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

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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 (800) 831-7133 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

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.

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

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

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.

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

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

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

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

(*) 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

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

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.

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

ustio

ent Bod

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

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

5. Use Listed firestop for floor and ceiling penetrations. Use Listed thimble for wall penetrations. Use a Listed roof flashing, roof jack, or roof thimble for all roof penetrations. Do not fill the space around the vent (that is, the clear air space in the thimble or firestop) with insulation. The roof opening must be located so that the vent is vertical.

6. Do not run the heater vent into a common vent

with any other appliance.

7. Fire Hazard. Do not vent the heater directly into a masonry chimney. Installation into a masonry chimney must use a chimney liner and must meet the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes requirements and all local code requirements.

HORIZONTAL OR VERTICAL VENTING POSITIVE

PRES

SURE (See Figure 13)

Vent the heater either horizontally or vertically using one of the 4-inch Special Gas Vent Pipes listed on Table 5 (Page 14). Install the vent pipe in accordance with local codes and the provisions of the National Fuel Gas Code, ANSI Z223.1 (U.S.), or the standards CSA B149.1, Natural Gas and Propane Installation Codes (Canada), and the vent manufacturer’s instructions. Do not use a draft hood with this heater. Use one of the special gas vents specified in Table 5 (Page 14) for positive-pressure venting of this heater – do not use any other vent with it. Install the vent according to the vent manufacturer’s detailed instructions.

Maintain clearance between the vent pipe and combustible surfaces according to the vent manufacturer’s instructions and code requirements. Do not place any insulating materials around the vent or inside the required clear air space surrounding the vent. See Table 6 (Page 15) for maximum permissible vent lengths. See Table 7 (Page 15) for Listed vent components.

CONNECTING SPECIAL GAS VENT TO THE HEATER

Metallic:

1. Order an Appliance Adapter kit:

- Part No. 77707-0086 for Saf-T Vent

or Saf-T Vent® CI.

- Part No. 77707-0087 for Z-Vent.

2. Remove the outside vent cover.

3. Install the Appliance Adapter in the Vent Body of the heater (located under the outside Vent Cover). Before connecting the Appliance Adapter 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 heater end of the Appliance Adapter. Attach the appliance adapter to the vent body using the adhesive specified by the vent manufacturer, following the vent manufacturer’s instructions.

Risk of carbon monoxide poisoning if adapter is improperly attached. Mechanical connections (such as screws) can cause cracking and leaks in the adapter. Do not drill holes or use screws to connect the appliance adapter to the heater vent body. Attach with manufacturer’s specified adhesive.

WARNING

FIGURE 12A: Typical Metal Vent Pipe Installation-Canada (Vertical – Negative Pressure)

FIGURE 12B: Typical Metal Vent Pipe installation-U.S. (Vertical – Negative Pressure)

Listed Termination

Min. 2 Ft.

(.7 M)

Min. 10 Ft. (3.3 M)

Cap

Storm Collar

Flashing

6" (15 cm) Minimum Clearance to Combustible Materials

Type B Double Wall

Metal Vent Pipe

Metal Flue

Ven t

Body

2731 1296 CAN

Collar

Condensate Drain w/trap

Firestop

Type B Double Wall

Metal Vent Tee

Support Vertical Vent Pipe so adapter does not take weight of pipe. Dispose of condensate according to local codes.

Min. 8 Ft.

6" Minimum Clearance to Combustible

Materials

See Table 4 For Min. Hght.

Listed Termination Cap

Storm Collar

Flashing

Class B Double Wall

Metal Vent Pipe

Metal Flue

Vent

Body

Collar

Firestop

Support Vertical Vent Pipe so adapter does not take weight of pipe.

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 installing 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 and local and National Fuel Gas Code (U.S.) or CSA B149.1, Natural Gas and Propane Installation Codes (Canada) requirements 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 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/M). Install Listed condensate drains at low points where condensate might collect. Plumb condensate drains to a drain through hard piping or high-temperature tubing such as silicone rubber or EPDM rubber – do not use vinyl or other low temperature tubing. Follow drain manufacturer’s installation instructions.

6. Vent Termination – Vertical (See Figures 12A and 12B, page 13, for height of vent termination above the roof. See Table 7, Page 15, for Listed terminations.) Use a Listed vent terminal specified by local and national codes and your manufacturer’s instructions. A roof termination must be vertical. In Canada, the Vent Cap location shall have a minimum clearance of 4 feet (1.2M) horizontally from electric meters, gas meters, regulators, and relief openings.

7. Vent Termination – Horizontal (See Table 7). Use a listed wall thimble and vent terminal from Table 7.

The terminal must be located (U.S.-See Figure 13):

• at least 3" and at most 12" out from the wall (see

Figure 14), following the vent manufacturer’s instructions.

• at least 12" above finished grade or the normally

expected snow accumulation level, whichever is higher

• at least 4 feet below or horizontally from, or 1 foot

above, any doors or windows or gravity air inlet to a building

• At least 3 feet above any forced air inlet located within

10 feet

• At least 4 feet horizontally from electric meters, gas

meters, regulators and relief equipment

• At least 7 feet above grade adjacent to walkways or

similar traffic areas.

Brand Manufacturer Material Type Sealant

Saf-T Vent®4” Heat-Fab, Inc. Metal Consult Manufacturer Special Gas Vent 38 Hayward Street (Single Wall) Greenfield, MA 01301

(800) 772-0739

Saf-T CI Vent

Heat-Fab, Inc. Metal Consult Manufacturer Special Gas Vent 38 Hayward Street (Double Wall) Greenfield, MA 01301

(800) 772-0739

Z-Vent 4” Special Z-Flex U.S., Inc. Metal G.E. RTV 106 Gas Vent (Type BH), 20 Commerce Park North Model SVE Bedrford, NH 03110-6911

(800) 654-5600

Table 5: Recommended Special Gas Vents (Positive Pressure)

Minimum Height

Roof Pitch Above Roof*

Flat to 6/12 1 Ft.

6/12 to 7/12 1 Ft. 3 in. >7/12 to 8/12 1 Ft. 6 in. >8/12 to 9/12 2 Ft.

