Pentair SR200NA, SR200LP, 460768, SR200HD, SR333NA Installation And User Manual

®

STA-RITE

MAX-E-THERM® POOL AND SPA HEATER

INSTALLATION AND USER’S GUIDE

FOR YOUR SAFETY - READ BEFORE OPERATING

Warning:

120/240 VAC NATURAL GAS/LP GAS

If you do not follow these instructions exactly , a fire or explosion may result, causing
property damage, personal injury or loss of life.
For additional free copies of this manual; call [phone].

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MODELS Natural Propane HD

200K BTU/HR SR200NA SR200LP SR200HD

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250K BTU/HR (ASME) 460767 460768
333K BTU/HR SR333NA SR333LP SR333HD
400K BTU/HR SR400NA SR400LP SR400HD
400K BTU/HR (ASME) 460763 460764

FOR YOUR SAFETY - This product must be
installed and serviced by authorized personnel,
qualified inpool/spa heater installation. Improper
installation and/or operation can create carbon
monoxide gas and flue gases which can cause
serious injury, property damage, or death. For
indoor installations, as an additional measure of
safety, Pentair Aquatic Systems strongly
recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this appliance
and in any adjacent occupied spaces. Improper
installation and/or operation will void the warranty.

OWNER:

Retain For

Reference

Warning: Improper installation, adjustment, alteration, service or maintenance can cause property

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

Future

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

For Your
Safety

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

• 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 dep artment.

DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity
of this or other appliances.

1620 Hawkins Ave., Sanford, NC 27330 • [phone] or [phone]

10951 W. Los Angeles Ave., Moorpark, CA 93021

Pentair Water Pool and Spa, Inc.

• [phone] or [phone]

2

Customer Service and Technical Support

If you have questions about ordering P entair Aquatic Systems replacement parts, and pool
products, please call:

Phone: [phone]
Fax: [phone]
(8 A.M. to 4:30 P.M. Eastern Time/Pacific Time)

Web sites

www.pentairpool.com - www .staritepool.com

P/N S794 REV H 8/14

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

Contents

Section 1. Introduction .......................................................................................................... 4

Importan t Notices................................................................................................................................................................................. 4

Warra nty In forma tion............................................................................................................................................................................ 4

Code Requirements .............................................................................................................................................................................. 5

Consumer Information and Safety Information ...................................................................................................................................... 6 - 8

General Specifications ......................................................................................................................................................................... 8

Section 2. Installation ............................................................................................................. 9

Heater Description................................................................................................................................................................................ 9

Sequence of Operation/Putting the Heater into Service ........................................................................................................................ 9

Specifications ...................................................................................................................................................................................... 10

Plumbing Connections.......................................................................................................................................................................... 11

Valves.................................................................................................................................................................................................. 11

Manual By-Pass .................................................................................................................................................................................. 11

Water Connections ............................................................................................................................................................................... 12

Below Pool Installation ......................................................................................................................................................................... 12

Gas Con nectio ns ................................................................................................................................................................................. 13

Sedime nt Tra ps.................................................................................................................................................................................... 13

Gas Pipe Sizing ................................................................................................................................................................................... 14

T esting Gas Pressure/Gas Pressure Requirements ............................................................................................................................. 15

Outdoor Installation .............................................................................................................................................................................. 16

Outdoor Installation Venting Guidelines ................................................................................................................................................ 17

Indoor Venting— General Requirements (Category I & Category III – clarification) ............................................................................... 18

Heater Clearances................................................................................................................................................................................ 18

Outside Vent Removal ......................................................................................................................................................................... 18

Combustion Air Supply ......................................................................................................................................................................... 19

Corrosive V apors and Possible Causes ................................................................................................................................................ 19

V ent Installation (Indoor Installation for U.S. or Outdoor Shelter for Canada) ........................................................................................ 20

Vertical V enting - Negative Pressure / Direct Air Intake with 3-inch PVC Pipe (indoor Installation)...................................................... 20 - 22

Horizontal or V ertical Venting - Positive Pressure................................................................................................................................ 23

