regulator setting.

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, consult your Pentair dealer. 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 Pentair dealer or other qualified
agency using factory specified and 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.

• Use heater only with the fuel for which it is designed.

• If a fuel conversion is necessary, refer this work to a

qualified service technician or gas supplier before
putting the heater into operation.

Risk of fire or explosion from flamma­ble vapors. Do not store gasoline, cleaning fluids, var-

nishes, paints, or other volatile flammable liquids near
heater or in the same room with heater.

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 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).

Risk of asphyxiation if exhaust is not
correctly vented. Follow venting instructions
exactly when installing heater. Do not use a draft

hood 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. A vent conversion kit (See Page 14
for Part Numbers for Conversion Kits) is available for
installations in enclosures (Canada) or indoors (U.S.). Use
the specified venting, and only the specified venting,
when heater is installed in an enclosure or indoors. In
Canada, this pool heater can only be installed outdoors
or in an enclosure that is not normally occupied and has
no openings directly into occupied areas. See Page 11 for
enclosure venting requirements.

Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Wiring errors
can also destroy the control board.

Connect heater to 120 or 240 Volt, 60 Hz., 1 Phase
power only.

Verify proper operation after servicing.
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.

GENERAL SPECIFICATIONS/
REQUIREMENTS

NOTICE: Combustion air contaminated by corrosive

chemical fumes can damage the heater and will void the
warranty.

NOTICE: The Combination Gas Control Valve on this
appliance differs from most appliance gas controls. If it
must be replaced, for safety reasons replace it only with
an identical gas control.

NOTICE: The access door panels must be in place to
provide proper ventilation. Do not operate the heater for
more than five (5) minutes with the access door panels
removed.

This heater is design certified by CSA International as
complying with the Standard for Gas Fired Pool Heaters,
ANSI Z21.56/CSA 4.7, and is intended for use in heating
fresh water swimming pools or spas.

NOTICE: Do not use this heater as a heating boiler,
water heater, or for heating salt-water pools. This heater
is intended for use in heating fresh water swimming
pools or spas only. The heater requires an external 120
or 240 VAC single-phase electric power source.

The heater is design certified by CSA International for
installation on combustible flooring. Specified minimum
clearances must be maintained to combustible surfaces
(see “Installation Instructions”, Pages 8 and 9).

The heater should be located in an area where leakage
of the heater or connections will not result in damage to
the area adjacent to the heater or to the structure. When
such locations cannot be avoided, it is recommended that
a suitable drain pan, adequately drained, be installed
under the heater. The pan must not restrict air flow.

CAUTION

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

3

The heater may not be installed within five feet of the
inside surface of a pool or spa unless it is separated by a
solid fence, wall or other permanent barrier.

A Propane (LPG) fired heater must not be installed in a
garage in Massachusetts, by order of the Massachusetts
State Fire Marshall. For more information, call the Fire
Marshall’s office.

DESCRIPTION OF THE HEATER

Figure 2 is a diagram of the heater showing how it oper­ates.

Precisely matched orifice plates meter the air and gas
into the mixer. The blower draws the air and gas through
the mixer and forces it into the burner’s flameholder. A
sealed heat exchanger surrounds the flameholder, dis­charging exhaust gases out the flue.

Two inch PVC water piping connects directly to the
manifold/header on the heat exchanger using 2" PVC slip
unions provided with the heater. The outer manifold
remains cool; no heat sinks are required. A thermal
regulator and an internal bypass regulate the water flow
through the heat exchanger to maintain the correct outlet
temperature. The heater operator control panel board
assembly is located on top of the heater.

SEQUENCE OF OPERATION

An electronic temperature sensing thermistor in the
manifold adapter inlet controls the heater operation.
When the inlet water temperature drops below the
temperature set on the operating control, the burner
controller supplies power to the combustion air blower
through a series of safety interlocks. The interlocks
consist of

• the pressure switch (PS), which senses that the pump
is running,

• the high limit switch (HLS), which opens if the heat
exchanger outlet temperature goes above 135° F
(57° C), and

• the automatic gas shutoff (AGS) switch, which opens
if the heat exchanger outlet temperature goes above
140° F (60° C).

• the stack flue sensor (SFS), which shuts down the
heater if the flue gas temperature reaches 500° F
(260° C).

The air flow switch (AFS) senses the pressure drop
across the air metering orifice. As soon as there is suffi­cient air flow, the AFS closes, closing the circuit to the
hot surface igniter (HSI), which ignites the fuel mixture.

