Pentair PG2000 Installation Manual
®
PG2000
Installation Manual
U.S. Patent Numbers
5,802,227; 5,825,954; 5,680,496;
Model No.s
840240
840241
840242
Pentair Water Pool and Spa, Inc.
1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000
10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400
Visit us on the Internet at: www.pentairpool.com or www.staritepool.com
Rev. C 7-29-05 1 P/N 840259
6,002,216
IMPORTANT SAFETY INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions should be followed, including
the following:
READ AND FOLLOW ALL INSTRUCTIONS
1. WARNING: To reduce the risk of injury, do not permit children to use this product unless they are closely
supervised at all times.
2. Check your local building codes before installation to ensure the PG2000 is located at least 5 feet from the
pool, or the minimum distance from the pool that local codes require.
3. The electrical supply for this product must include a suitable rated switch or circuit breaker to open all
ungrounded supply conductors to comply with Section 422-20 of the National Electrical Code, ANSI/
NFPA 70-2002. The disconnection means must be readily accessible to pool and spa users, but installed
at least 5 feet (1.5m) from the pool or spa water.
WARNING
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
This PG2000 must be installed by a licensed or certified electrician in accordance with the National Electrical
Code and all applicable local codes and ordinances. Improper installation will create an electrical hazard which
could result in death or serious injury to pool users, installers, or others, due to electrical shock, and may also
cause property damage.
Disconnect all power before starting the installation process to all associated pool equipment. Failure to do so may
lead to severe electrical shock, which can result in death or severe personal injury.
WARNING
Before installing this FIBERworks® product, read and follow all warning notices and instructions accompanying this light
product. Failure to follow safety warnings and instructions can result in severe injury, death, or property damage. You are
going to be using a sophisticated device which requires knowledgeable handling in order to insure its optimum
performance. Please do not touch anything until you have read and understood these instructions. If you have any
questions, please call our service hotline, Monday through Friday, 7:30 a.m. to 4:30 p.m.: (800) 831-7133.
WARNING
It is recommended that FIBERworks® be installed by trained and certified FIBERworks® dealers only. This installation
manual assumes that your PG2000 will be properly installed in full accordance with the instructions provided, the National
Electrical Code, and any local codes applicable for an electrical installation of this type.
SAVE THESE INSTRUCTIONS.
P/N 840259 2 Rev. C 7-29-05
Table of Contents
SECTION I. Before You Begin Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
®
The Installer’s Ten Laws of FIBERworks
The Pool Designer/Salesperson’s Ten Laws of FIBERworks
A. FIBERCAD Design Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
B. Wide Angle Lens positioning with the PG2000 centered at end of the pool . . . . . . . . . . . . . . . . . 6
C. Wide Angle OptiFusion Lens positioning on the side of the pool with the PG2000
centered on side of pool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION II. Running Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION III. Installing Lens Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION IV. Preparing to Mount the PG2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SECTION V. Feeding or Pulling the AmerGlow Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION VI. AmerGlow Lens Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
SECTION VII. Installing the Ferrule Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
SECTION VIII. Installing the PG2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SECTION IX. Synchronization of SAm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
®
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
®
/SAL® and Fiberworks® (Wiring Diagrams) . . . . . . . . . . . . . . . . .25
SECTION X. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PG2000 Specifications
Electrical
Input Voltage .............................. 120 V @ 2 A
Power Consumption ................... Approximately 200 Watts
Mechanical
Dimensions ................................. 15 in. x 10½ in. x 12 in.
Weight ....................................... 20 lbs.
Materials .................................... High strength plastic
This unit will accommodate up to 600 FIBERworks® fibers.
Contents of the Shipping Carton
This package should contain all of the following items:
√ PG2000
√ Sub-terrain Mounting Base
√ Ferrule Kit
√ PG2000 Installation Manual - (this manual)
√ Owner's Manual
√ Warranty Registration Card
®
To perform this installation, you will need the following items:
Electrical wire and conduit to connect main power, FIBERworks® cable and fittings as required,
Professional Termination Kit, (p/n 21005500), and the tools/equipment listed in relevant sections of this
manual.
Rev. C 7-29-05 3 P/N 840259
SECTION I. Before You Begin Installation
The Installer’s Ten Laws of FIBERworks
1. DO NOT ATTEMPT INSTALLATION WITHOUT RECEIVING CERTIFIED TRAINING OR
WATCHING INSTALLATION VIDEO.
2. Take your time and be patient when terminating - Rushing a 90 second FiberKnife 400 fiber termination can
cause 30% loss of light.
3. Use only prescribed Termination tools - FIBERworks® FiberKnife and shield.
(DO NOT USE MECHANICAL CUTTERS OR KNIFE BLADE HEATED WITH TORCH.)