Connecting Special Gas Venting .......................................................................................................................................................... 23 - 25

Outdoor Shelter Installation .................................................................................................................................................................. 26

Garage or Utility Room Installation ....................................................................................................................................................... 26

Control Panel Indexing ......................................................................................................................................................................... 27

Final Installation Check ........................................................................................................................................................................ 27

Electrical Connections.......................................................................................................................................................................... 28

Fireman’s Switch Connection/Remote Control Connections .................................................................................................................. 29

Max-E-Therm heater

Electrical Schematic Ladder Diagram ................................................................................................................................................... 31

Section 3. Operation ............................................................................................................... 32

Basic System Operation ...................................................................................................................................................................... 32

HSI (Hot-Surface Ignition) Lighting/Operation ....................................................................................................................................... 32

Operating Instructions .......................................................................................................................................................................... 33

To Turn Of f Gas to Appliance............................................................................................................................................................... 33

Safety Controls .................................................................................................................................................................................... 34 - 36

Section 4. Troubleshooting ................................................................................................... 37

Initial Troubleshooting and Troubleshooting Chart ................................................................................................................................. 37

Heater Will Not Fire Troubleshooting .................................................................................................................................................... 38 - 41

LED Diagnostics .................................................................................................................................................................................. 42 - 43

Burner / Heat Exchanger Troubleshooting ............................................................................................................................................ 44

Section 5. Maintenance ..........................................................................................................45

Care and Maintenance.......................................................................................................................................................................... 45

Pressure Relief V alve........................................................................................................................................................................... 45

After Start-Up ...................................................................................................................................................................................... 46

Spring, Fall and Winter Operation ......................................................................................................................................................... 46

Maintaining Pool T emperature............................................................................................................................................................... 47

Energy Saving Tips.............................................................................................................................................................................. 47

Chemical Balance ................................................................................................................................................................................ 47 - 48

Replacement Parts .............................................................................................................................................................................. 49 - 53

®

Wiring Diagram .................................................................................................................................................. 30

3

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

4

Introduction

Section 1. Introduction

Max-E-Therm

®

Pool and Spa Heater

Congratulations on your purchase of a Max-E-Therm high performance heating system. Proper installation and service
of your new heating system and correct chemical maintenance of the water will ensure years of enjoyment. The
Max-E-Therm heater is a lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be
directly connected to schedule 40 PVC pipe, [schedule 80 CPVC for ASME models only]. The Max-E-Therm heater also
comes equipped with the Pentair multifunction temperature controller which shows, at a glance, the proper functioning of
the heater. All Max-E-Therm heaters are designed with a direct ignition device, HSI (hot-surface ignition), which eliminates
the need for a standing pilot. The Max-E-Therm heater requires an external power source (120/240 VAC 60 Hz) to
operate.

SPECIAL INSTRUCTIONS TO OWNER: Retain this manual for future reference. This instruction manual provides
operating instructions, installation and service information for the Max-E-Therm heater high performance heater. The
information in this manual applies to all Max-E-Therm heater models. READ AND REVIEW THIS MANUAL
COMPLETELY, it is very important that the owner/installer read and understand the section covering installation
instructions, and recognize the local and state codes before installing the Max-E-Therm heater. Its use will reduce service
calls and chance of injury and will lengthen product life. History and experience has shown that most heater damage is
caused by improper installation practices.

IMPORTANT NOTICES

...For the installer and operator of the Max-E-Therm pool and spa heater. The manufacturer’s warranty may be void if,
for any reason, the heater is improperly installed and/or operated. Be sure to follow the instructions set forth in this
manual. If you need any more information, or if you have any questions regarding to this pool heater, please contact
Pentair Aquatic Systems at [phone].

WARRANTY INFORMATION

The Max-E-Therm pool heater is sold with a limited factory warranty. Specific details are described on the warranty
registration card which is included with the product. Return the warranty registration card after filling in the serial

number from the rating plate inside the heater.

The high standards of excellence of Pentair Aquatic Systems includes a policy of continuous product improvement
resulting in your state-of-the-art heater. We reserve the right to make improvements which change the specifications
of the heater without incurring an obligation to update the current heater equipment.