On a call for heat, the blower and HSI are energized. In
about 20 seconds, the gas valve opens and ignition
occurs. The HSI then switches to a sensing mode and
monitors the flame.

The heater is equipped with a digital operating control
that enables the user to pre-set the desired pool and spa
water temperatures. The control enables the user to
select between pool and spa heating, and features a
digital display that indicates the water temperature.

OWNER’S OPERATING
INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

IF YOU DO NOT FOLLOW THESE
INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION
MAY RESULT, CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.

START-UP AND OPERATION

START-UP AND SHUTDOWN INSTRUCTIONS ARE ON THE
LABEL ATTACHED TO THE COVER OF THE APPLIANCE
CONTROL BOX.

BEFORE START-UP

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights the
burner. Do not try to light the burner by hand.

B. BEFORE OPERATING check for odor. Sniff all around

the appliance area for gas. Be sure to sniff next to
the floor, because some gas (such as propane) is
heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• 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.

WARNING

4

FIGURE 2

Gas

Inlet
(Cold
Water)

Air

Blower

Mixer

Exhaust

Outlet
(Mixed
Water)

Burner

Heating Coils

C. Use only your hand to turn the gas control on or off.

Never use tools. If you cannot change the ON/OFF
setting by hand, don’t try to repair it, call a qualified
service technician. Force or attempted repair may
result in fire or explosion.

D. Do not use this heater if any part has been under

water. Immediately call a qualified service technician
to inspect the heater and to replace any part of the
control system and any gas control which has been
under water.

E. Do not operate the pool heater unless the pool or

spa is properly filled with water.

F. Before operating the appliance for the first time or

after it has been off for an extended time, perform
the following checklist:

1. Remove debris or other articles from inside the
heater and the area around the heater and its
exhaust vent. Make sure the ventilation openings
are clear of debris or obstruction. For installations
in an enclosed space, make sure openings for
combustion and ventilation air are unobstructed.

2. Keep heater area clear and free from com­bustibles, flammable liquids and chemicals.

3. Check that all water connections are tight.

4. Water must be flowing through the heater during
operation. Make sure that pool/spa is filled with
water and have pump operating. Check that water
flow is unobstructed from the appliance. When
operating for the first time or after an extended
shut-down, run filter pump for several minutes to
clear all air from the system.

SPA TEMPERATURE CAUTION

All safety rules recommended by the U.S. Consumer
Product Safety Commission should be observed when
using a spa or hot tub, including:

1. Spa or hot tub water temperatures should never
exceed 104° F (40° C). A temperature of 100°F
(38°C) is considered safe for a healthy adult. Special
caution is suggested for young children.

2. 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.

3. Pregnant women beware! Soaking in water above
102° F (39° C) can cause fetal damage during the
first three months of pregnancy (resulting in the birth
of a brain-damaged or deformed child). Pregnant
women should follow the 100° F (38° C) maximum
rule.

4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err in
regulating water temperature.

5. Persons with medical history of heart disease, circula­tory problems, diabetes or blood pressure problems
should obtain their physician’s advice before using
spas or hot tubs.

6. Persons taking medications which induce drowsiness,
such as tranquilizers, antihistamines or
anticoagulants, should not use spas or hot tubs.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set both pool and spa thermostats to the lowest
settings.

3. Turn off all electric power to the appliance.

4. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do not try to light the burner by hand.

5. Remove the access door panels by unfastening the
four 1/4-20 phillips head screws located on each
door, then lift up and out from the bottom of the
panel to remove. If necessary, the screws may be
used as handles. See Figure 3.

6. Toggle-Style Valve: Pull toggle toward you to turn gas
off.

7. Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow “B” in the “Before
Startup” instructions (Page 4). If you don’t smell gas,
go to the next step.

5

FIGURE 3: Removal of Access Door Panels

8. Push the toggle switch away from you to switch the
gas on.

9. Replace the Door Access Panels. All panels must be
in place when operating the heater.

10. Set 3-way valves on inlet and outlet to pool or spa,
as appropriate.

11. Turn on all electric power to the appliance.

12. Press either the POOL ON or SPA ON button switch
on the operating control.

13. Set the thermostat to desired setting (NOTICE: Set
point must be above actual water temperature or
burner will not fire). See “OPERATING CONTROL.”

