Pentair Pool Products 175K BTU/HR, 400K BTU/HR ASME, 200K BTU/HR, 250K BTU/HR HD, 300K BTU/HR Operation & Installation Manual

MasterTemp

Pool & Spa Heater

OPERATION & INSTALLATION MANUAL

120/240 VAC NATURAL GAS/LP GAS

MODELS Natural Propane

175K BTU/HR 460792 460793 200K BTU/HR 460730 460731 250K BTU/HR 460732 460733 250K BTU/HR (HD) 460806 – 300K BTU/HR 460734 460735 400K BTU/HR 460736 460737 400K BTU/HR (HD) 460805 – 400K BTU/HR

(ASME)

460775 460776

Consumer

Retain For

Future

Reference

WARNING

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.

• Improper installation, adjustment, alteration, service or maintenance can cause property

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

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

heater or other appliances.

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.

For additional free copies of this manual; call (800) 831-7133.

1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000

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

Rev. C 10-5-07 P/N 472592

Pentair Water Pool and Spa, Inc.

• (805) 553-5000

Customer Service

If you have questions about ordering Pentair replacement parts, and pool products, please use the following contact information.

Customer Service and Technical Support (8 A.M. to 5 P.M. Eastern Time/Pacific Time)

Phone: (800) 831-7133

Fax: (800) 284-4151

Web site

visit

www.pentairpool.com

www.staritepool.com

to find information about Pentair products

1620 Hawkins Ave., Sanford, NC 27330 • (800) 831-7133 or (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (800) 831-7133 or (805) 553-5000 293 Wright Street, Delavan, WI 53115 • (262) 728-5551

This document is subject to change without notice.

Trademarks and Disclaimers: The

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 any proprietary interest in trademarks and trade names other than its own.

P/N 472592 Rev. C 10-5-07

Pentair Pool Products logo

and MasterTemp are registered trademarks of Pentair Water Pool and

Table of Contents

Section 1. Heater Identification Information ....................................................................... 4

Section 2. Introduction .......................................................................................................... 5

Important Notices ................................................................................................................................................................................. 5

Warranty Information ............................................................................................................................................................................ 5

Code Requirements .............................................................................................................................................................................. 6

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

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

Section 3. Installation ............................................................................................................. 9

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

Putting the Heater into Service ............................................................................................................................................................ 9

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

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

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

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

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

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

Gas Connections ................................................................................................................................................................................. 13

Sediment Traps .................................................................................................................................................................................... 13

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

Testing Gas Pressure/Gas Pressure Requirements ............................................................................................................................. 15

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

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

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

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

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

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

Corrosive Vapors and Possible Causes ................................................................................................................................................ 19

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

Vertical Venting - Negative Pressure ................................................................................................................................................... 20 - 22

Horizontal or Vertical Venting - Positive Pressure ................................................................................................................................ 23

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

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

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

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

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

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

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

MasterTemp Wiring Diagram

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

Section 4. Operation ............................................................................................................... 32

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

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

Operating ............................................................................................................................................................................................. 33

To Turn Off Gas to Appliance ............................................................................................................................................................... 33

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

Section 5. Troubleshooting ................................................................................................... 37

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

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

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

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

Section 6. Maintenance ..........................................................................................................45

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

Pressure Relief Valve ........................................................................................................................................................................... 45

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

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

Maintaining Pool Temperature ............................................................................................................................................................... 47

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

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

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

................................................................................................................................................................. 30

Rev. C 10-5-07 P/N 472592

Section 1. Heater Identification Information

Heater Identification Information

To identify the heater, see rating plate on the inner front panel of the heater. There are two designators for each heater, one is the Model Number and the other is the Heater Identification Number (HIN).

a. Heater Identification Number (HIN)

The following example simplifies the identification system:

1) MT : MasterTemp

2) Model Size : (175, 200, 250, 300 or 400) : Input rating (Btu/hr) X 1000

3) Fuel Type : (LP = Propane gas or NA = Natural gas)

4) Construction :(STD = Standard Model) (HD = Heavy Duty Model) (ASME = ASME Certified Model)

HEATER IDENTIFICATION INFORMATION — (HIN)

H. I. N.

HEATER IDENTIFICATION NUMBER

ID DESIGNATOR FOR PENTAIR WATER POOL & SPA MASTERTEMP HEATERS

Example:

1 2 3 4

MT 250 NA ASME

STD = STANDARD MODEL

CONSTRUCTION =

FUEL TYPE =

MODEL SIZE = BTU INPUT in 1000 of BTU / HR

HD = HEAVY DUTY MODEL

ASME = ASME CERTIFIED MODEL

NA = NATURAL GAS

LP = PROPANE GAS

P/N 472592 Rev. C 10-5-07

MT = MASTERTEMP

Section 2. Introduction

Introduction

MasterTemp

Pool and Spa Heater

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

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

IMPORTANT NOTICES

...For the installer and operator of the MasterT emp pool and spa heater. The manufacturer’s warranty may be void if, for any reason, the heater is improperly installed and/or operated. Be sure to follow the instructions set forth in this manual. If you need any more information, or if you have any questions regarding to this pool heater, please contact Pentair W ater Pool and Spa, Inc. at (800) 831-7133.

WARRANTY INFORMATION

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

number from the rating plate inside the heater.

Pentair Water Pool and Spa’s high standards of excellence include a policy of continuous product improvement resulting in your state-of-the-art heater. We reserve the right to make improvements which change the specifications of the heater without incurring an obligation to update the current heater equipment.

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

CAUTION

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

Rev. C 10-5-07 P/N 472592

Section 2. Introduction

CODE REQUIREMENTS

Installation must be in accordance with all local codes and/or the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and the National Electrical Code, ANSI/NFP A70 (U.S.), or standards CSA B149 – INST ALLA TION CODES FOR GAS-BURNING APPLIANCES AND EQUIPMENT and/or local codes and Standard CSA C22.1 – Canadian Electrical Code, Part 1 (Canada). The heater, when installed, must be electrically grounded and bonded in accordance with local codes, or, in absence of local codes, with the Canadian Electrical Code or the National Electrical Code, ANSI/NFPA70, as applicable.

CONSUMER INFORMATION AND SAFETY

WARNING

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

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

2. Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning.

3. Pregnant women beware! Soaking in water above 100° F. can cause fetal damage during the first three months of pregnancy (resulting in the birth of a brain-damaged or deformed child). Pregnant women should stick to the 100° F . maximum rule.

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

5. Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure problems should obtain their physician's advice before using spas or hot tubs.

6. Persons taking medication which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants should not use spas or hot tubs.

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater. Do not use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of control system and gas control which has been under water.

P/N 472592 Rev. C 10-5-07

WARNING

Section 2. Introduction

SAFETY INFORMATION

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

WARNING — FOR YOUR SAFETY

This product must be installed and serviced by a professional service technician, qualified in pool heater installation. Some jurisdictions require that installers be licensed. Check with your local building authority about contractor licensing requirements. Improper installation and/or operation could create carbon monoxide gas and flue gases which could cause serious injury or death. Improper installation and/or operation will void the warranty.

WARNING —

This heater is equipped with an unconventional gas control valve that is factory set with a manifold pressure of -.2 inches wc. Improper installation, adjustment, alteration, service or

maintenance can cause property damage, personal injury or loss of life. Installation or service must be performed by a qualified installer, service agency or the gas supplier. If this control is replaced, it must be replaced with an identical control.

Do not attempt to adjust the gas flow by adjusting the regulator setting.

WARNING —

Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should attempt to convert heater from one fuel to the other. Do not attempt to alter the rated input or type of gas by changing the orifice. If it is necessary to convert to a different type of gas, consult your Pentair dealer. Serious malfunction of the burner can occur which may result in loss of life. Any additions, changes, or conversions required in order for the appliance to satisfactorily meet the application needs must be made by a Pentair dealer or other qualified agency using factory specified and approved parts. The heater is available for use with natural gas or LP (propane) gas only. It is not designed to operate with any other fuels. Refer to the nameplate for the type of gas the heater is

equipped to use.

• Use heater only with the fuel for which it is designed.

• If a fuel conversion is necessary, refer this work to a qualified service technician or gas supplier before putting the heater into operation.

Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, varnishes, paints, or other volatile flammable liquids near heater or in the same room with heater.

Risk of explosion if unit is installed near propane gas storage. Propane (LP) gas is heavier than air. Consult local codes and fire protection authorities about specific installation requirements and restrictions. Locate the heater away from propane gas storage and filling equipment as specified by the Standard for the Storage and Handling of Liquefied Petroleum Gases, CAN/CSA B149.2

(latest edition) or ANSI/NFPA 58 (latest edition).