These heaters are designed for the heating of chlorine, bromine or salt system swimming pools and spas or
in non-stationary installations, and should never be employed for use as space heating boilers or general
purpose water heaters. The manufacturer’s warranty may be void if, for any reason, the heater is improperly
installed and/or operated. Be sure to follow the instructions set forth in this manual.

CAUTION

OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 68° F. WILL CAUSE HARMFUL
CONDENSATION AND WILL DAMAGE THE HEATER AND VOID THE WARRANTY. Do not use the heater to protect
pools or spas from freezing if the final maintenance temperature desired is below 68° F., as this will cause condensation
related problems.

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

Section 1. Introduction

5

CODE REQUIREMENTS

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 – INSTALLA TION
CODES FOR GAS-BURNING 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.

DANGER

CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains toxic levels of carbon monoxide, a dangerous,

poisonous gas you cannot see or smell.

CONSUMER INFORMATION AND SAFETY

WARNING

The U.S. Consumer Product Safety Commission warns that elevated water temperature can be hazardous.
See below for water temperature guidelines before setting temperature.

1. Spa or hot tub water temperatures should never exceed 104° F. A temperature of 100° F is considered safe for a
healthy adult. Special caution is suggested for young children. Prolonged immersion in hot water can induce hyperthermia.

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 100° F 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 stick to the 100° F
maximum rule.

4. Before entering the spa or hot tub, the user should check the water temperature with an accurate thermometer.
Spa or hot tub thermostats may err in regulating water temperatures by as much as 4° F.

5. Persons with a 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 medication which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants should not
use spas or hot tubs.

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater.
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 control system and gas control which has been under water.

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

WARNING

6

Section 1. Introduction

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

SAFETY INFORMATION

The Max-E-Therm® pool heaters are designed and manufactured to provide many years of safe and reliable service when
installed, operated and maintained according to the information in this manual. Throughout the manual, safety warnings and
cautions are identified by the “ “ symbol. Be sure to read and comply with all of the warnings and cautions.

DANGER —

CARBON MONOXIDE GAS IS DEADLY

READ OWNERS MANUAL COMPLETELY BEFORE OPERATING

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.

Exhaust from this pool heater contains toxic levels of carbon monoxide, a dangerous, poisonous gas
you cannot see or smell. Symptoms of carbon monoxide exposure or poisoning include dizziness,
headache, nausea, weakness, sleepiness, muscular twitching, vomiting and inability to think clearly.
IF YOU EXPERIENCE ANY OF THE ABOVE SYMPTOMS, IMMEDIATELY TURN OFF THE POOL
HEATER, LEAVE THE VICINITY OF THE POOL OR SPA AND GET INTO FRESH AIR IMMEDIATELY.
THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE
RESUMING OPERATION.

EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR DEATH.

NEVER use this pool heater indoors without specified ventilation system (and properly installed vent pipe).
NEVER use this pool heater in the home or in partly enclosed areas (such as garages), unless

the specified ventilation system is used. If used outdoors, install far from open windows, doors,
vents and other openings.

Pentair strongly recommends that all vents, pipes and exhaust systems be initially and periodically
tested for proper operation. This testing can be accomplished by using a hand-held carbon monoxide
meter and/or by consulting with a gas professional.

Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool heater.
The carbon monoxide detectors must be periodically inspected for proper operation so as to insure
continued safety. Broken or malfunctioning carbon monoxide detectors must be replaced immediately.

WARNING — 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.

WARNING —

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

This heater 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.

Section 1. Introduction

SAFETY INFORMATION, (cont’d.)

7

WARNING —

WARNING —

WARNING —

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, 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).

WARNING —

WARNING —

CAUTION —

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.
A vent conversion kit (See

Page 23 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 19 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., Single 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.

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

8

Section 1. Introduction

GENERAL SPECIFICATIONS

NOTICE:

• Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty.

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

• 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.

• The heater is designed for the heating of chlorine, bromine or salt system swimming pools and spas. It should NOT
be used as a space heating boiler, or general purpose water heater. 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 “Heater Clearances”,

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.

page 18).