14. The blower should come on immediately, and after
about 20 seconds, the burner should fire. When
operating for the first time, the burner may not fire
on the first try because of air in the gas line. If it
does not fire at first, push the OFF switch, wait five
minutes, and again push the POOL or SPA ON switch.
The burner should fire after about 20 seconds. You
may have to repeat this until all of the air has cleared
the gas line.

15. The burner should fire until the pool/spa temperature
reaches the desired temperature set on the thermo­stat. The blower will continue to run for about 45
seconds after the burner shuts off. If any of the
safety interlocks should open during burner opera­tion, the burner shuts off immediately, but the blower
continues to run for about 45 seconds.

Should overheating occur or the gas supply fail to
shut off, turn off the manual gas control valve to the
appliance.

16. If the appliance will not operate, follow the instruc­tions “TO SWITCH OFF GAS TO THE APPLIANCE”,
and call your service technician or gas supplier.

TO SWITCH OFF GAS TO THE APPLIANCE

1. Press the OFF button on operating control.

2. Switch off all electric power to the unit.

3. Remove the access door panels.
See Figure 3, page 5.

HEATER PARTS MAY BE HOT.

4. Toggle-Style Valve: Pull toggle toward you to turn gas
off.

5. Replace the Access Door Panels.

OPERATING CONTROL

The five operating switches are:

POOL ON Press this button to govern heater operation
by the pool temperature setting.

SPA ON Press this button to govern heater operation by
the spa temperature setting.

HEATER OFF Press this button to switch off the heater.

▲▲

TEMP Press this button to raise the temperature

setting.

▼▼

TEMP Press this button to lower the temperature

setting.
To toggle the display between degrees Centigrade (°C)

and degrees Fahrenheit (°F):

1. Turn the Operating Control OFF.

2. Press

▲▲

TEMP or

▼▼

TEMP for 5 seconds. The dis­play will flash once and change modes (°C to °F or
vice versa).

When either the

▲▲

TEMP or

▼▼

TEMP buttons are
depressed, the digital display will indicate the tempera­ture setting. After five seconds, the display will return to
the actual pool/spa temperature.

In addition to the digital temperature display, there are
five indicator lights:

The POOL ON light indicates that the pool water tem­perature is governing operation of the heater.

The SPA ON light indicates that the spa water tempera­ture is governing operation of the heater.

The HEATING light comes on and stays on when the
burner is firing. This light should be on whenever the
burner is on. It blinks when the heater is calling for heat
but not firing. If this light is on but the burner fails to
come on, one of the “service” lights should come on,
indicating a fault in the system.

WARNING

6

FIGURE 5: Turning Gas Control ON

FIGURE 6: Operating Control for all models.

Temperature

Up and Down

Digital Temperature

Display

Dual Temperature

Controls

System Operation

Indicator Lights

Heater OFF

Switch

You are
here

Gas control is shown
OFF. Push toggle
switch away from you
to switch ON.

The SERVICE SYSTEM light indicates that there is
insufficient water flow to the heater. If the pump is oper­ating, this usually indicates that the filter and/or skim­mers should be cleaned (some filters may require back­washing). If the light remains on after the filter/skimmers
have been serviced, the system should be checked by a
qualified service technician.

The SERVICE HEATER light indicates a fault in the
heater or its controls. If this light comes on, shut down
the heater (See TO SWITCH OFF GAS TO THE
APPLIANCE on page 6), and have a qualified service
technician check the system.

Risk of explosion or fire causing burns or
death if safety interlocks are disabled. DO NOT attempt
to operate heater when SERVICE HEATER light is on or if
blower or burner will not start. Instead, follow instruc­tions under “To Switch Off Gas to the Appliance,” and call
a qualified service technician to repair unit.

AFTER START-UP

CHECKING WATER FLOW

Fire or flooding hazard. If the unit overheats
and the burner fails to shut off, follow instructions under
“To Switch Off Gas to the Appliance”, Page 6, and call a
qualified service technician to repair unit.

After start-up, the outlet water pipe should feel slightly
warmer than the inlet pipe. If it feels hot, or if you hear
the water in the heater boiling, there may not be enough
water flow to the appliance. Make sure that the filter is
not plugged. If water temperature remains high but the
unit continues to operate, turn off the appliance and call
your service technician.

SPRING AND FALL OPERATION

If the pool is only used occasionally, lower the pool ther­mostat to 65° F (18° C). and leave the heater on. This
will keep the pool and the surrounding ground warm
enough so that the heater should restore the pool to a
comfortable temperature within about one day.