WARNING —

Rev. C 10-5-07 P/N 472592

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.

SAFETY INFORMATION, (cont’d.)

WARNING —

Risk of asphyxiation if exhaust is not correctly vented. Follow venting instructions exactly when installing heater. Do not use a drafthood with this heater, as the exhaust is under

pressure from the burner blower and a draft hood will allow exhaust fumes to blow into the room housing the heater. The heater is supplied with an integral venting system for outdoor installation. A vent conversion kit ( in enclosures (Canada) or indoors (U.S.). Use the specified venting, and only the specified venting, when heater is installed in an enclosure or indoors. In Canada, this pool heater can only be installed outdoors or in an enclosure that is not normally occupied and has no openings directly into occupied areas. See

Page 19 for enclosure venting requirements.

See Page 23 for Part Numbers for Conversion Kits) is available for installations

Section 2. Introduction

CAUTION —

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Wiring errors can also destroy the control board.

• Connect heater to 120 or 240 Volt, 60 Hz., Single Phase power only.

• Verify proper operation after servicing.

• Do not allow children to play on or around heater or associated equipment.

• Never allow children to use the pool or spa without adult supervision.

• Read and follow other safety information contained in this manual prior to operating this pool heater.

GENERAL SPECIFICATIONS

NOTICE:

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

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

• The access door panels must be in place to provide proper ventilation. Do not operate the heater for more than five (5) minutes with the access door panels removed.

• This heater is design certified by CSA International as complying with the Standard for Gas Fired Pool Heaters, ANSI Z21.56/CSA 4.7, and is intended for use in heating fresh water swimming pools or spas.

• The heater is designed for the heating of chlorine, bromine or salt system swimming pools and spas. It should NOT be used as a space heating boiler, or general purpose water heater. The heater requires an external 120 or 240 VAC single-phase electric power source.

• The heater is design certified by CSA International for installation on combustible flooring. Specified minimum clearances must be maintained to combustible surfaces (see “Heater Clearances”,

• The heater should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the heater. The pan must not restrict air flow.

• 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.

P/N 472592 Rev. C 10-5-07

page 18).

Section 3. Installation

Gas

Air

Mixer

Blower

Inlet (Cold Water)

Exhaust

Heating Coils

Outlet (Mixed Water)

Burner

Installation Instructions

HEATER DESCRIPTION

Figure 1 is a diagram of the heater showing how it operates. Precisely matched orifice plates meter the air and gas into the mixer. The blower draws the air and gas through the mixer and forces it into the burner’s flame holder. A sealed heat exchanger surrounds the flame holder, discharging exhaust gases out the flue.

T wo inch PVC water piping connects directly to the manifold/header on the heat exchanger using 2" PVC slip unions provided with the heater . The outer manifold remains cool; no heat sinks are required. A thermal regulator and an internal bypass regulate the water flow 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 air flow switch (AFS), which senses the pressure drop across the air metering orifice,

• the automatic gas shut-off (AGS) switch, which opens if the heat exchanger outlet temperature goes above 140° F

(60° C).

• the stack flue sensor (SFS), which shuts down the heater if the flue gas temperature reaches 500° F (260° C).

The air flow switch (AFS) senses the pressure drop across the air metering orifice. As soon as there is suf ficient air flow , the AFS closes, closing the circuit to the hot surface igniter (HSI), which ignites the fuel mixture. On a call for heat, the blower and HSI are energized. In about 20 seconds, the gas valve opens and ignition occurs. The HSI then switches to a sensing mode and monitors the flame.

The heater is equipped with a digital operating control that enables the user to pre-set the desired pool and spa water temperatures. The control enables the user to select between pool and spa heating, and features a digital display that indicates the water temperature.

PUTTING THE HEATER INTO SERVICE

If the heater is installed below the level of the pool, or more than two feet above pool level, the pressure switch setting should be adjusted. See WATER PRESSURE SWITCH, in the SAFETY CONTROLS Section.

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

Figure 1.

page 32)

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

Rev. C 10-5-07 P/N 472592

Section 3. Installation

SPECIFICATIONS

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

DIMENSIONS IN INCHES

23.02"

(58.5 cm)

16"

(40.6 cm)

28.15"

(71.5 cm)

ELECTRICAL CONDUIT PORT

32.61"

(82.8 cm)

21.0"

(53.3 cm)

TOPFRONT

EXHAUST SIDE

P/N 472592 Rev. C 10-5-07

16.0"

(40.6 cm)

22.7"

(57.7 cm)

28.2"

(71.6 cm)

Figure 2.

