Pentair WIRE HARNESS REPLACEMENT User Manual

WIRE HARNESS REPLACEMENT KIT

USA (P/N 461107) AND AUSTRALIA (P/N 461108)
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 [phone] for additional free copies of these instructions.

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS - SAVE THESE INSTRUCTIONS

Wire harness Instructions for USA and Australian heater models

The following instructions describe how to replace the wire harness in a MasterTemp or Sta-Rite pool
and spa heater (USA and Australia models) that doesn’t have RS-485 communication capability and
a legacy Ignition Control Module. If you do not know what Ignition Control Module is installed, please
contact customer service at 800.831.7133.

Contents

Wire Harness Replacement (USA) page 3-6

Wire Harness Replacement (Australia) page 7-11

P/N 476250.A 9/2020

1

WIRE HARNESS REPLACEMENT INSTRUCTIONS (USA)

Parts List

P/N Description Qty.
466225 WH HRN US W/ FC 1
476204 ADAPT 6 PIN 1
476209 ADAPT F1-F2 1
476212 ADAPT 5 PIN 1
476250 INSTALLATION INSTRUCTIONS 1

P/N 476204

Parts List

P/N Description Qty.
476226 WH HRN AUSTRALIA W/ FC 1
476205 ADAPT 5 PIN FOR AU 1
476250 INSTALLATION INSTRUCTIONS 1

P/N 476205

P/N 476209

P/N 476212

2

WIRE HARNESS REPLACEMENT INSTRUCTIONS (USA)

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Retaining

Pins

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.

To replace the wire harness on a MasterTemp® or Max-E-Therm® Heater:

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

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1. MasterTemp Heater: Remove right side panel from the

heater (Fig. 1 and Fig. 2).

FIG. 1

MasterTemp STD Heater MasterTemp 125 Heater

FIG. 2.

2. Max-E-Therm Heater: Unbolt the four bolts and separate
the
jackets halves. Pull hair pin clips. (Fig. 3).

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

4. Lift control panel assembly o of support plate.

5. Disconnect the connectors from the control panel
assembly.

7. Install wire harness (USA) (P/N 476221):
BEFORE YOU START, LAY OUT THE WIRING
HARNESS.

8. Route the 12-pin plug in the control box from the back.
The plug is shown from inside the control box. Note:
Narrow key hole in the upper right corner of the plug.
(Fig. 4).

FIG. 4.

FIG. 3.

Max-E-Therm Heater

6. 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.

9. Connect the 5-pin plug into the ICM from the new wire
harness as shown in Fig 21. If the heater has the legacy
ICM. Connect the 5-pin wire adapter (476205) to the cor­responding terminals in the ICM (S1/120, L1, L2 and S2).
Connect the female multi-pin connector of the adapter to
the new wire harness. (Fig. 5).

FIG. 5.

3

WIRE HARNESS REPLACEMENT INSTRUCTIONS (USA)

7. Install the bushing in the top of the control box. Use
(Fig. 6)

FIG. 6.

8. 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. Note: The plugs
are shown in the control box and the Fireman’s jumper
installed. (Fig. 7).

10. Connect the Stack Flu sensor. (Fig. 10)

FIG. 10.

11. Connect the Gas Valve. (Fig. 11).

FIG. 7

9. If the heater has a legacy ICM, connect each wire from
P/N 476204 wire adapter to its correct location labeled
in the ICM. Otherwise, connect the multi-pin connec­tor from the Wire Harness to lower right side of ICM as
shown in Fig 8.

FIG. 8.

FIG.11.

12. Connect the Blower assembly. (Fig. 12).

FIG.12.

4