• The heater may not be installed within 5 ft. (1.5M ) of the inside surface of a pool or spa unless it is separated by a solid
fence, wall or other permanent barrier.

CONSUMER INFORMATION AND SAFETY

WARNING

The U.S. Consumer Product Safety Commission warns that carbon monoxide is an "invisible killer". Carbon monoxide
is a colorless and odorless gas.

1. Carbon monoxide is produced by burning fuel, including natural gas and propane.

2. Proper installation, operation and maintenance of fuel-burning appliances in the home is the most important
factor in reducing carbon monoxide poisoning.

3. Be sure that fuel burning appliances such as heaters are installed by professionals according to manufacturer's
instructions and codes.

4. Always follow the manufacturer's directions for safe operation.

5. Have the heating system (including vents) inspected and serviced annually by a trained service technician.

6. Examine vents regularly for improper connections, visible cracks, rust or stains.

7. Install battery-operated carbon monoxide alarms. The alarms should be certified to the requirements of the
most recent UL, IAS, CSA and IAPMO standard for carbon monoxide alarms. Test carbon monoxide alarms
regularly and replace dead batteries.

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

Section 2. Installation

Installation Instructions

HEATER DESCRIPTION

9

Figure 1 is a diagram of the heater showing how it operates. Precisely

matched orifice plates meter the air and gas into the mixer. The

Gas

blower draws the air and gas through the mixer and forces it into
the burner’s flame holder. A sealed heat exchanger surrounds the
flame holder, dischar ging exhaust gases out the flue.

Air

Blower

Exhaust

T wo 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

Inlet
(Cold
Water)

Mixer

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

Outlet
(Mixed
Water)

Burner

Heating Coils

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

Figure 1.

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 air flow switch (AFS), which senses the pressure drop across the air metering orifice,

•the automatic gas shut-off (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 480° F (249° C).

The air flow switch (AFS) senses the pressure drop across the air metering orifice. As soon as there is suf ficient 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.

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 WATER PRESSURE SWITCH, in the SAFETY CONTROLS Section.

Before putting the heater into service for the first time, follow the instructions under “BEFORE ST AR T -UP” ( page 32) in
the front of this manual. Check for proper operation of the heater by following the steps under “OPERATION
INSTRUCTIONS.”

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

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

10

Section 2. Installation

SPECIFICATIONS

These installation instructions are designed for use by qualified personnel only, trained especially for installation of this
type of heating equipment and related components. Some states require installation and repair by licensed personnel. If
this applies in your state, be sure your contractor bears the appropriate license. See Figure 2 for Outdoor and Indoor
Installations.

DIMENSIONS IN INCHES

13.59

30.03

19.41

25.15

FRONT VIEW

H O T

DRAIN

KEEP OPEN

INLET

4.57

9.19

4.62

OUTLET

18.02

31.69

RIGHT SIDE VIEW

25.83

.63

14.94

4.87

BACK VIEW

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

TOP VIEW

Figure 2.

r

Out to Pool or Spa

l

Section 2. Installation

PLUMBING CONNECTIONS

11

The Max-E-Therm® heater has the unique capability of direct
schedule 40 PVC, [schedule 80 CPVC for ASME models]

Modular Media

Filter

TM

From Filter Outlet

to Heater

Inlet

plumbing connections. A set of bulkhead fittings is included
with the Max-E-Therm heater to insure conformity with
Pentair’s recommended PVC plumbing procedure. Other
plumbing connections can be used. See

Figure 3 for plumbing

connections.

CAUTION

Before operating the heater on a new installation, turn
on the circulation pump and bleed all the air from the

To Filter

Inlet

Corrosion Resistant,

Positive Seal

Check Valve

Cool Water
In From Spa

Warm Wate

To Poo

To Spa

Sanitizer

filter using the air relief valve on top of the filter. Water
should flow freely through the heater. Do not operate
the heater unless water in the pool/spa is at the proper

Cool Water
In From Pool

Figure 3.