>9/12 to 10/12 2 Ft. 6 in. >10/12 to 11/12 3 Ft. 4 in. >11/12 to 12/12 4 Ft.

>12/12 to 14/12 5 Ft. >14/12 to 16/12 6 Ft. >16/12 to 18/12 7 Ft. >18/12 to 20/12 7 Ft. 6 in. >20/12 to 21/12 8 Ft.

* Vent must be at least eight (8) feet away from nearest vertical surface. Vents extending five (5) feet or more above the roof must be braced or guyed. Consult your local code officials for detailed information.

Table 4: Vent Termination Height vs.

Roof Pitch – U.S.

WARNIN

The terminal must be located (Canada):

• at least 10 feet (3.3M) from any opening into a building.

• at least 12" (.3M) above finished grade or the normally expected snow accumulation level, whichever is higher

• At least 4 feet (1.2M) horizontally from electric meters, gas meters, regulators and relief equipment

• At least 7 feet (2.1M) above grade adjacent to walkways or similar traffic areas.

Allow at least three feet (1M) vertical clearance over vent termination when terminating under an overhang or deck.

Avoid corners or alcoves where snow or wind could have an effect. Exhaust may affect shrubbery and some building materials. Keep shrubbery away from termination. To prevent staining or deterioration, sealing or shielding exposed surfaces may be required.

8. Fire Hazard. Do not run the heater vent into a common vent with any other appliance. Do not run the Special Gas Vent into, through, or within any active vent such as a factory built or masonry chimney.

Final Installation Check

Check that horizontal vent pipe runs slope uniformly at least 1/4" per foot (2cm per meter) to condensate drain(s). No sags, no dips, no high or low spots.

Check that vent is supported at elbows, tees, and horizontal and vertical runs according to manufacturer’s instructions and code requirements.

Check that vent supports and wall and ceiling penetrations allow free movements up, down, and sideways without putting any strains on the heater or vent body.

Check for at least six inch (15cm) free air clearance between the heater vent pipe and combustible materials.

Check that all joints are completely together and sealed.

WATER CONNECTIONS

The heater requires proper water flow and pressure for its operation. See Figures 15 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 16 for setting of the manual bypass valve.

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 as noted below). To switch flow between the pool and spa, use a diverter valve. Do not use any valve that can shut off the flow. Do not use a shut-off valve to isolate the heater unless it is below the level of the pool or spa.

Vent Brand Wall Thimble Horizontal Terminal Vertical Terminal

Saf-T Vent

(Part of Vent term.) 5490CI Horizontal Term. 5400 Cap

Saf-T CI Vent

(Part of Vent term.) 5490CI Horizontal Term. 5400 Cap

Z-Vent 2SVSWTF04 2SVSTTF04 Tee 2SVSRCF04 Cap

Table 7: Listed Thimbles and Vent Terminals (for Special Gas Vents)

4" Special Gas Vent (Vertical or Horizontal)*

No. of 90° Elbows Maximum Length in Feet (M)

0 70 ft. (21.3M) 1 57 ft. (17.4M) 2 45 ft. (13.7M) 3 32 ft. (9.8M) 4 20 ft. (6.1M)

* Minimum vent length is one foot (.34M), or in accordance with vent manufacturer’s instructions, and local and national codes. Horizontal vents 3’ (1M) or less in length do not require a condensate tee, but must slope down toward the outlet at 1/4” to the foot (2cm/M) to allow condensate to drain.

FIGURE 14: Typical Special Gas Vent Pipe Installation (Horizontal-Positive Pressure)

4' Min.4' Min.

4' Min.

1' Min.

Forced Air Inlet

4' Min.

3' Minimum clearance if horizontal distance to exhaust opening is less than 10 feet.

WARNIN

Metal Vent Body

Metal Special Gas Vent requires Appliance Adapter

Support weight of pipe

Condensate Te e

Listed Termina

Condensate drain w/Trap

Slope at least 1/4" per foot (2 cm per Meter) down towards condensate drain

3" (7.6 cm) Min., 12" (30.5 cm)Max. Clearanc

Install a check valve to prevent back-siphoning through the heater when the pump is off.

NOTICE: Improper operation of chemical feeders can cause severe damage to the heater which is not covered by the warranty. Install the chemical feeder downstream of the heater (see “Water Chemistry,” below).

Install a chemical resistant one-way check valve between the heater and the chemical feeder.

NOTICE: If you install a chemical feeder and check valve,

you must install a relief valve on the heater. See “Pressure Relief Valve”, Page 18.

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

WATER PIPING

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.

WATER FLOW RATE

Maximum and minimum water flow rates required by the heater are listed below:

If the water flow rate to the heater is above 120 GPM (454 LPM), it must be reduced by installing a manual bypass valve (Figure 16). 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 prevent tampering.

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.

WATER CHEMISTRY

Water chemistry should follow good swimming pool water chemistry practices. See Table 9 (page 17) for water chemistry parameters. When using a chlorinator, install it downstream from the heater and at a lower level than the heater outlet. Install a corrosion resistant positive seal Check Valve (see Figure 15) between the heater and the chlorinator to prevent concentrated chemicals from back-siphoning into the heater. Back-siphoning 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.

WATER PRESSURE SWITCH

Hazardous pressure. Do not bypass the

Water Pressure Switch or render it inoperable.

Switch Settings

The water pressure switch turns off the burner if the water flow is interrupted. If the water flow is restricted, the water pressure switch may prevent the burner from firing and cause the “Service System” light to go on. If the light remains on after the filter has been serviced, have a qualified service technician check the system.

For deck-level heater installations, the Pressure Switch is factory set at 3 psi (20.6 kPa). If the pressure switch is one to two feet (.3-.6M) below or one to five feet (.3-

1.5M) above the pool water level, reset the switch so that it is open when the pump is off and closed when the pump is running. Turn the star-wheel on the switch clockwise ( ) to raise setting (heater below the pool) and counterclockwise ( ) to lower the setting (heater above the pool – see Figures 17 and 18). Test the switch after resetting.