4. Make conduit runs as direct as possible - plastic fiber loses 2% of light per foot; see Table 1, Light
Transmission Versus Distance.
5. When handling the cable do not bend final 12 in. of cable before lens.
6. Push lens and final 1 in. of cable into lens body - DO NOT PULL IN!
7. Sub-terrain Mounting Base should be installed below grade so that bottom of PG2000 is at or slightly above
finished landscape or concrete grade and protected from grass.
Locate the PG2000 above water level whenever possible. If raised water features are being lit, be sure
the end of the conduit inside the Generator is filled with RTV, other suitable sealant or conduit seal kit
#22002000 and locate the Generator so water will drain away from it and not accumulate inside of or
around the PG2000. This will prevent water from flooding the electrical portion of the unit.
®
8. Be sure conduits are located by cable size as in the template in the back cover of this manual and cut off level
with top of Sub-terrain Base (finished grade).
9. PROPER TERMINATION AT PG2000; see PG2000 Installation Steps.
a. First, mechanically cut all cables to equal length about 14 in. above the top of the Sub-terrain Base.
b. Strip all cable jackets 0-2 in. above Sub-terrain Base.
c. SANITY SAVER- one wrap of electrical tape over fiber bundle end.
d. Install ferrule and tighten with 3-4 in. of fiber extending out of fiber disk; see Picture 9, pg. 20.
e. Hot knife cut. Hold blade angled at 15 degrees, as if you were cutting cream cheese. Don’t stop and
restart, but rather keep continuous light pressure. Don’t saw or wiggle knife. Ease up pressure as you
come to end of cut.
f. Be sure ferrule is fully rotated and secured by ferrule thumb screws.
g. Wrap electrical tape or tie wrap around bundle at 2-3 in. above conduit.
10. WHEN IN DOUBT CALL your FIBERworks® Specialist or Technical Service at 800-831-7133.
P/N 840259 4 Rev. C 7-29-05
The Pool Designer/Salesperson’s Ten Laws of FIBERworks
®
1. The color of fiber optics is fantastic... but don’t just sell fiber optics, sell FIBERworks®! More Light... More
Color... More Friendly than other similar fiber optic systems... from the World’s Leading Manufacturer of
Underwater Lights!
2. Delight your customers and get referrals. Don’t undersize - never use fewer fibers or fewer lights than
recommended.
3. The Longer the fiber optic cable, the more it will cost and the less light it will transmit to the pool, spa, water
feature or landscape light. Distance costs 2% of light per foot; see Table 1, Light Transmission Versus
Distance.
4. Choose your PG2000 location(s) wisely. Give your biggest cables the shortest runs. If you design “never
ending” decks, design a planter between 5 and 10 feet (depending on code) from the primary lens location.
5. Colored surfaces absorb light. The darker the surface, the more light it will absorb. Do not waste your
customer’s money on underwater fiber optics for dark surfaces. They will not fully appreciate the dramatics of
fiber optic colors. Use Amerlites
®
, AquaLights® or HiLites®.
6. The darker your pool surface, the more dramatic will be perimeter FIBERworks®. Dark pools make great
reflecting pools and fantastic perimeter FIBERworks pools. For perimeter installations over 200' consult your
FIBERworks® Specialist.
7. FIBERworks® powerfully illuminates the wall and floor surface toward which the lens is pointed... modest
illumination is on the wall which holds the lens. AmerGlow 12, 30, 50, 70 or 100 cables make great step lights
and shadow fillers when directed toward or across the wall holding the AmerGlow 325, 225 or 170 cables.
8. There are two underwater lenses available. The Wide Angle Lens spreads light about 180 degrees and should
be used for most underwater applications. The Standard Lens spreads light about 70 degrees and should be
used for opposite wall shadow filling, up lighting into a fountainhead, and up lighting into a waterfall or cascade.
9. Always use Certified FIBERworks ®Installers. A rushed or poor installation can kill performance by 30%.
Schedule training as soon as possible or order FIBERworks® Installation Video [P/N P3-202].
10. WHEN IN DOUBT CALL Technical Service at 800-831-7133 OR- complete a FIBERCAD FORM
(located in the Pentair Water Pool and Spa, Inc. Catalog), AND fax a scale drawing to 727-461-5080.
NOTE
FIBERworks Application Manual is available on-line @ www.pentairtraining.com and www.pentairpool.com.
Rev. C 7-29-05 5 P/N 840259
A. FIBERCAD Design Assistance.
NOTE
FIBERworks Application Manual is available on-line @ www.pentairtraining.com and www.pentairpool.com.
For assistance in designing your fiber optic lighting, fax a FIBERCAD form (located in the Pentair Water
Pool and Spa, Inc. Catalog) and scale drawing to 727-461-5080.