Typical Installation

level. If a manual by-pass is installed, temporarily close it
to insure that all air is purged from the heater.

VALVES

When any equipment is located below the surface of the pool or spa, valves should be placed in the circulation piping
system to isolate the equipment from the pool or spa. Check valves are recommended to prevent back-siphoning. Back­siphoning is most likely to occur when the pump stops, creating a pressure-suction differential. Do NOT sanitize the pool
by putting chlorine tablets or sticks into the skimmer(s). When the pump is off, this will cause a high concentration of
chlorine to enter the heater, which could cause corrosion damage to the heat exchanger.

CAUTION

Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater, filters
or pump. When chemical feeders are installed in the circulation of the piping system, make sure the feeder outlet line
is down stream of the heater, and is equipped with a positive seal noncorrosive “Check Valve”, (P/N R172288),
between the feeder and heater.

MANUAL BY-PASS

Where the water flow rate exceeds the maximum 120 GPM, a manual bypass
should be installed and adjusted. After installing the valve, adjust the valve to
bring the flow rate within the acceptable range. Then remove the valve handle
or lock it in place to avoid tampering. See

ledoM)MPL()MPG(.niM*)MPL()MPG(.xaM

002)67(02)454(021

333)521(33)454(021

004)251(04)454(021

See page 45 for Pressure Relief Valve Installations.

Figure 4.

.gnipipgnitcennocehtrofetar

wolfdednemmocermumixamehtdeecxetonoD*

Table 1.

Warm Water Out

1. Set Manual
Bypass Valve

2. Remove handle

Figure 4.

Cool Water In

Outlet to

Pool

Inlet from

Filter

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

12

Section 2. Installation

WATER CONNECTIONS

Figure 5.

The heater requires proper water flow and pressure for its
operation. See

Figure 5 for the recommended installation.

The filter pump discharges to the filter , the filter discharges
to the heater, and the heater discharges directly to the pool
or spa.

A manual bypass valve should be installed across the heater
when the pump flow exceeds 120 GPM (454 LPM). See
“WATER FLOW RATE” on

page 11- Table 1 for setting of

the manual by-pass valve.

Main

Drain

Pool

Make sure that the outlet plumbing from the heater contains
no shut-off valves or other flow restrictions that could prevent
flow through the heater (except for below pool installations
as noted below

, or winterizing valves where needed). To
switch flow between the pool and spa, use a diverter valve.
Do not use any valve that can shut off the flow.

From Pool

3-Way

Valve

Install the chemical feeder downstream of the heater. Install
a chemical resistant one-way check valve between the heater and the chemical feeder to prevent back-siphoning through
the heater when the pump is off.

NOTICE: If the heater is plumbed in backwards, it will cycle continuously. Make sure piping from filter is not reversed
when installing heater.

Connect the heater directly to 2" PVC pipe, using the integral unions provided. Heat sinks are not required. The low
thermal mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down
unexpectedly.

Occasionally a two-speed pump will not develop enough pressure on the low speed to operate the heater. In this case, run
the pump at high speed only to operate the heater. If this does not solve the problem, do not try to run the heater. Instead,
correct the installation.

Do not operate the heater while an automatic pool cleaner is also operating. If the circulation pump suction is plugged (for
example by leaves), there may not be adequate flow to the heater. Do not rely on the pressure switch in this case.

3-Way

Valve

Spa

Chlorinator

Check Valve

Heater

Filter

Pump

3-Way

Valve

BELOW POOL INSTALLATION

If the heater is below water level, the pressure switch must be adjusted. This adjustment must be done by a qualified
service technician.

See following CAUTION before installation.

BELOW OR ABOVE POOL INSTALLATION

The water pressure switch is set in the factory at 3.00 PSI (± 0.75 PSI). This setting is for a heater installed at pool level.
If the heater is to be installed more than 1’ above or below, the water pressure switch must be adjusted by a qualified
service technician.

If the heater is installed more than 5’ above the pool or more than 4’ below the pool level, you will be beyond the limits
of the pressure switch and a flow switch must be installed. Locate and install the flow switch externally on the outlet
piping from the heater, as close as possible to the heater. Connect the flow switch wires in place of the water
pressure switch wires.