NOTICE: When the heater is mounted more than five feet (1.5M) above or two feet (.6M) below the deck level, a Pressure Switch is no longer adequate. A Flow Switch must be installed instead.

NOTICE: Heater operation with incorrect Pressure Switch setting may cause operation with no water flow. Operation of the heater without sufficient water flow may severely damage it.

WARNING

Model Minimum Flow Maximum Flow

200 20 (76) 120 (454) 250 25 (95) 120 (454) 300 30 (114) 120 (454) 400 40 (152) 120 (454)

FIGURE 15: Typical pool piping layout

Table 8: Maximum and Minimum Flow Rate in GPM (LPM)

Main

Drain

Pool

3-Way

Valve

Spa

Chlorinator

Check valve

Heater

Filter

Pump

3-Way

Valve

From Pool

3-Way

Valve

Verify proper operation of the water pressure switch at the start of every season and every six months thereafter by the following steps:

1. Lower the thermostat setting to turn off the heater.

2. Wait at least 15 minutes after the burner is off, and then turn off the filter pump.

3. Turn up the thermostat as though to fire the burner.

4. Wait one minute. The “Service System” light should go

on but the burner should not fire and the blower should not start. If the blower or burner do start, or if the “Service System” light does not go on, there is a pressure switch malfunction. Immediately press the OFF button on the operating control to turn the burner off and call a qualified service technician to check the system.

Live steam hazard. If the Burner and the Pump stop at the same time, wait at least 15 minutes before starting the filter pump to avoid severe damage to the heater.

CAUTION

Table 9: Water Chemistry Parameters

Disinfectant levels Minimum Ideal Maximum Free Chlorine, ppm 1.0 2.0-4.0 10.0 Combined Chlorine, ppm None None 0.2 Bromine, ppm 2.0 4-6 10.0 Other Sanitizers Levels not established. Consult local health department before use.

Chemical Values pH 7.2 7.4-7.6 7.8 Total Alklinity (Buffering), ppm 60 80-100 180 as CaCO

Total Dissolved Solids, ppm N/A N/A 1,500 ppm > TDS at startup* Calcium Hardness, ppm, as CaCO

150 200-400 500-1,000

Heavy Metals None None None Biological Values

Algae None None None Bacteria None None Refer to Local Code

NOTICE: Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger and will void the warranty. *Start-up TDS includes source water TDS and any other inorganic salt added at start-up.

FIGURE 16: Manual bypass valve

FIGURE 17: Remove side panel for access to Water Pressure Switch

PRESSURE RELIEF VALVE

Canadian code requires and some U.S. local codes may require installation of a pressure relief valve. Purchase separately and install a 3/4" pressure relief valve complying with the ANSI/ASME Boiler and Pressure Vessel Code, having a capacity equal to the Btu/hr rating of the heater. The relief pressure of the valve MUST NOT EXCEED 50 PSI.

A 3/4" NPT connection is provided in the manifold for installing a pressure relief valve. The relief valve must be installed vertically. To install the valve, use a 3/4" brass nipple and elbow (user supplied), as illustrated in Figure

19. No valve is allowed to be placed between the manifold adapter and the relief valve.

To avoid water damage or scalding from operation of the relief valve, install a drain pipe in the outlet of the pressure relief valve that will direct water discharging from the valve to a safe place for disposal. Do not install any reducing couplings or valves in the drain pipe. The drain pipe must be installed so as to allow complete drainage from the valve and drain line. The relief valve should be tested at least once a year by lifting the valve lever.

Explosion hazard. Any heater installed with restrictive devices in the piping system downstream from the heater (including check valves, isolation valves, flow nozzles, or therapeutic pool valving) must have a relief valve installed as described above.

WARNING

Risk of fire and explosion. Improper installation, adjustment, alteration, service, or maintenance of the Combination Gas Control Valve can lead to fire or explosion, causing loss of life, personal injury, or property damage.

These instructions are for the use of qualified service technicians only!

Do not attempt this procedure unless you have been trained and certified in the care and repair of gas-fired appliances!

Do not attempt this procedure if the following instructions are confusing!

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 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 endcap air orifice as shown in Figure 20.

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.

To check that the gas pressure setting is correct, use the following procedure:

1. Turn off the heater and remove the access door pan-

els for access to the Combination Gas Control Valve.

2. Use a 3/16" hex key to remove the plug from the

‘PRESSURE TAP’ port on the outlet side of the Combination Gas Control Valve.

3. Install a 1/8" NPT barbed fitting into the ‘PRESSURE TAP’ port. Use a flexible tube to connect it to the low side of a differential pressure gauge or a slope gauge.

NOTICE: If you are using a slope gauge or a differential pressure gauge of less than 3" capacity, close the shutoff valve of the gauge to avoid pulling the liquid out of the gauge when the blower starts.

4. Disconnect the tube from the Gas Valve ‘VENT’ port. Connect it to a tube with a tee running to the high side of a differential pressure gauge and to the blower’s air orifice grille (See Figure 20).

5. Turn on the heater and verify the gas supply pressure (Page 20).

6. After the burner ignites, open the shutoff valve of the gauge. The pressure gauge should then read 0.2" wc ±0.1" wc (0.5cm wc ± 0.25cm wc) (0.0" to 0.1" wc (0.0 to 0.2 cm) = rich mixture; 0.3" (.75 cm) and above = lean mixture). (Since the pressure tap is connected to the low side of the gauge, the pressure is actually negative.)

Risk of fire or explosion if Combination Gas Control Valve is incorrectly adjusted. If it is necessary to adjust the gas valve, this must be done only by a qualified service agency.

7. Turn off the heater.

8. Replace the plastic hose between the ‘VENT’ port and the inlet of blower mixer. Remove the barbed fitting and replace the plug in the ‘PRESSURE TAP’ port of the gas valve, using a thread sealant approved for use with natural gas and propane.

9. Replace the access door panels and cycle the heater to check for proper operation.

WARNING

Instructions For Checking the Gas Pressure

Through the Combination Gas Control Valve

FIGURE 20: Connect Gas Valve to End Cap Air Orifice

NOTE: The gas piping and unions have been omitted for clarity; make this test with all gas piping connected (as for normal service).