PLUMBING SIDE

5.6"

(14.2 cm)

10.13"

(25.7 cm)

Section 3. Installation

PLUMBING CONNECTIONS

The MasterTemp heater has the unique capability of direct schedule 40 PVC plumbing connections. A set of bulkhead fittings is included with the MasterT emp to insure conformity with Pentair’s recommended PVC plumbing procedure. Other plumbing connections can be used. See Figure 3 for plumbing connections.

CAUTION

POOL HEATER

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

MANUAL BY-PASS

TO POOL

GATE VALVE

FILTER

PUMP

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

Figure 3.

FROM POOL

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

VALVES

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

CAUTION

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

MANUAL BY-PASS

Where the water flow rate exceeds the maximum 120 GPM, a manual bypass should be installed and adjusted. After installing the valve, adjust the valve to bring the flow rate within the acceptable range. Then remove the valve handle or lock it in place to avoid tampering. See Figure 4.

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

571)67(02)454(021

002)67(02)454(021

052)59(52)454(021

003)411(03)454(021

004)251(04)454(021

See page 45 for Pressure Relief Valve Installations.

Rev. C 10-5-07 P/N 472592

Figure 4.

Cool water

Warm water out

wolfdednemmocermumixamehtdeecxetonoD*

.gnipipgnitcennocehtrofetar

Table 1.

1. Set Manual By-Pass Valve.

2. Remove Handle.

Outlet to pool

Inlet to heater

Section 3. Installation

WATER CONNECTIONS

3-Way

The heater requires proper water flow and pressure for its

Valve

operation. See Figure 5 for the recommended installation. The filter pump discharges to the filter, the filter dischar ges to the heater, and the heater discharges directly to the pool or spa.

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

page 11- Table 1 for setting of

the manual by-pass valve.

Main

Drain

Pool

Heater

Spa

Make sure that the outlet plumbing from the heater contains no shut-off valves or other flow restrictions that could prevent flow through the heater (except for below pool as noted below , or winterizing valves where needed). T o 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

From Pool

3-Way

Valve

Figure 5.

pool or spa. Install the chemical feeder downstream of the heater. Install a chemical resistant one-way check valve between the

heater and the chemical feeder to prevent back-siphoning through the heater when the pump is off. NOTICE: If the heater is plumbed in backwards, it will cycle continuously. Make sure piping from filter is not reversed

when installing heater. Connect the heater directly to 2" PVC pipe, using the integral unions provided. Heat sinks are not required. The low

thermal mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down unexpectedly.

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

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

Chlorinator

Check Valve

Filter

Pump

3-Way

Valve

BELOW POOL INSTALLATION

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

See following CAUTION before installation.

BELOW OR ABOVE POOL INSTALLATION

The water pressure switch is set in the factory at 3.00 PSI (± 0.75 PSI). This setting is for a heater installed at pool level. If the heater is to be installed more than 1’ above or below, the water pressure switch must be adjusted by a qualified service technician. See page 34, Figure 29.

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

P/N 472592 Rev. C 10-5-07

CAUTION

FLOW SWITCH

Section 3. Installation

GAS CONNECTIONS

GAS LINE INSTALLATIONS

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

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

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

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

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

Figure 6.

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

NOTE

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

WARNING

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

SEDIMENT TRAPS

Install a sediment trap and union located outside the heater panels in accordance with National code requirements. Do not use a restrictive gas cock. The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet which can be removed for cleaning, as illustrated in Figure 6, or an other device recognized as an effective sediment trap. All gas piping should be tested after installation in accordance with local codes.

18–24" of 3/4" Gas line from Val ve

Union

Sediment Tr ap

1" Dia. or larger

(See "Recommended Pipe Sizes" Chart)

Bell Reducer

At least 9"

At least 3"

Figure 6.

Manual Shut-off Val ve

Rev. C 10-5-07 P/N 472592

GAS PIPE SIZING

LEDOM

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Section 3. Installation

Table 2.