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

See page 34, Figure 32.

CAUTION

FLOW SWITCH

Section 2. Installation

GAS CONNECTIONS

GAS LINE INSTALLATIONS

Before installing the gas line, be sure to check which gas the heater has been designed to burn. This is important because
different types of gas require different gas pipe sizes. The rating plate on the heater will indicate which gas the heater is
designed to burn. The tables, shown on
the heater. The table is for natural gas at a specific gravity of .65 and propane at a specific gravity of 1.55.

When sizing gas lines, calculate three (3) additional feet of straight pipe for every elbow used. When installing the gas line,
avoid getting dirt, grease or other foreign material in the pipe as this may cause damage to the gas valve, which may result
in heater failure.

The gas meter should be checked to make sure that it will supply enough gas to the heater and any other appliances
that may be used on the same meter. The gas line from the meter will usually be of a larger size than the gas valve
supplied with the heater. Therefore a reduction of the connecting gas pipe will be necessary. Make this reduction
as close to the heater as possible.

The heater requires a gas supply of not less than 4" (10.2cm) wc and not more than 14" (35.6cm) wc. Gas supply
pressures outside of this range may result in improper burner operation. A minimum flowing or dynamic inlet pressure
(while the heater is running) of 4" (10.2cm) wc is required to maintain input rating with no more than a 2” pressure drop
between static and dynamic. The gas supply must be installed in accordance with the National Fuel Gas Code,
ANSIZ223.1, or standard CSA B149.1, Natural Gas and Propane Installation Codes, as applicable and all applicable
local codes. Install a manual shut-off valve and a sediment trap and union located outside the heater panels, see
Do not use a restrictive gas cock. The following minimum gas pipe sizes are recommended for natural gas supply piping,
see Table 2 on page 14. For low pressure LP gas, pipe size may be reduced by 1/4", with a minimum pipe size of 1/2".
Check for compliance with local codes.

page 14, show which size pipe is required for the distance from the gas meter to

Figure 6.

13

The heater and any other gas appliances must be disconnected from the gas supply piping system during any pressure
testing on that system, (greater than ½ PSI). The heater and its gas connection must be leak tested before placing the
heater in operation. Do not use flame to test the gas line. Use soapy water or another nonflammable method.

NOTE

A manual main shut-off valv e must be installed externally to the heater.

WARNING

DO NOT INSTALL THE GAS LINE UNION INSIDE THE HEATER CABINET. THIS WILL VOID YOUR WARRANTY.

SEDIMENT TRAPS

Install a sediment trap and union located outside the heater
panels in accordance with National code requirements. Do
not use a restrictive gas cock. The sediment trap shall be
either a tee fitting with a capped nipple in the bottom outlet
which can be removed for cleaning, as illustrated in
or an other device recognized as an effective sediment
trap. All gas piping should be tested after installation in
accordance with local codes.

Figure 6,

18–24" of 3/4"
Gas line from
Valve

Union

Sediment
Trap

1" Dia. or larger

(See "Recommended
Pipe Sizes" Chart)

Bell
Reducer

At least 9"

At least 3"

Figure 6.

Manual
Shut-off
Valve

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

14

GAS PIPE SIZING

Section 2. Installation

Table 2.

SNOITCENNOCENILSAGROFGNIZISEPIP

HTGNELEPIPTNELAVIUQEMUMIXAM

).tF(

tooFcibuCrep.U.T.B0001tasaGlarutaN

tooFcibuCrep.U.T.B0052tasaGenaporP

”2/1”4/3”1”4/1-1”2/1-1”2”2/1-2

LEDOM

TANORPTANORPTANORPTANORPTANORPTANORPTANORP
002-’02’03’08’521’052’054’006 -----­333--’01’03’05’001’002’053’004’006 ---­004 --- ’01’02’06’001’051’002’054’004 ---

“RESIDENTIAL”

PROPANE

GAS 2 ST AGE REGULATION

In many Propane gas line installations, the gas supplier and/or installer will utilize a two stage regulation process
where by at the supply tank they will install the first stage gas regulator, which would be at a higher pressure, usually
10 psi. This higher pressure allows for a much longer distance and in a much smaller pipe size. Then within a short
distance of the pool heater, usually around 24 inches, they will install a second regulator, which is the second stage,
and this would be set at the required inlet pressure of the heater.