To High Side of Differential Pressure Gauge

To Low Side of Differential Pressure Gauge

To Air Flow Switch

Connection for Test

To Gas Valve Vent

Pressure Tap

Vent

WARNIN

GAS CONNECTIONS

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 of 4" (10.2cm) wc is required to maintain input rating. The gas supply must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1, 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 (Figure 21). Do not use a restrictive gas cock.

The following minimum gas pipe sizes are recommended for natural gas supply piping. For low pressure LP gas, pipe size may be reduced by 1/4", with a minimum pipe size of 3/4". Check for compliance with local codes.

NOTICE: DO NOT use a corrugated flexible gas line to supply the heater. it will not deliver enough gas (at nominal diameter) to supply heater.

PRESSURE TESTING

Before operating the heater, the heater and its gas connections must be leak tested. Test all gas connections for leaks with soapy water.

Risk of fire or explosion. Do not use an open flame to test for leaks. The heater and its individual shutoff valve must be disconnected from the gas supply pip-

ing 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 shutoff valve during any pressure testing of the gas supply at test pressures equal to or less than 1/2 psig (3.5 kPa).

SUPPLYING POWER TO THE HEATER

The heater requires a 120V or 240V/60Hz/1Ph power supply. Enclose the line to the heater in an approved flexible conduit connected directly to the junction box on the inside of the access door panel.

Line voltage field wiring should be 14 gauge, with a circuit capacity of 15 amps.

ELECTRICAL WIRING

NOTICE: Before making any electrical connections to the power supply, remove the access door panels, open the control box, remove the 12-pin plugs from their bag, and plug in the correct plug (120 volt or 240 volt). Note that installing the 120V plug and then connecting the heater to 240V line current will immediately destroy the transformer, control board and ignition control module, and will void warranty. If you install the 240V plug and connect the heater to 120 volts line current, the heater will not operate. Please read the boxes headed “IMPORTANT! READ ME FIRST!” on pages 23 and 27 before proceeding.

1. All wiring must be in accordance with all applicable codes.

2. The heater, when installed, must be electrically grounded and bonded in accordance with local codes or, in the absence of local codes, with the National Electrical Code or the Canadian Electrical Code (as applicable). A bonding lug is provided on the outside of the panel under the vent for this purpose.

3. Electrical power circuits to the pool heater must follow local codes and National Electrical Code or Canadian Electrical Code (as applicable).

4. All wiring between the heater and devices not attached to it, or between separate devices which are installed in the field, must be Type T wire rated for 35°C rise.

5. All line voltage wiring shall be enclosed in approved flexible conduit, and shall be securely attached to the field wiring box located inside the access door panel. The conduit or cable connector at the field wiring box should contain an insulating bushing or its equivalent to prevent abrasion of the wires as they enter the box.

6. The filter pump should run continuously when the heater is on, and for at least 15 minutes after the heater turns off. Any switches in the pump circuit (including circuit breakers) that can disconnect the pump must also disconnect the heater.

7. Do not wire single pole switches, including protective devices, into a grounded line. The heater is not sensitive to polarity.

WARNING

Recommended Pipe Size For Natural Gas

1,000 BTU/ft3, 0.6 Sp Gr, 0.5" wc Pressure Drop

0-25’ 26-50’ 51-100’ 101-200’ 201-300’

Model (0-7.6M) (7.6-15M) (15-31M) (31-62M) (62-92M)

200 3/4 in. 1 in. 1 in. 1-1/4 in. 1-1/4 in.

250 3/4 in. 1 in. 1-1/4 in. 1-1/4 in. 1-1/4 in. 300 1 in. 1-1/4 in. 1-1/4 in. 1-1/2 in. 1-1/2 in. 400 1 in. 1-1/4 in. 1-1/4 in. 1-1/2 in. 2 in.

FIGURE 21: Gas line and Trap

Table 10

Sediment trap

Union

Manual shut-off valve

18"-24" of 3/4"

GAS LINE

AT LEAST 4"

Connect the L1 of the power supply to the black wire, the L2 or neutral lead to the red wire, and the ground wire to the green wire.

A time clock controlling the filter pump should have a low-voltage Fireman’s Switch that switches off the heater at least 15 minutes before shutting off the pump.

FIREMAN’S SWITCH CONNECTION

NOTICE: If, while there is line voltage connected to the heater, you touch either line voltage terminal with any 24VAC wire that is connected to the control board (including the Fireman’s Switch jumper), you will immedi- ately destroy the control board and void the warranty.

NOTICE: When using a timer and Fireman’s Switch, the heater’s power supply should come from the load side of the timer. The Fireman’s Switch completes the circuit for the low voltage safety switches. It DOES NOT get any line voltage power from the power supply.

Connect the Fireman’s switch to the heater as follows:

1. Switch off power to heater at main circuit breaker panel.

2. Unbolt and remove the access door panels (see Figure 3, Page 5).

3. Open control box cover (see Figure 22).

4. Remove the factory-installed jumper between the Fireman’s Switch terminals (see Figure 23).

5. Connect the wires between the Fireman’s Switch ter- minals on the heater and those on the time clock using 18 gauge wire with a minimum 3/64" (1.2mm) thick insulation rated for a temperature rise of at least 105°C. Route the wires out through the knock- out on the bottom of the Control Box. Use a 90° con- duit elbow and conduit run out through the cutout on the Lower Enclosure, next to the Junction Box.

6. Reinstall the access door panels. The fuse for the Fireman’s Switch is a 1.25 amp

1-1/4x1/4" fast blow fuse, available locally.

MAXIMUM TEMPERATURE SET POINT

1. Unbolt and remove the Door Panels (see Figure 3, Page 5).

2. Access the control panel board on the underside of the top cover. Locate the red button on the corner of the control board (see Figure 24).

3. Push the Max. Temp. Set Point button on the back of the control board (see Figure 24).

The following sequence should happen:

A. The unit will come on and the POOL ON light will

come on.

