Pentair RS-485 INSTALLATION INSTRUCTIONS

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RS-485 COMBO CONVERSION REPLACEMENT KIT

USA (P/N 476211) AND AUSTRALIA (P/N 462049) FOR MASTERTEMP® AND MAX-E-THERM® POOL AND SPA HEATERS

INSTALLATION INSTRUCTIONS

FAILURE TO FOLLOW ALL INSTRUCTIONS AND WARNINGS CAN RESULT IN SERIOUS BODILY INJURY OR DEATH. THIS PRODUCT SHOULD BE

INSTALLED AND SERVICED ONLY BY A QUALIFIED POOL SERVICE PROFESSIONAL. INSTALLERS, POOL OPERATORS AND OWNERS MUST READ THESE WARNINGS AND ALL INSTRUCTIONS IN THE HEATER INSTALLATION AND USER’S GUIDE BEFORE USING THIS PRODUCT. THESE INSTRUCTIONS MUST BE LEFT WITH THE POOL OWNER.

Pentair Water Pool and Spa heater related products are available at: https://www.pentair.com/en/products/pool-spa-equipment/pool-heaters.html Call (800) 831-7133 for additional free copies of these instructions.

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS

RS-485 Combo Conversion Instructions for USA and Australian heater models

The following instructions describe how to replace the PCBA, Membrane Pad, Ignition Control Module (ICM) and Wiring Harness in a MasterTemp or Sta-Rite pool and spa heater (USA and Australia models) that doesn’t have RS-485 communication capability.

Contents

RS-485 Combo Conversion Replacement (USA) page 2-5

RS-485 Combo Conversion Replacement (Australia) page 6-8

P/N 476251.A 9/2020

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

476211 RS-485 COMBO CONVERSION (USA)

Parts List

P/N Description Qty.

466225 WH HRN US W/ FC 1 476221 ICM W/ FLAME SENSE US 1 476201 MEM PAD MT 6 BUTTONS 1 476199 PCBA MT/MET HTR W/RS485 1 476251 INSTALLATION INSTRUCTIONS 1

462049 RS-485 COMBO CONVERSION (AUSTRALIA)

Parts List

P/N Description Qty.

476226 WH HRN AUSTRALIA W/ FC 1 476222 ICM W/ FLAME SENSE AU 1 476251 INSTALLATION INSTRUCTIONS 1 476201 MEM PAD MT 6 BUTTONS 1 476199 PCBA MT/MET HTR W/RS485 1

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

When installing this kit, basic safety precautions should always be followed. Read and follow all instructions.

Required installation tools:

• Powered socket/nut driver

• 1/4” nut driver bit

• 5/16” socket and nut driver

• 3/8” nut driver

CAUTION! Before starting: Always disconnect AC power to the heater before proceeding with the wire harness replacement instructions.

CAUTION!: Before unplugging ICM connector plugs, be sure to match the

wire identication on both the existing and replacement wire harnesses.

To replace the membrane pad PCBA on a MasterTemp

Heater

To open the heater:

1. Remove left side panel from the heater (Fig. 1 and Fig. 2). Remove the four (4) wing nuts holding the top in place.

FIG. 1.

MasterTemp

2. Disconnect the wire harness from the back of the PCBA.

3. Disconnect the membrane pad from the PCBA.

4. Remove the four (4) screws holding the PCBA and remove the PCBA.

5. Peel the membrane pad from the top panel by pulling one of the corners. Set the panel aside.

6. Disconnect the wires from the ICM. Remove the two (2) screws that secure the ICM to the junction box.

7. Route the membrane pad connector through the top panel slot in order to connect it to the control board. Peel off the membrane pad backing off the new membrane.

8. Align the membrane pad with the bottom of the recess in the lid and press ﬁrmly into place. Smooth the membrane pad with your hand.

9. Place new PCBA into underside of cover and secure with four (4) mounting screws.

10. Reconnect the membrane pad to the PCBA (note the arrow on the membrane connector should be on the bottom)the upper jackets halves from the heater (Fig. 3).

11. Place lid assembly aside and continue with replacing the ICM and Wire Harness.

STD Heater

FIG. 2.

MasterTemp 125 Heater

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

F I L

T E R

PUMP

AUX 1

AUX 2

H IG

H SPE

L OW

S PE

BOOS

TE R P

UM P

Retaining

Pins

To replace the membrane pad and PCBA on a Sta-Rite Max-E-Therm

1. Unbolt the four bolts and separate the jackets halves. Pull hair pin clips. (Fig. 3).

2. Press the plastic clips on the control panel assembly.

3. Lift control panel assembly off of support plate.

4. Disconnect the connectors from the control panel assembly.

FIG. 3.

Max-E-Therm Heater

5. Disconnect the wire harness from the back of the PCBA.

6. Disconnect the membrane pad from the PCBA.

7. Remove the four (4) screws holding the PCBA and remove the PCBA

8. Peel the membrane pad from the top panel by pulling one of the corners.

9. Route the membrane pad connector through the top panel slot in order to connect it to the control board. Peel off the membrane backing

10. Align the membrane pad with the bottom of the recess in the lid and press ﬁrmly into place. Smooth the membrane pad with your hand.

11. Place new PCBA into underside of cover and secure with four (4) mounting screws.

12. Reconnect the membrane pad to the PCBA (note the arrow on the membrane connector should be on the bottom)the upper jackets halves from the heater (Fig. 3).

13. Route the membrane pad connector through the top panel slot to connect to the control board. Peel of the membrane backing. Align the membrane pad properly onto the area of the top panel.

14. Set the lid assembly aside and continue replacing the ICM and wire harness replacing it with the new Control Board with RS-485 communication. Note: The PCBA is not serviceable.