See “Gas Pressure Requirement Charts”

gniziSepiPsaG"erusserPwoL"owTegatS

HTGNELEPIPTNELAVIUQEMUMIXAM

Table 4.

ledoM.tF05ot0.tF001ot05.tF051ot001

004hguorht002.ni2/1.ni2/1.ni2/1

gniziSepiPsaG"erusserPhgiH"enOegatS

.TF.UCreP.U.T.B0052@ISP01

HTGNELEPIPTNELAVIUQEMUMIXAM

ledoM.tF01ot0.tF02ot01

004hguorht002.ni4/3.ni4/3

Ta b l e 3 .

.C.W.ni41tates2egatS

“RESIDENTIAL”

In many Natural gas line installations, the gas supplier and/or installer may utilize a two stage regulation process
where by at the streets main gas supply they will install the first stage gas regulator, which would be at a higher
pressure. This higher pressure is usually set at 2 psi or 5 psi and can be for long distances and in a much smaller pipe
size. Then within a short distance of the pool heater, generally around 24 inches, they will install a second regulator,
which is the second stage. This second stage regulator would be set at the minimum operating pressure for the heater.
For “Natural Gas Pentair Pool Heaters” the minimum is 7 inches W.C.

See “Gas Pressure Requirement Charts”

ledoM.tF05ot0.tF001ot05.tF051ot001

333hguorht002.ni2/1.ni2/1.ni2/1

004.ni4/3.ni4/3.ni

004hguorht002.ni2/1.ni2/1.ni2/1

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

NATURAL

gniziSepiPsaG"erusserPhgiH"enOegatS

.TF.UCreP.U.T.B0001@ISP2

HTGNELEPIPTNELAVIUQEMUMIXAM

4/3

.TF.UCreP.U.T.B0001@ISP5

Table 5.

GAS 2 STAGE REGULATION

gniziSepiPsaG"erusserPwoL"owTegatS

.C.W.ni7tates2egatS

HTGNELEPIPTNELAVIUQEMUMIXAM

ledoM.tF01ot0.tF02ot01

333hguorht002.ni4/3.ni4/3

004.ni4/3.ni1

.C.W.ni7tates2egatS

004hguorht002.ni4/3.ni1

Table 6.

Section 2. Installation

15

TESTING GAS PRESSURE

Before operating the heater, the heater and its gas connections must be leak tested. Do NOT use an open flame to test
for leaks. Test all gas connections for leaks with soapy water or another non-flammable method (see page 14).

The heater and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

The heater must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure
testing of the gas supply at test pressures equal to or less than 1/2 psig (3.5 kPa).

CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE

WARNING

Risk of fire and explosion. Improper installation, incorrect adjustment, alteration, service, or maintenance of the Combination

Gas Control Valve can lead to fire or explosion, causing loss of life, personal injury, and/or property damage. If it is necessary
to adjust the gas valve, this must be done by only by a qualified service agency. These instructions are for the use of

qualified service technicians only!

This appliance is equipped with an unconventional gas control valve that is factory set with a manifold pressure of –.2"
(–0.5cm) wc. Installation or service must be performed by a qualified installer, service agency, or the gas supplier. If this
control valve is replaced, it must be replaced with an identical control.

The combination gas
valve incorporates dual
shut-off valves and a
negative-pressure regulator.
For proper operation, the
regulated pressure at the

To Air Flow
Switch

Connection

for Service

To Air Flow
Switch

To Gas
Valv e V ent

To Gas
Valve Vent

outlet manifold of the valve
must be –0.2" (–0.5cm) wc
below the reference pressure
at the blower mixer inlet,
and the gas valve ‘VENT’
tap must be connected to the
end cap air orifice as shown
in

Figure 7.