B. Press the

▲▲

TEMP or

▼▼

TEMP pad (on TOP of

the panel) to set maximum pool temperature.

C. Wait up to 30 seconds; the POOL ON light will go

off and the SPA ON light will come on. To override the time delay, push the Max. Temp. Set Point button again.

D. Press the

▲▲

TEMP or

▼▼

TEMP button on the control panel and set maximum spa temperature to 104°F (40°C) or less.

E. Wait up to 30 seconds; the SPA ON light will go

off and the unit will shut down. To override the time delay, push the Max. Temp. Set Point button again.

4. Reinstall the access door panels.

SET

MAX

Hazardous voltage. Can shock, burn or kill.

Disconnect power before servicing any components.

Fire and Explosion hazard. Do not jumper

switch terminals to remedy a failed safety switch.

Initial Troubleshooting

Only qualified, trained service technicians with appropriate test equipment should service the heater. Remember that all parts of the system affect heater operation. Before starting this troubleshooting procedure, make sure that the pump is running correctly, that there are no blockages in the system, that the valves are correctly set and that the time clock is correctly set and is running.

Go to chart “HEATER WILL NOT FIRE - A” (Page 24)

Go to chart “HEATER WILL NOT FIRE - B” (Page 25)

Go to specific safety switch troubleshooting chart (Pages 28 and 29)

Go to chart ‘HEATER WILL NOT FIRE -C” (Page 26)

Are any red diagnostic LED’s on back of board (AGS, AFS, SFS, HLS, PS or THERMISTOR) “on”

YES

Does red “SERVICE HEATER” LED come “on”

Verify that water temperature setting is above water temperature reading. If it is, and heater either will not fire or no red LED’s come “on”, replace Control Board.

YES

Is green “POOL” or “SPA” LED “on”?

Is red “SERVICE SYSTEM” LED “on”?

Is red “SERVICE HEATER” LED “on”?

Turn off power to heater for about 5 seconds, and turn back on. Make sure temperature setting is above water temperature. Wait one minute.

Do any diagnostic LED’s on back of board (AGS, AFS, SFS, HLS, PS, or THERMISTOR) come “on” and stay on?

NOTICE: Any or all of the diagnostic LED’s may come “on” momentarily when you turn on the power to the heater.

NOTICE: Installing the black 120 volt plug in the control box and then connecting the heater to a 240 volt line will destroy the transformer, control board, and ignition control module, and will void the warranty. If you install the red 240 volt plug and then connect the heater to a 120 volt line, the heater will not operate.

READ THE FOLLOWING CAREFULLY:

1. Check the line voltage to your heater. This heater will operate

on either 120 Volts AC or 240 Volts AC.

2. Remove the covers and check the 12-pin plug in the back of the control box. The plug must match the voltage in the heater circuit.

3. If the 12-pin plug is not plugged into the back of the control box, select the correct plug from the bag in the control box and plug it in. The BLACK plug is for 120 volts, the RED plug is for 240 volts.

IMPORTANT! READ ME FIRST!!

Start here for directions to specific Troubleshooting Chart

WARNIN

Heater Will Not Fire - A

Start

GO TO “HEATER WILL NOT FIRE - B” Page 25

Heater should fire on demand for heat.

Check Fireman’s Switch circuit connections (time clock, wiring, external controller relay).

Remove jumper. Check wiring between Transformer and J7 terminals on Control Board and between J7 and Fireman’s Switch on Terminal Board, check fuse, and restore continuity.

Restore power to heater.

Replace Transformer.

Heater should fire on demand for heat.

Replace Control Board.

Replace Membrane Pad.

Check wiring connections between power supply and Junction Box and between Junction Box and Terminal Board; restore continuity.

Check wiring connections between Terminal Board and Transformer primary and restore continuity.

Is green “SPA” or “POOL” LED “on”

YES

Depress “POOL” or “SPA” ON button on Membrane Pad. Does “POOL” or “SPA” LED come on?

Check for line voltage to heater.

Check for 24 VAC at secondary of Transformer.

Check for Line Voltage at Transformer primary pins. White connects to Pin 3 on Transformer, Black to Pin 2, Orange to Pin 1. 240V: check Pin1 to Pin 3. 120V: check Pin 2 to Pin 3.

Jumper Fireman’s Switch at Terminal Board and depress “POOL” or “SPA” ON button on membrane pad. Does “SPA” or “POOL” LED come “on”?

Leaving jumper in place, check for 24 VAC between Fireman’s Switch terminals and ground.

Jumper pins 6 and 5 on J6 of Control Board. Does “SPA” LED come on? Jumper pins 6 and 4 on J6 of Control Board. Does “POOL” LED come on?

Check for Line Voltage between L1 and L2 terminals on Terminal Board.

YES

Check that correct 12-pin plug is installed (red is 240V, black is 120V)

If plug is not installed: Install correct plug. 240V plug in 120V circuit: Replace with correct plug. 120V plug in 240V circuit: Replace transformer, control board, and ignition control module (see “HEATER WILL NOT FIRE-C and

-D”, Pages 26 and 27). Check fuse and all other 24V components for damage.

Remove jumper. Check ribbon cable connection between Membrane Pad and J6 on Control Board. Depress “POOL” or “SPA” On pad again. Does “POOL” or “SPA” LED come on?

Heater Will Not Fire - B

Start

Increase POOL/SPA temperature setting on Membrane Pad above actual water temperature. Heater should fire on demand for heat. If not, and no other red LED’s light, replace Control Board.

Service pump/filter and eliminate other flow obstructions.

Heater should fire on call for heat. Re-verify that water flow is above minimum requirement.

Minimum Flow Requirements

Model Flow

200 20 gal/min (76 LPM) 250 25 gal/min (95 LPM) 300 30 gal/min (114 LPM) 400 40 gal/min (151 LPM)

If water pressure is outside of adjustment range that will open switch with pump off and close switch with pump on, replace with flow switch set above minimum flow requirement.