COLD WEATHER OPERATION

The heater may be operated in the wintertime, provided
air temperatures remain above freezing and the water
temperature is not permitted to drop below 65° F (18°
C). Extended heater operation with water temperatures
below 65° F (10° C) can result in serious damage to the
heater and is not covered by warranty.

NOTICE: When starting the heater for the swimming sea­son with a water temperature below 50° F (10° C), the
heater may be used to heat the water; however, make
sure that the heater operates continuously until the water
temperature reaches the heater’s minimum setting of 65°
F (18° C).

DO NOT operate this unit outdoors at temperatures
below 40° F (4° C).

During cold weather, if there is no danger of freezing,
operate the filter pump continuously even if the heater is
not operating. If air temperatures are expected to drop
below freezing (32° F/0° C), shut down the heater and
winterize it (See ”WINTERIZING”, Page 8). Allowing the
heater to freeze will void the warranty.

MAINTAINING POOL TEMPERATURE

To maintain pool temperature, make sure that the heater
switch and valving are reset to pool settings after using
the spa.

ENERGY SAVING TIPS

1. Keep the pool or spa covered when not in use. This
will reduce heating costs, reduce water evaporation,
conserve chemicals and reduce load on the filtering
system.

2. Reduce pool thermostat to 78° F (25° C) or lower;
reduce spa temperature to 100° F (38° C).

3. Use a time clock to start the filter pump at 6 a.m. or
later. The swimming pool loses less heat after day­break.

4. For pools used only on weekends, lower the thermo­stat setting by 10° F to 15° F (5° C to 8° C) during
the week to reduce heat loss. A properly sized heater
will restore normal temperature within one day.

5. Turn the heater off when the pool will not be used
for an extended period.

6. Follow a regular program of preventive maintenance
for the heater each new swimming season. Check
operation of the heater and its controls.

WARNING

WARNING

7

CARE AND MAINTENANCE

MAINTENANCE INSTRUCTIONS

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.

The following maintenance is recommended every six
months and at the start of every swimming season:

1. Inspect the heater panels and venting system to

make sure that there are no obstructions to the flow
of ventilating air or burner exhaust. Check that room
air intakes are open and clear of obstructions.

2. Keep the area in and around the heater clear and

free from combustible materials, gasoline and other
flammable vapors and corrosive liquids.

3. Test the operation of the pressure relief valve by lift-

ing the valve lever.

4. Test for proper operation of the pressure switch. (See

“SWITCH SETTINGS” for testing instructions).

5. On enclosed installations with high-temperature

Special Gas Vent systems, repeat the “Final
Installation Check,” page 15. Check for evidence of
joint leakage. Make sure that joints have not slipped
partially or completely apart. Check pipe and fittings
for cracks or breaks.

The combustion air blower is permanently lubricated, and
does not require periodic lubrication. The burner does not
require maintenance or adjustment by the user. Call a
qualified service technician if you suspect that the burner
may require maintenance.

WINTERIZING

For outdoor heaters in freezing climates, shut the heater
down and drain it for winter as follows:

1. Turn off electrical supply to the heater and pump.

2. Close main gas control valve and manual gas valve

(located outside the heater). Turn switch on heater
gas valve to OFF.

3. Open drain cock located on the bottom of the manifold

adapter, and drain the heat exchanger and manifold
adapter completely. If heater is below pool water level,
be sure to close isolation valves to prevent draining
the pool (isolation valves are not required and should
not be used on heaters installed above pool water
level). Assist the draining by blowing out the heat
exchanger through the pressure switch fitting with low
pressure compressed air (less than 5 PSI or 35 kPa).

Explosion hazard. Purging the system with
compressed air can cause components to explode, with
risk of severe injury or death to anyone nearby. Use only
a low pressure (below 5 PSI or 35 kPa), high volume
blower when air purging the heater, pump, filter, or pip­ing.

4. Remove the Water Pressure Switch. Plug the port in

the manifold to prevent bugs and dirt from getting

into the manifold.

5. Drain the plastic inlet/outlet manifold through the
outlet pipe. If the pipe does not drain naturally to the
pool, install a drain cock in the outlet pipe to drain
the manifold.

6. Cover air inlet grate with a plastic bag to prevent
bugs, leaves, etc., from getting into the heater.

NOTICE: Water trapped in the heater can cause freeze
damage. Allowing the heater to freeze voids the
warranty.