Control Panel

FIG. 3b

AUX 2

EED

SP W LO

PUMP TER OS

PEE

IGH

ER LT FI

PUM

Heater Display Cover

AUX

SPEE

M PU TER

BOOS

D E

AUX

H SPE

FILTER

F F O

NT VE

SS E PR

B TA

T LO I P

PUMP

Membrane Pad (Included with Kit)

Control Board Enclosure Kit

Control Board

Index Plate

FIG. 4.

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

To replace the Ignition Control Module:

1. Disconnect all connector plugs and wires from the legacy ICM. Remove the screws from the legacy ICM. Remove ICM from the heater. (Fig. 5).

2. Install the new ICM into the heater Control Box compartment. Secure the unit with the two (2) screws.

FIG. 5.

To replace the wire harness:

- LEGACY WIRE HARNESS (USA) (P/N 42001-0104): Disconnect all connector plugs and wires from all heater components. Remove the wire harness from the heater.

- Install wire harness (USA) (P/N 476221):BEFORE

YOU START, LAY OUT THE WIRING HARNESS.

3. Bring the Flat 5-pin plug, 2-pin plug and multi-pin connector into the control box. Install the bushing in the hole. Also, bring the Flame current cable into the control box. (Fig. 7).

FIG. 7.

4. Route the Red and Green wires into the Control Box through the bottom hole. Plug the Fireman’s jumper into the terminal board. Install bushing. Be sure the bushings are install when routing the wires into the Junction box. (Fig. 8). Note: The plugs are shown in the control box and

the Fireman’s jumper installed.

1. Cut one tie to release two jumpers.

2. Route the 12-pin plug in the control box from the back. The plug is shown from outside the Control Box. (Fig. 6.)

Note: Narrow key hole in the upper right corner of the plug.

FIG. 6.

FIG. 8.

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

5. Connect BLACK and RED wires to terminal board connections. Match wire identiﬁcation with terminal marking. (Fig. 9).

FIG. 9.

6. From outside the Control Box, push the clip through its hole in the back of the box. (Fig. 10).

8. Connect the 2-pin connector to F1 / F2 at the upper right side of the ICM. (Fig. 12)

FIG. 12.

9. Connect 5-pin connector to lower right side of the ICM and connect multi-pin connector next to 5-pin connector. (Fig. 13).

FIG. 10.

7. Install the bushing in the top of the control box. Use (Fig. 11)

FIG. 13.

10. Mount the bundle of wires on the blower. Plug in the blower motor. (Fig. 14).

FIG. 14.

FIG. 11.

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

11. Connect the Stack Flu sensor. (Fig. 15)

FIG. 15.

12. Connect the Gas Valve. (Fig. 16)

14. Connect the Blower assembly. (Fig. 18).

FIG. 18.

15. Plug in the Transformer. (Fig. 19).

FIG. 16.

13. Connect the Air Flow Switch. (Fig. 17).

FIG. 17.

FIG. 19.

16. Route wires (HL, AGS, WP, etc) to the manifold. (Fig. 20).

FIG. 20.

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (USA)

17. Connect the Thermistor sensor and High Limit Switch.

Note: The Thermistor sensor is located at the top of the manifold. The High Limit switch is located at the bottom of the manifold. (Fig. 21).

FIG. 21

18. Connect the Water Pressure Switch and AGS switch. The AGS is located on the right side. (Fig. 22).

20. Connect one end of the ﬂame cable (Red/Black wires) to Control Board and the other end to the upper left side of the ICM. (Fig 24)

FIG. 24.

21. Reassemble the heater control panel assembly. Be sure that the control panel can be adjusted without having to lean over the exhaust vent.

22. Replace hair pin clips. See Fig. 2, 3) page 3.

23. Replace jacket halves and bolts and tighten.

FIG. 22.

19. Plug the harness into the back of the circuit board. (Fig. 23).

FIG. 23.

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RS-485 COMBO CONVERSION REPLACEMENT INSTRUCTIONS (AUSTRALIA)

When installing this kit, basic safety precautions should always be followed. Read and follow all instructions.

Required installation tools:

• Powered socket/nut driver

• 1/4” nut driver bit

• 5/16” socket and nut driver

• 3/8” nut driver

CAUTION! Before starting: Always disconnect AC power to the heater before proceeding with the wire harness replacement instructions.

CAUTION!: Before unplugging ICM connector plugs, be sure to match the

wire identication on both the existing and replacement wire harnesses.

To replace the membrane pad PCBA on a MasterTemp

1. MasterTemp Heater: Remove left side panel from the heater (Fig. 1 and Fig. 2).

FIG. 1.

MasterTemp

2. Disconnect the wire harness from the back of the PCBA.

3. Disconnect the membrane pad from the PCBA.

4. Remove the four (4) screws holding the PCBA and remove the PCBA.

5. Peel the membrane pad from the top panel by pulling one of the corners. Set the panel aside.

6. Disconnect the wires from the ICM. Remove the two (2) screws that secure the ICM to the junction box.

7. Route the membrane pad connector through the top panel slot in order to connect it to the control board. Peel off the membrane pad backing

8. Align the membrane pad with the bottom of the recess in the lid and press ﬁrmly into place. Smooth the membrane pad with your hand.

9. Place new PCBA into underside of cover and secure with four (4) mounting screws.

10. Reconnect the membrane pad to the PCBA (note the arrow on the membrane connector should be on the bottom)the upper jackets halves from the heater (Fig. 3).

11. Place lid assembly aside and continue with replacing the ICM and Wire Harness.

STD Heater

FIG. 2.

MasterTemp 125 Heater

Heater

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