To Low Side of
Differential Pressure Gauge

Pressure Tap

Do not attempt to adjust the gas input by adjusting the regulator setting. The correct gas regulator setting is
required to maintain proper combustion and must NOT be altered.

Vent

Connection

for Test

To High Side
of Differential
Pressure Gauge

Figure 7.

Pressure Tap
Inlet

The use of Flexible Connectors (FLEX) is NOT recommended unless they are properly sized according to the
supplier recommendations for the heater rating.

GAS PRESSURE REQUIREMENTS

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

CAUTION

:ETON retaehelihw

.smelborp

erusserPsaG

telnImumixaM

telnImuminiM

dlofinaM

larutaNenaporP

.C.WsehcnI

4141

44

1.0±2.0-1.0±2.0­nekatebtsumsgnidaerllA

edamsgnidaerrostnemtsujdaynA.gnitareposi
ecnamrofrepnitluserlliwffosiretaehelihw

Table 7.

16

Section 2. Installation

OUTDOOR INSTALLATION

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

(U.S. and Canada)

WARNING

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 and specific installation restrictions of the heater relative to propane storage tanks and
filling equipment. Installation must meet the requirements for 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.

T o 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, P/N 42001-0085S, see

Figure 8.

Bolt Down Bracket Kit

P/N 42001-0085S

Lead
Anchor

HEATER CLEARANCES – OUTDOOR

IMPORTANT!

• In an outdoor installation it is important to ensure water is diverted from
overhanging eves with a proper gutter/drainage system. The heater must
be set on a level foundation for proper drainage.

• This unit shall not be operated outdoors at temperatures below -20oF.

If the heater is located under a roof 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, see Figure 9. If the heater is under a roof overhang, the space
around the heater must be open on three sides. DO NOT, under any

circumstances, install the heater under ANY deck.

For minimum exhaust vent clearances for allbuilding openings, includin g bu t
not limited to vented eaves, doors, windows, gravity air inlet, see

page 1

7.

In Canada, the heater must be installed with the top of the vent at least 10 feet
(3M) below

page 17

Orient the heater for convenient access to the water connections and the gas
and electrical connections. Note: Check local building codes for installing

the heater from any property line set back requirements.

, or to either side of, any opening into a building, see

.

Figure 10,

Figure 11,

Figure 8.

3 ft. (1 M) or more

CAUTION

If installing the heater next to or near an air conditioning unit or a heat
pump, allow a minimum of 36 in. between the air conditioning unit
and the heater.

MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev. H 8-11-14

Figure 9.

Section 2. Installation

OUTDOOR INSTALLATION

SIDE VIEW

Building

6 in.

Exhaust
Grill
(Vent)

From building wall

VENTING GUIDELINES

From window or door

4'

3'

4'

Property Line

4'

Exhaust
Grill

Force

Air Inlet

(Vent)

Check local building codes

for setback requirements.

Vent Termination:

Must be at least 3 ft. above any forced
air inlet located within a 10 ft. radius.

Must be located 6 in. away from the building
wall and the following distances away from any building
wall openings, included but not limited to vented eaves,
doors, windows, gravity air inlet:

4 ft. below,
4 ft. horizontally

17

Building

OUTDOOR INSTALLATION

VENTING GUIDELINES

FOR CANADA

SIDE VIEW

6 in.

(15.24cm)

Exhaust
Grill
(Vent)

From building wall

10'

(3M)

3'

(.9M)

10'

(3M)

Property Line

10'

(3M)

Exhaust
Grill

Force

Air Inlet

(Vent)

Check local building codes

for setback requirements.

Vent Termination:

Must be at least 3 ft. (.9M) above any forced
air inlet located within a 10 ft. (3M) radius.

Must be located 6 in. (15.24cm) away from the building
wall and the following distances away from any building
wall openings, included but not limited to vented eaves,
doors, windows, gravity air inlet:

10 ft. (3M) below,
10 ft. (3M) horizontally

Figure 10.

From window or door

P/N S794 Rev. H 8-11-14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide

Figure 11.