Minimum Flow Requirements

Model Flow

200 20 gal/min (76 LPM) 250 25 gal/min (95 LPM) 300 30 gal/min (114 LPM) 400 40 gal/min (151 LPM)

Is red “SERVICE HEATER” LED “on”

YES

Is red “SERVICE SYSTEM” LED on?

Verify that pump is on, filter is not blocked, and the water flow is above the minimum requirement.

Check that water pressure is within the adjustment range of the Pressure Switch (0-5 psig)

Verify that switch wiring is OK and Pressure Switch port is not blocked, and replace water Pressure Switch.

Check whether any of the red diagnostic LED’s on back of board (AGS, AFS, SFS, HLS or PS) are “on”

GO TO

“HEATER WILL NOT FIRE - C”

Page 26

Go to “Diagnostic LED’s”, (Pages 28 and 29)

With pump running, adjust Water Pressure Switch to lower pressure until ‘SERVICE SYSTEM” LED goes out. Then verify that “SERVICE SYSTEM” LED goes on with pump off.

YES

CONTINUE

Heater Will Not Fire - C

Start

Go to “INITIAL TROUBLESHOOTING”

Continue to observe heater for several minutes. Cycle heater on and off several times. Observe for delayed or rough ignition, poor combustion, premature extinction of flame, evidence of boiling, or operation of any diagnostic LED. Go to pertinent troubleshooting section if any malfunction is observed.

Replace Control Board.

Replace Gas Valve with identical part.

Fix wiring between TH and GND terminals of Ignition Control Module and Control Board.

Replace Control Board.

Fix wiring between GAS terminals on Control Board and Gas Valve.

NOTE 1: Voltage appears immediately after call for heat, and may be on for only about 30 seconds.

NOTE 2: Voltage appears about 24 seconds after call for heat, and may be on for only about 7 seconds.

Verify that gas supply is open all the way to Gas Valve, and Gas Valve is set at “on” position. Check for 24 VAC to Gas Valve terminals during ignition try. (Voltage appears about 24 seconds after call for heat). SEE NOTE 2.

Turn off power to heater for 5 seconds, and turn back on. Make sure temperature setting is above water temperature. Wait one minute.

Does heater fire and stay on?

Did Blower come on?

Verify that gas is flowing to burner during ignition try. Observe gas meter for movement during ignition try (wait for about 30 seconds after calling for heat).

Check for 24 VAC between TH and GND terminals on Ignition Control Module. SEE NOTE 1.

Check for 24 VAC between TH and GND terminals on Control Board. SEE NOTE 1.

Check for 24 VAC between GAS terminals on Control Board. SEE NOTE 2.

Replace Control Board.

CONTINUE

YES

Is “SERVICE HEATER” LED “on”?

Go to “BURNER TROUBLESHOOTING” (Page 30)

Go to “HEATER WILL NOT FIRE-D” (Page 27)

Check for 24 VAC between VAL and GND terminals on Ignition Control Module. SEE NOTE 2.

Check for 24 VAC between VAL and GND terminals on Control Board. SEE NOTE 2.

If any red diagnostic LED’s (AGS, AFS, SFS, HLS, PS, or THERMISTOR) come “on”, go to to Pages 28 and 29.

Did burner fire at all?

Replace Ignition Control Module.

YES

Fix wiring between VAL and GND terminals of Ignition Control Module and Control Board.

YES

Heater Will Not Fire - D

Start

IMPORTANT! READ ME FIRST!! If your heater is correctly connected to 240 Volts AC, The Ignition Control Module (ICM) will convert the 240VAC to an intermittent pulse to the ignitor. Digital meters don’t read this type of signal well. (An analog meter will give a better reading than a digital meter). If the ICM is bad, your volt-

meter will read either 0 VAC or 240 VAC. If your ICM is good, your meter will read some voltage between 0 and 240 VAC. Exactly what reading you get will depend on the meter, but with a good ICM, the reading won’t be 0 VAC or 240 VAC, but somewhere in between.

IMPORTANT! READ ME FIRST!!

Gas flows during ignition try, but burner does not fire.

YES

Go back to chart “HEATER WILL NOT FIRE-C” (Page 26).

Check voltage across igniter leads; OK?

Replace Ignition Control Module. On a 120 V installation, check the ignitor for damage if it has seen 240 VAC.

YES

Replace HSI Igniter.

Check gas pressure. OK?.

Increase gas flow into heater:

• Replace gas line with larger line;

• Replace regulator;

• Replace meter; or

• All of the above.

YES

Diagnostic LED’s: AGS, AFS, HLS, PS, THERMISTOR

Do not jumper a safety switch to

remedy a failed switch.

NOTE: ES1 is a spare and should be jumpered.

Service pump and filter to restore proper flow. After servicing, verify proper operation of Pressure Switch (PS).

Replace thermistor or Control Board to correct overheating.

Replace High Limit Switch (HLS) or Automatic Gas Shutoff (AGS)

If problem persists, verify proper operation of Internal Bypass Valve and Thermal Governor, and check for Heat Exchanger blockage.

YES

AGS or HLS “on”

Verify that water flow rate is above minimum required for heater.

Verify that inlet water temperature is below 104° F.

YES

CONTINUE

YES

CONTINUE

Verify that there is no blockage in Blower intake, Heat Exchanger, and exhaust and that exhaust is not too long (see “Indoor Vent Installation”, Page 15.

Verify correct connection of wiring and that pressure taps to AFS are OK.

Verify that vinyl tubing to AFS and Blower is not misrouted, kinked, disconnected, or punctured.

Replace Air Flow Switch (AFS).

If problem persists, replace Blower.

Replace Blower.

Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board, and replace Control Board.

YES

AFS “on”

Does Blower operate?

THERMISTOR “on”

Verify Thermistor wiring. If OK, replace Thermistor.

Disconnect Blower and check for line voltage between pins 1 and 3 of Blower Connector on ignition try.

Connect correctly and retry. Does Blower start?

Replace Blower. Does Blower start on ignition try?

Replace Ignition Control Module.

Verify that wires BM and F1 are correctly connected at the terminal strip (see Heater Connection Diagram, Page 36).

Disconnect wires F1 and F2 from Ignition Control Module and short them together. Does Blower come on?