To return the heater to service after winterizing:

1. Close drain cock and fittings.

2. Before starting the heater, circulate water through
the heater for several minutes until all air noises
stop. See also “BEFORE STARTUP” (Page 4) and
“CARE AND MAINTENANCE” (above).

INSTALLATION INSTRUCTIONS

Risk of fire, explosion, or asphyxiation if heater

is improperly installed, adjusted, serviced or maintained.
These instructions are for licensed, certified, trained and

experienced installers only. Be sure your installer or ser­vice technician holds all required licenses or certification
for your area. Attempts by unqualified persons to service
or repair this heater are dangerous and could be fatal.

PRE-EXISTING VENT SYSTEMS

If you are considering connecting this heater to a pre-exist­ing vent system, make sure that the vent system meets the
appropriate venting requirements as given in this manual,
Pages 9-15. If not, replace the vent system. DO NOT use a
draft hood with this heater.

PUTTING THE HEATER INTO SERVICE

If the heater is installed below the level of the pool, or
more than two feet above pool level, the pressure switch
setting should be adjusted. See PRESSURE SWITCH, in
the MAINTENANCE section.

Before putting the heater into service for the first time,
follow the instructions under “BEFORE START-UP” (page

4) in the front of this manual. Check for proper operation

of the heater by following the steps under “OPERATING
INSTRUCTIONS.”

Damage to equipment caused by improper installation or
repair will void the warranty.

WARNING

WARNING

WARNING

8

OUTDOOR INSTALLATION INSTRUCTIONS

For heaters located outdoors, using the built-in stackless
venting system.

Risk of explosion if a unit burning propane
gas is installed in a pit or other low spot. Propane is heav­ier than air. Do not install the heater using propane in pits
or other locations where gas might collect. Consult your
local building code officials to determine installation require­ments of heater relative to propane storage tanks and fill­ing equipment. Installation must meet the requirements of
the Standard for the Storage and Handling of Liquid
Petroleum

Gases, ANSI/NFPA 58 (latest edition) in the U.S., or
CAN/CSA B149.2 (latest edition) in Canada. Consult local codes
and fire protection authorities about specific installation restric­tions.

Locate the heater on a level surface in an open area that
is protected from drainage or run-off. Install the heater in
an area where leaves or other debris will not collect on
or around the heater.

This heater is designed for outdoor installation. However,
to avoid damage to the electronic components in the
heater, take care to prevent prolonged exposure to dri­ving sources of water (such as lawn sprinklers, heavy
roof runoff, hoses, etc.). Avoid operation in persistent,
extreme, moist or salty environments.

In extreme weather, shut down the heater and discon­nect the power to it until the weather has moderated. In
areas subject to hurricanes or very high winds, purchase
the Bolt Down Bracket Kit, Part No. 460738.

HEATER CLEARANCES – OUTDOOR

In the U.S.: If the heater is located under a roof or
deck overhang, there must be at least three feet (1M) of
clearance between the bottom of the overhang and the
top of the heater exhaust vent. If the heater is under a
roof or deck overhang, the space around the heater must
be open on three sides. See Figure 8 for minimum clear­ances.

For minimum exhaust vent clearances for building open­ings, see Figure 13, Page 15.

In Canada: If the heater is located under a roof or deck
overhang, there must be at least three feet (1M) of clear­ance between the bottom of the overhang and the top of
the heater exhaust vent. If the heater is under a roof or
deck overhang, the space around the heater must be
open on three sides. See Figure 8 for minimum clear­ances.

The heater must be installed with the top of the vent at
least 10 feet (3M) below, or to either side of, any open­ing into a building.

In the U.S. and Canada: The heater is certified for instal­lation on combustible flooring.

The following clearances must be maintained from
combustible surfaces:

TOP ...................................3 ft. (1 m)

EXHAUST SIDE................6 in. (15 cm)

HEADER SIDE..................18 in. (.5 m)

DOOR PANELS* ............12 in. (30 cm)

Note (*) For service access it is recommended to leave
at least 24 in. clearance for one of the door panels.

Orient the heater for convenient access to the water
connections and the gas and electrical connections.

Install the heater at least 18 in. (45 cm) from any
property line.

WARNING

9

(*) Recommended 24"

clearance or more on

one

or both door

(*) Recomme

panels for servicing

FIGURE 8: Combustible clearances

Leave at least 6 in. (15 cm) of clearance or more
between the heater and combustible surfaces

12 in.*

18 in.