If designing your own lighting layout, it is critical to keep the PG2000 as close to the pool as possible (less
than 15’ is desirable) and cable runs as short as possible to maximize light output; see Table 1, Light
Transmission vs Distance.
B. Wide Angle Lens positioning with the PG2000 centered at end of the pool.
1. AmerGlow 170, 225 and 325 only, with the lens(es) positioned at the end of the pool. Whenever possible, the
lens(es) should not face directly toward the home or entertainment area.
a. For white or nearly white concrete, fiberglass or vinyl pools, Wide Angle Lenses intended to illuminate the
entire length of the pool can be placed in either the shallow end or deep end 6 to 8 inches below water
level.
b. For light or medium colored pools, place the Wide Angle lens(es) in the deep end 6 to 8 inches below
water level.
c. Use single AmerGlow 170, 225, 325 in center of end wall or Dual AmerGlow 170’s or 225’s each 2 to
3.5 feet from center line (4 to 7 feet apart). Pools over 18 feet wide should have dual lenses in the end wall.
C. Wide Angle OptiFusion Lens positioning on the side of the pool with the PG2000 centered on side of pool.
1. AmerGlow 100, 70, 50 and 30 only, unless pool is over 20 ft. wide, with the lens(es) positioned at the side of
the pool. Whenever possible, the lens(es) should not face directly toward the home or entertainment area.
a. Lenses should be located and directed to offer uniform illumination of the entire pool allocating more light
for areas with greater floor and wall surface area such as the deep end. Also see Light Transmission vs
Distance table for more help.
b. The best lighting is achieved on the surfaces the lens is facing.
c. Lens(es) in concrete or fiberglass pools should be located approximately 1/3 of the distance between the
water surface and the beginning of the transition from wall to floor.
• Place 9 in. below water level in 3 foot shallow ends to reduce the intensity of hot spots on the floor.
d. In vinyl pools, locate lens(es) as follows:
HTPED
WOLEBSEHCNI
LENAPFOPOT
.tf3.ni21
.tf4.ni21
.tf5.ni51
.tf6.ni51
.tf7.ni81
.tf8.ni81
.tf9.ni12
.tf01.ni12
P/N 840259 6 Rev. C 7-29-05
.1ELBAT
.tf01taNOISSIMSNARTTHGILTNELAVIUQEREBIF
SEZISELBACWOLGREMA
elbaC
htgneL
0152352207100107050321
212136123616976849221%0.4
410038027512956648211%8.7
618829911519826447211%4.11
816721915415806346201%9.41
026624819312875145201%3.81
52042661621472573229 %1.62
03712051311767433028 %2.33
53691631301062403817 %6.93
0477132139558372617 %4.54
5406111148945352516 %7.05
0554100167541322315 %4.55
551311986048202215 %7.95
068112826635281114 %6.36
0779761503125194 %2.07
523
.viuqerebif
522
.viuqerebif
071
.viuqerebif
001
.viuqerebif
07
.viuqerebif
05
.viuqerebif
03
.viuqerebif
21
.viuqerebif
thgiLfo%
tsoL
0897551442712173 %7.57
0956544302410162 %1.08
0013573826111852 %8.38
This table shows the effect of longer cable runs on light transmission. Longer cable runs have the same effect as cutting
down on the number of fibers.
** The first 10’ is considered unavoidable and is used here as a standard for comparison.
(For example: 69' of 325, 50' of 225 and 37' of 170 all have the same output as 10' of 100.)
WARNING
Provide adequate lighting to your pool for nighttime use. The amount of light needed will vary with the size and shape of the
pool. This may require additional lighting sources. Failure to provide adequate lighting can result in swimming and diving
hazards that can cause severe injury or death. Consult your local building department or a lighting professional to determine
lighting requirements.
Rev. C 7-29-05 7 P/N 840259
SECTION II. Running Conduit
A. General conduit tips.
• Use electrical sweep elbows and 45’s or heat bend PVC pipe. DO NOT use plumbing 90° or 45° elbows. Using
the right conduit and fittings will allow the cable to be fed much easier, and will prevent damage to the fiber optics.
• Use rigid PVC pipe or SMOOTH ID flexible electrical PVC for all cable runs. Flexible water PVC pipe
is not recommended for this type of installation because of its high friction walls.
• Make your job easier - use electrician’s lube when feeding cable.
B. Choosing the best size conduit for the job.
a. For AmerGlow 325, 225 or 170 use 1 in. or larger rigid PVC conduit; use 1½ in. for AmerGlow 325 over 20 ft.
b. Use ¾ in. or larger conduit for AmerGlow 100 or 70.
c. Use ½ in. or larger conduit for AmerGlow 50, 30 or 12.
NOTE
Do not reduce fiberglass lens housing or standard gunite lens housing to less than 1 in. in rear socket or lens assembly will not seat properly.