Check for 24 VAC between 24 VAC and GND terminals on Ignition Control Module on ignition try. Check that IND wire is correctly connected.

Service pump and filter to restore proper flow.

Verify that wiring is OK and pressure tap is not blocked. Replace Pressure Switch

CONTINUE

PS “on”

Verify that water flow rate is above minimum required for heater.

Adjust Water Pressure Switch to close with pump running and open with pump off.

YES

CAUTIO

Diagnostic LED’s: SFS

(HD )

(Basic)

Reset power to Heater and retry. Heater should fire.

Does the Digital Temperature Display show Error Code “E05” or “E06”?

Heater starts and runs OK, but temperature of exhaust climbs to 450º–500º in 3–5 minutes.

Heater starts after several tries, exhaust temperature stays below 250º.

OR Heater doesn’t start at all (exhaust stays cold).

Check pressure and volume of fuel supply

Check the J3 and J6 connectors for corrosion/ looseness on the male pins.

Check continuity in wiring harness between Control Board and Probe. Continuity OK?

Disconnect the sensor and check continuity across its terminals. Resistance should be 3.5-4.0 megaohms.

 = open circuit; 0 = shorted.

Does sensor check OK?

Clean/tighten pins as needed.

Reset power to Heater and retry. Heater should fire.

NOT OK

SFS “on”

Replace Stack Flue Sensor

Correct Fuel Supply, reset Heater and retry. Heater should fire correctly.

Repeat checks on fuel supply, Thermal Regulator, check for correct orifices, etc.

DONE

YES

Replace Heater Control Board.

Replace Heater Membrane Pad.

Reset power to Heater and retry. Heater should fire.

Check Heat Exchanger Coil for leaks, liming, soot, or low flow.

Correct problem; Heater should fire.

Check Heat Exchanger Coil for leaks, liming, soot, or low flow.

Check Thermal Regulator: Open at 120º?

Check Thermal-Regulator: Seats correctly?

DONE

Replace Heater Membrane Pad.

Replace Heater Control Board.

Reset power to Heater and retry. Heater should fire.

DONE

YES

DONE

Burner Troubleshooting

SYMPTOM CAUSE REMEDY

Loud, high-pitched whine Flame is too rich. Verify pressure tap between gas valve

and blower inlet. Turn to Page 19 and verify that the

gas

regulator setting is 0.2" (0.5cm) wc below the blower inlet pressure.

Replace gas orifice with smaller size.

Flame is “fluttery.” Flame is too lean. Turn to Page 19 and verify that the gas Exhaust may have acrid regulator setting is 0.2" (0.5cm) wc smell or burner may fail below the blower inlet pressure. to stay lit.

Replace gas orifice with larger size.

Burner pulsates or Exhaust vent is too long. Reduce length of exhaust vent and/or surges, especially on number of elbows.

ignition.

Combustion appears Flame current is not Check for wet or damaged igniter with normal, but flame does being sensed. low resistance to ground. Replace with not stay lit. new igniter.

Verify burner flameholder is properly grounded. Replace Ignition Control Module.

Heat Exchanger Troubleshooting

SYMPTOM CAUSE REMEDY

Boiling in heat exchanger. Low water flow to heater. Service pump and or filter. May be accompanied by

Heat exchanger plugged. Service heat exchanger. Correct water

“bumping” sounds.

chemistry.

Bypass valve stuck open. Service bypass valve.

Thermal governor stuck Replace thermal governor. closed.

Sweating. Thermal governor failed. Replace thermal governor.

313233

REPAIR PARTS – BURNER SYSTEM

Model

Key Part 200NA 250NA 300NA 400NA

No. Description Qty. 200LP 250LP 300LP 400LP

1 Combination Gas Control Valve Kit 1 42001-0051S 42001-0051S 42001-0051S 42001-0051S

2 3/4" Union 2 38404-4097S 38404-4097S 38404-4097S 38404-4097S

3 Gas Orifice 1

• Gas Orifice Kit – NG (Incl. Key Nos. 3 and 4)† 77707-0431 460739 460753 77707-0411

• Gas Orifice Kit – Propane (Incl. Key Nos. 3 and 4)† 77707-0461 460740 460754 77707-0441

• NG to Propane Conversion Kit

(Incl. Key Nos. 3 and 4)† 77707-1461 460741 460755 77707-1441

• Propane to NG Conversion Kit

(Incl. Key Nos. 3 and 4)† 77707-1431 460742 460756 77707-1411

5 Air Blower Kit

Natural Gas Units 1 77707-0251 460743 460757 77707-0253

Propane Units 1 77707-0254 460744 460758 77707-0256

• Air Orifice Kit (Includes Key Nos. 6 and 7) 1 77707-0111 460745 460759 77707-0113

6 Air Orifice 1

7 Air Orifice Grill 1 42001-0114S 42001-0114S 42001-0114S 42001-0114S

• Blower/Adapter Plate Gasket Kit

(Includes Key Nos. 8, 9, 10, 12) 1 77707-0011 77707-0011 77707-0011 77707-0011

• Flameholder Kit (Includes

Key Nos. 10, 11, 12, 13 and on 300 & 400

models only - Flameholder Insert) 77707-0202 460746 77707-0203 77707-0204

8 Blower/Adapter Plate Gasket 1

9 Blower Adapter Plate 1

10 Flameholder/Adapter Plate Gasket 1

11 Flameholder Assembly 1

12 Flameholder/Combustion Chamber Gasket 1

13 Flameholder Insulation Cap 1

• Flameholder Insert 1

15 Condensate Evaporator Plate 1

16 One Piece Metal Chamber/Combustion Chamber

Assembly 1 42001-0200S 42001-0200S 42001-0200S 42001-0200S

• Insulation Kit (Includes Key Nos. 13, 15, 23, 24, 25

and 26) 1 77707-0008 77707-0008 77707-0008 77707-0008

23 Bottom Outer Insulation Blanket 1

24 1" Bottom Inner Insulation 1

25 1" Top Insulation 1

26 Top Outer Insulation Blanket 1

• Lower Enclosure Insulation 1 42001-0074S 42001-0074S 42001-0074S 42001-0074S

27 One Piece Metal Elbow/Combustion Chamber

Cover Assembly 1 42001-0214S 42001-0214S 42001-0214S 42001-0214S

28 Metal Vent Cover 1 42002-0005S 42002-0005S 42002-0005S 42002-0005S

* Not available separately.