12 in.*

6 in.

CONTROL PANEL INDEXING

The exhaust discharges vertically from outside the vent
cover. The heater control panel assembly located on the
top panel can be rotated to any of three positions for
convenient access to the panel as follows:

1. Remove the bolts from the door panels. Remove both

door panels.

2. Remove the four corner screws that secure the top

panel.

3. Lift the top panel upward to remove the top panel.

4. Rotate the top panel to the desired position located

at 90 degree angles. Note that the control board can­not be located on the same side as the exhaust.

5. Replace the top panel down onto the side panels. Be

sure that there are no wires caught under the panel.

6. Secure the top panel using the four corner screws.

7. Reattach the door access panels.

OUTDOOR SHELTER

INSTALLATION INSTRUCTIONS

This pool heater can only be installed outdoors or in an
enclosure that is not normally occupied and has no direct
openings into occupied areas.

Risk of asphyxiation if exhaust is not cor­rectly vented. Follow venting instructions exactly when
installing heater. Do not use a draft hood 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. Exhaust venting to the out­doors is required for all outdoor shelter installations.

Risk of explosion if a unit burning propane
gas is installed in a pit or other low spot. Propane is heav­ier than air. Do not install the heater using propane in pits
or other locations where gas might collect. Consult your
local building code officials to determine installation require­ments of heater relative to propane storage tanks and fill­ing equipment. Installation must meet the requirements for
the Standard for the Storage and Handling of Liquefied
Petroleum Gases, CAN/CSA B149.2 (latest edition) or
ANSI/NFPA 58 (latest edition). Consult local codes and fire

protection authorities about specific installation restrictions.

The heater is design certified by CSA International for
installation on combustible flooring; in alcoves; base­ments; in closet or utility rooms (in the U.S.)

INSTALLATION IN A GARAGE OR UTILITY ROOM

In Canada, the heater must be installed in a room that is
not normally occupied and has no openings directly to
occupied areas.

Risk of fire and explosion if installed at floor
level in an automotive garage or near gasoline or flam­mable liquid storage. Gasoline fumes are heavier than air
and will settle to floor level in closed spaces. Gasoline
fumes and spilled gasoline or other volatile liquids (such
as some paints and varnishes) will travel across the floor
and can be ignited by a gas appliance. In a utility room
or residential garage installation, install the heater with
the base at least 18 inches (.5M) above the floor. In a
garage, install a rail or wall to protect the heater from
physical damage by a moving vehicle.

Provide an adequate ventilation air supply (See Table 2,
Page 11). Choose a location that will avoid contamination
by chemical fumes.

NOTICE: A PROPANE (LPG) fired heater must not be
installed in a garage in Massachusetts, by order of the
Massachusetts State Fire Marshall. For more information,
call the State Fire Marshall’s office.

WARNING

WARNING

WARNING

10

FIGURE 9: Indexing Control Panel

FIGURE 10: Minimum outdoor shelter clearances (Canada)
or minimum garage or utility room clearances (U.S.)

Top panel

Door
access
panel

Door access
panel

18 in.

HEATER INSTALLATION IN A
GARAGE OR UTILITY ROOM

Leave 3 ft. (1 M) or
more of clearance
above heater

Leave 6 in. (15cm)
of clear space
between heater
and combustible
surface

RAISE AT LEAST
18 in. (.5M) above

floor to avoid
flammable vapors

NOTICE: Combustion air contaminated by corrosive
chemical fumes can damage the heater and will void the
warranty (See Table 1 below).

HEATER CLEARANCES –
OUTDOOR SHELTER (Canada) or INDOOR (U.S.)

The following clearances must be maintained from com­bustible surfaces:

TOP......................................3 ft. (1 m)

EXHAUST SIDE ................6 in. (15 cm)

HEADER SIDE...................18 in. (.5 m)

DOOR PANELS* .............12 in. (30 cm)

Note (*) For service access it is recommended to leave at
least 24 in. clearance for one of the door panels.

The heater is design certified by CSA International for
installation on combustible flooring. For installation on
carpeting, the heater must be mounted on a metal or
wood panel that extends at least three inches (10cm)
beyond the base of the heater. If the heater is installed
in a closet or alcove, the entire floor shall be covered by
the panel. On an outdoor shelter installation, the exhaust
discharges into a vent pipe. Orient the heater so that the
vent pipe does not interfere with adjustment of the operat­ing controls. The control panel located on the top panel can
be rotated to any of the three sides of the heater for easy
access. However, the control panel must not be located on
the side where the vent is located.