C. Electrical conduit requirements, see Wiring the PG2000 for Wiring Diagram.
a. For manual operation at PG2000, RF2000 Wireless Control or single remote toggle switch operation, use
½ in. electrical conduit to run 3 - 18 AWG (black, white and green) or larger wires to each PG2000 location.
b. For dual remote toggle switch or automated remote control operation (Compool, etc.), use ½ in. electrical
conduit to run 4 - 18 AWG (red, black, white and green) or larger wires to each PG2000 location.
c. It is very important that the unit be properly grounded - there is serious risk of electrical shock or
electrocution otherwise.
WARNING
The PG2000 must be properly grounded. Consult the National Electrical Code and all other applicable local codes and
ordinances for proper grounding techniques. Improper installation will create an electrical hazard which could result in death or
serious injury to pool users, installers, or others, due to electrical shock, and may also cause property damage.
d. Make sure the conduit comes up in the correct area in the front of the PG2000; see Section IV for this information.
e. Extend conduit up above the bottom of the PG2000 at least six inches.
D. Running the conduit for AmerGlow fiber optic cable.
a. Using the sizes determined above, run the conduit from the pool wall to the PG2000 location.
b. Conduit near the PG2000 should be at least 4 in. deep if using the sub-terrain mounting base to mount the PG2000.
c. Use only electrical sweep elbows and 45’s - DO NOT use plumbing 90’s or 45’s, as they can damage the
fiber optics or prevent pulling the cable.
d. The lens body should be located according to recommendations in the “Before You Begin Installation...”
Section. Conduit should slope to that depth.
e. If using smaller than 1 in. conduit, do not bush down
within 2 in. from rear of lens body.
f. Use a 12 in. minimum straight section of conduit
behind the lens housing.
4 in.
Gunite
1¼ in. min.
g. For gunite pools, the recessed cut back for lens
housing should be as shown in Figure 1. Dimension
“A” should be 1 in. for a FIBERworks Standard
A
Conduit
Gunite fitting, and 1½ in. for a FIBERworks Invisible
Gunite fitting.
P/N 840259 8 Rev. C 7-29-05
Plaster
Surface
Figure 1.
h. At the PG2000 location, leave at least 6 in. of conduit
above the anticipated sub-terrain mounting base or deck
surface and place tape over both ends of conduit. The
tape and extra length will help prevent debris from getting
into the conduit until the cable is run. The conduit should
be cut off level with top of Sub-terrain Base (finished
grade) location just before the fiber optic cable is run
(does not apply to electrical conduit).
(FINISHED LANDSCAPE
OR DECK LEVEL)
i. Use the template on the back page of this manual to
determine conduit location inside the PG2000 if you are
Figure 2.
installing on a poured concrete deck, on a wood deck or
in the ground.
j. For either type of installation, use duct tape or tie wrap to bundle the conduit together in the PG2000 area.
Keeping the conduit together will help when preparing the cable later.
SECTION III. Installing Lens Housings
• FIBERworks® lens housings are installed the same way regular water return fittings are installed.
CAUTION
Use only FIBERworks lens housings. Other fittings will not seal conduit. Each FIBERworks lens housing has a label identifying it
as such. Do not use excessive glue, as the overflow may run onto the O-ring sealing surface.
SECTION IV. Preparing to Mount the PG2000
A. Choose one of the following two methods for installation of the PG2000.
1. Mount the PG2000 on BURIED Sub-terrain Mounting Base (included). This allows the unit to be located
away from the deck, for example, in a garden near the pool, among some shrubbery, etc. Be sure the unit is
situated such that the air vents are not going to be blocked by overgrowth. The sub-terrain mounting base can
also be poured into the concrete deck or pad.
2. Mount the PG2000 directly onto a flat concrete surface or a wood deck without the Sub-terrain Base using the
lag screws, washers and anchors (included).
B. Installing the Sub-Terrain mounting base; see Figure 2 and Pictures on pg. 10.
1. If conduit has already been run, set mounting base over top of conduit to determine if the bottom flange or side
arches need to be cut. The top shoulder of the base should be at or slightly above finished landscape or deck
level.
2. Leveled base can be secured in place with 3/8 in. rebar angled through holes provided in corners of bottom
flange, see Picture 3 on pg. 10
3. Cut fiber conduit below or at top of base and cut electrical conduit 6 in. above finished landscape or deck level,
see Figure 2. See PG2000 Conduit Template on pg. 28 of these instructions.
Note
Flat side of base is back of the PG2000. Locate this side away from line of site to the PG2000.
C. Mounting to a wood deck or a poured concrete surface.
1. What you’ll need:
√ Drill with ½ in. Masonry Bit
√ Hammer
√ ½ in. Nut Driver
(continued on page 11)
Rev. C 7-29-05 9 P/N 840259
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