† Not included with heater. Order separately.

REPAIR PARTS – WATER SYSTEM

* Not available separately.

• Not illustrated.

Model

Key Part 200NA 250NA 300NA 400NA

No. Description Qty. 200LP 250LP 300LP 400LP

1 Tube Sheet Coil Assembly Kit (NA, LP Series)

(Includes Key No.3) 1 77707-0232 460747 77707-0233 77707-0234

2 Manifold Kit (Includes Key Nos. 3-14, 21, and

Key Nos. 7-9 in “Electrical System”, Page 35 1 77707-0014 460748 77707-0015 77707-0016 3 Coil/Tubesheet Sealing O-Ring Kit ( ) 77707-0117(6) 460749(8) 77707-0118(10) 77707-0119(12) 4 Manifold Bottom Plate 1 5 Manifold O-Ring 1

• O-Ring Kit (Incl. Key Nos. 3, 5) 1 77707-0120 77707-0120 77707-0120 77707-0120 6 Manifold Insert* 1 7 Manifold Baffle Plate 1 8 Manifold Bypass Valve 1 9 Water Pressure Switch 1 42001-0060S 42001-0060S 42001-0060S 42001-0060S 10 Manifold 1 11 5/16" Washer, S.S. 10 12 5/16x18x2-3/4" Hex Cap screw 10 13 Connector Tube O-Ring 2 14 Connector Tube Kit (Includes 1 Connector Tube

and 1 O-Ring) 2 77707-0017 77707-0017 77707-0017 77707-0017 15 Thermal Regulator Kit

(Incl. Key Nos. 16, 17, 18, 19 and Spring Clip) 1 77707-0010 77707-0010 77707-0010 77707-0010 16 Thermal Regulator (Includes Spring Clip) 1 38000-0007S 38000-0007S 38000-0007S 38000-0007S 17 Thermal Regulator Spring 1 18 Thermal Regulator Cap O-Ring 1 35505-1313 35505-1313 35505-1313 35505-1313

• Thermal Regulator Spring Clip 1 19 Thermal Regulator Cap 1 20 Drain Plug 1 U178-920P U178-920P U178-920P U178-920P 21 3/4" Pipe Plug 1 472618 472618 472618 472618 22 Pressure Relief Valve (Recommended -

Purchase Separately) 1 38674-0719 38674-0719 38674-0719 38674-0719

REPAIR PARTS – ELECTRICAL SYSTEM

Pool Heater Wiring Connection Diagram

Plug –12 pin

120V – Black 240V – Red

JMP

External Control Interface Circuit Disabled, Heater Membrane Pad Enabled

External Control Interface Circuit Enabled, "Pool On" and "Spa On" Keys Disabled. "OFF" Key on Membrane Pad Remains Functional

CONNECTION DIAGRAM

AGS Switch

Stack Flue Sensor

Gas Valve

Air Flow Switch

Extra Switch 1

Hi-Limit Switch

Pressure Switch

VAL

IND

GND

24VAC

THERMISTOR

OPERATING CONTROL

HLS

ES1

AFS

AGS

SFS

GAS

MEMB RANE PAD

CONNECTION

Spa Line

Common Line

Pool Line

IGNITION CONTROL

MODULE

DIAGNOSTIC INDI CATOR

F1 F2

VAC

240

S1/ 120

L2S2TH IND

VALGND

GND

BLOWER

Line 2

120VAC IGNITER

TRANS

Line 1

Ground

JUNCTION BOX

F I R E M A N S

I T C H

Replace jum per with

leads to Fireman' s

Switch (field installed) .

24VAC

SEC

Y/W

Y/R

Y/O Y/BL

GYGYBK

BK BK

RRW

Y/W

Y/R Y/BL Y/O Y/W

Y Y

Y Y Y

YYYYY

BR BR

3661 0200

External Control Interface

NOTICE: Touching any 24VAC wire, including the Fireman's Switch wire, to any 120/240V terminal while the heater is connected to line power will immediately destroy the control board and void the warranty.

GND

12 Position Receptacle

NA/LP Models Only

Y/R

Y/BL

Y/O

Y/W

NA/LP Models: J6 incl. pins 1-6; Connect 9-Wire Cable as show

Pool Heater Electrical Schematic Ladder Diagram

L1 L2

120/240

VAC

120/240

VAC

IGNITER

S1 S2 L2

F2 BLOWER

GND

CLASS II

TRANSFORMER

24 VAC

24V

OPERATING

CONTROL

24 VAC

LOGIC

IND

AIR

FLOW

SWITCH

HI LIMIT SWITCH

WATER

PRESSURE

SWITCH

COM NO

AGS

SWITCH

VAL

GAS VALVE

THERMISTOR

SENSOR

STACK FLUE

SENSOR

NOTES:

1.)

AND TH

L1 L2 F1 F2 S1 24 VAC

S2 GND IND VAL

ARE CONNECTED ON THE IGNITION MODULE.

2. )

3. )

PIN AND SOCKET CONNECTOR.

IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, THEY MUST BE REPLACED WITH TYPE 105C OR ITS EQUIVALENT.

LADDER DIAGRAM

This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 553-5000 Trademarks and disclaimers: MasterTemp and the Pentair Pool Products and Pentair Water Pool and Spa logos are trade-

marks of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products. Pentair Water Pool and Spa Inc. disclaims proprietary interest in marks and names of others.

P/N 472592 - Rev A - 04/04/06

Customer Support

Sanford, North Carolina (8 A.M. to 5 P.M. Eastern Standard Time)

Phone: (800) 831-7133

Fax: (919) 566-8920

Moorpark, California (8 A.M. to 5 P.M. Pacific Standard Time)

Phone: (800) 831-7133

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