COMBUSTION AND VENTILATION AIR SUPPLY

For shelter installation, the heater requires air supply open­ings for ventilation and combustion. The minimum require­ments are for two (2) openings: one 12 inches (30cm)

from the ceiling for ventilation air and one 12 inches
(30cm) from the floor for combustion air, in accordance
with the latest edition of ANSI Z223.1, or the National Fuel
Gas code, the CSA B149.1, Natural Gas and Propane
Installation Codes, as applicable, and any local codes that
may apply.

The minimum net free area in square inches are as follows:

OUTDOOR SHELTER VENT INSTALLATION
(Canada) or INDOOR INSTALLATION (U.S.)

Always vent the heater to the outdoors.

• Vent it horizontally or vertically using a Special Gas

Vent, (see Table 4, Page 14), or

• Vent it vertically using Type “B” double wall vent con-

nector pipe.

Locate the heater so as to minimize the length of hori­zontal venting and the number of vent elbows required.
Horizontal vent runs must slope up 1/4" per foot (2cm/M)
from the heater to allow exhaust condensate to drain and
must have a condensate drain as described in the venting
installation instructions.

11

Area Likely Contaminants

Chlorinated swimming Pool or spa cleaning
pools and spas chemicals. Acids, such as

hydrochloric or muriatic acid

New construction and Glues and cements,
remodeling areas construction adhesives,

paints, varnishes, and
paint and varnish strippers.
Waxes and cleaners
containing calcium or
sodium chloride

Beauty parlors Permanent wave solutions,

bleaches, aerosol cans
containing chlorocarbons
or fluorocarbons

Refrigeration plants or Refrigerants, acids, glues
various industrial and cements, construction
finishing and processing adhesives
plants

Dry cleaning and Bleaches, detergents, or
laundry areas laundry soaps containing

chlorine.
Waxes and cleaners
containing chlorine,
calcium or sodium chloride

All Air From All Air From

Inside Building Outside Building

Model Combustion Vent Combustion Vent

200

100 sq. in. 100 sq. in. 50 sq. in. 50 sq. in.

645 sq. cm. 645 sq. cm. 323 sq. cm. 323 sq. cm.

250

125 sq. in. 125 sq. in. 63 sq. in. 63 sq. in.

807 sq. cm. 807 sq. cm. 403 sq. cm. 403 sq. cm.

300

150 sq. in. 150 sq. in. 75 sq. in. 75 sq. in.

969 sq. cm. 969 sq. cm. 485 sq. cm. 485 sq. cm.

400

200 sq. in. 200 sq. in. 100 sq. in. 100 sq. in.

1290 sq. cm. 1290 sq. cm. 645 sq. cm. 645 sq. cm.

Com

b

ustio

C

r

ent Bod

y

y

C

C

Table 1: Corrosive Vapors and Possible Causes

FIGURE 11: Flue Collar

Table 2: Combustion and Ventilation Air Requirements

lean the Interior Surface

4" x 8" Metal
Flue Collar

Vent Pipe

lean and RTV

This Surface

hambe

Flue Collar

OUTSIDE VENT COVER REMOVAL

The heater is supplied from the factory with a built-in
stackless outside vent for outdoor installation. Remove
the outside vent cover for outdoor shelter installation.

VERTICAL VENTING - NEGATIVE PRESSURE
(See Figures 11 and 12)

Vent the heater vertically in a
negative pressure (positive draft) system in accordance with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CSA B149.1, Natural Gas and Propane Installation Codes,
and local codes. Type “B” Double-wall vent connector is rec­ommended; however single-wall pipe is allowed by the
National Fuel Gas Code in some circumstances. Consult your
local code official for detailed information. Do not use a
draft hood with this heater.

To connect a negative pressure metal gas vent to the
heater, order the appropriate Metal Flue Collar from the
chart below:

1. See Table 3, below, to determine allowable vent sizes

for your heater.

NOTICE: Table 3 is for installations in which the total lat­eral vent length (that is, the horizontal distance from the
flue collar to the main vertical portion of the vent) is less
than 1/2 the total vent height (the vertical distance from
the flue collar to the vent termination) and which have
three or less elbows in the system. For venting systems
which do not meet these conditions, consult the National
Fuel Gas Code, ANSI Z223.1 (U.S.), or the standards CSA
B149.1 and B149.2 (Canada).

2. Install the metal Flue Collar in the Vent Body of the

heater (located under the outside vent cover). Fasten
the metal Flue Collar to the Vent Body with two #10
sheet metal screws. Use UltraCopper

®

silicone RTV to
seal the Flue Collar to the Vent Body. Before connecting
the metal Flue Collar to the Vent Body, wet a clean

cloth or paper towel with isopropyl alcohol (rubbing
alcohol) and vigorously wipe the socket of the Vent
Body. Immediately wipe the cleaned surfaces dry with
a clean cloth or paper towel. Repeat for the exterior of
the 4" end of the metal Flue Collar. Attach the metal
Flue Collar to the Vent Body using the RTV supplied
with the kit, following the vent manufacturer’s instruc­tions (included with kit). Do not use a draft hood with
this heater.

3. Attach the vent pipe to the metal Flue Collar with
sheet-metal screws.

Risk of fire or asphyxiation if vent is not
assembled according to manufacturer’s instructions or if
vent parts from different manufacturers are mixed. Vent
parts from different manufacturers ARE NOT interchange­able. Mixing parts from more than one manufacturer may
cause leaks or damage to vent. When assembling a vent,
pick one manufacturer and be sure that all vent parts
come from that manufacturer and are specified by the
manufacturer for your system. Follow manufacturer’s
instructions, local code requirements, National Fuel Gas
Code requirements (U.S.) or standards CSA B149.1 and
B149.2 (Canada) carefully during assembly and installa­tion.

4. Install vent pipe so that it can expand and contract

freely as the temperature changes. Support the vent
pipe according to applicable codes and the vent manu­facturer’s instructions. Pipe support must allow the
vent pipe free movement out and back, from side to
side, or up and down as necessary, without putting a
strain on the heater or vent body. Slope horizontal
pipe runs up from the heater at least 1/4" per foot
(2cm per meter). Install Listed condensate drains at
low points where condensate might collect. Plumb con­densate drains to a drain through hard piping or high­temperature tubing such as silicone rubber or EPDM
rubber – do not use vinyl or other low temperature
tubing. Follow drain manufacturer’s installation
instructions.

WARNING

12

Table 3: Permitted Minimum and Maximum Vent Heights By Size and Heater Model

Read “VERTICAL VENTING – NEGATIVE PRESSURE” (above) before using this table.

Type B Double Wall Vent With Type B Double Wall Connector In Feet (Meters)

Model 200 Model 250 Model 300 Model 400

Vent Size Height min./max. Height min./max. Height min./max. Height min./max.

6 in. 6 ft. (1.8)/100 ft. (30.5) 18 ft. (5.5)/100 ft. (30.5) 30 ft. (9)/100 ft. (30.5) Not Rec.
7 in. 6 ft. (1.8)/100 ft. (30.5) 8 ft. (2.4)/100 ft. (30.5) 10 ft. (3)/100 ft. (30.5) 15 ft. (4.6)/100 ft. (30.5)
8 in. 6 ft. (1.8)/100 ft. (30.5) 6 ft. (1.8)/100 ft. (30.5) 6 ft. (1.8)/100 ft. (30.5) 8 ft. (2.4)/100 ft. (30.5)
9 and 10 in. 6 ft. (1.8)/50 ft. (15.3) 6 ft. (1.8)/50 ft. (15.3) 6 ft. (1.8)/100 ft. (30.5) 6 ft.(1.8)/100 ft. (30.5)

Type B Double Wall Vent With Single Wall Connector In Feet (Meters)

Model 200 Model 250 Model 300 Model 400

Vent Size Height min./max. Height min./max. Height min./max. Height min./max.

6 in. 6 ft. (1.8)/15 ft. (4.6) 6 ft. (1.8)/15 ft. (4.6) Not Rec. Not Rec.
7 in. 6 ft. (1.8)/8 ft. (2.4) 6 ft. (1.8)/8 ft. (2.4) 10 ft. (3)/20 ft. (6) 15 ft. (4.6)/50 ft. (15.3)
8 in. Not Rec. Not Rec. 6 ft. (1.8)/20 ft. (6) 8 ft. (2.4)/20 ft. (6)
9 in. Not Rec. Not Rec. Not Rec. 6 ft. (1.8)/6 ft. (1.8)
10 in. Not Rec. Not Rec. Not Rec. Not Rec.

Metal Flue Collar Part No.

4x6" 77707-0076

4x8" 77707-0077