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tooFcibuCrep.U.T.B0001tasaGlarutaN

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TANORPTANORPTANORPTANORPTANORPTANORPTANORP

05’001’002’053’004’006 ----

“RESIDENTIAL”

PROPANE

GAS 2 STAGE REGULATION

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

See “Gas Pressure Requirement Charts”

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HTGNELEPIPTNELAVIUQEMUMIXAM

Table 4.

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“RESIDENTIAL”

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HTGNELEPIPTNELAVIUQEMUMIXAM

Table 3.

NATURAL

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GAS 2 STAGE REGULATION

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

See “Gas Pressure Requirement Charts”

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P/N 472592 Rev. C 10-5-07

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4/3

Table 5.

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Table 6.

Section 3. Installation

TESTING GAS PRESSURE

Before operating the heater, the heater and its gas connections must be leak tested. Do NOT use an open flame to test for leaks. Test all gas connections for leaks with soapy water.

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

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

CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE

WARNING

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

qualified service technicians only!

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

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

To Air Flow Switch

Connection

for Service

To Air Flow Switch

To Gas Valve Vent

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

Figure 7.

To Low Side of Differential Pressure Gauge

Pressure Tap

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

Ven t

Connection

for Test

To High Side of Differential Pressure Gauge

Figure 7.

Pressure Tap Inlet

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

GAS PRESSURE REQUIREMENTS

Rev. C 10-5-07 P/N 472592

CAUTION

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TM4 4

TM1.0±2.0-1.0±2.0-

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Table 7.

Section 3. Installation

OUTDOOR INSTALLATION

(U.S. and Canada)

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

WARNING

Risk of explosion if a unit burning propane gas is installed in a pit or other low spot. Propane is heavier than air. Do not install the heater using propane in pits or other locations where gas might collect. Consult your local building code officials to determine installation requirements and specific installation restrictions of the heater relative to propane storage tanks and filling equipment. Installation must meet the requirements for the Standard for the Storage and Handling of Liquid Petroleum Gases, ANSI/NFPA 58 (latest edition) in the U.S., or CAN/CSA B149.2 (latest edition) in Canada. Consult local codes and fire protection authorities about specific installation restrictions.

Locate the heater on a level surface in an open area that is protected from drainage or run-off. Install the heater in an area where leaves or other debris will not collect on or around the heater.

T o avoid damage to the electronic components in the heater, take care to prevent prolonged exposure to driving sources of water (such as lawn sprinklers, heavy roof runoff, hoses, etc.). A void operation in persistent, extreme, moist or salty environments.

In extreme weather, shut down the heater and disconnect the power to it until the weather has moderated. In areas subject to hurricanes or very high winds, purchase the Bolt Down Bracket Kit, P/N 460738.

HEATER CLEARANCES – OUTDOOR

For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No.

460738.

Lead Anchor

IMPORTANT!

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

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

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, see Figure 8. If the heater is under a roof or deck

3 ft. (1 M) or more

overhang, the space around the heater must be open on three sides. For minimum exhaust vent clearances for building openings, see

Figure 9,

page 17.

In Canada, 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.

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.

CAUTION

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

Figure 8.

P/N 472592 Rev. C 10-5-07

Section 3. Installation

OUTDOOR INSTALLATION

SIDE VIEW

4 ft.

Window

VENTING GUIDELINES

Property Line

Building

Exhaust Grill (Vent)

4 ft.

Force

Air Inlet

Check local building codes

for setback requirements.

Vent Termination:

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

Must be located 4 feet away from the building wall openings, and at the following distances away from any door, window, or gravity air inlet:

4 ft. below, 4 ft. horizontally

Figure 9.

Rev. C 10-5-07 P/N 472592

INDOOR VENTING — General Requirements

The heater may be installed as a Category I or Category III appliance.

Section 3. Installation

Vented Appliance (Category I) –

Vertical only

An appliance that operates with a nonpositive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent, see

Vented Appliance (Category III) –

pages 20-22.

Vertical or Horizontal

An appliance that operates with a positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent, see pages 23-25.

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 on

pages 18-27. If not, replace the vent system. DO NOT use

a draft hood with this heater. The vent pipe must be the same size or larger. The MasterTemp heaters are capable of a 270-degree discharge rotation

and operate with a positive vent static pressure and with a vent gas temperature less than 400° F. The total length of the horizontal run must not exceed the length that is listed in

table 11 on page 23.

HEATER CLEARANCES — General Requirements

INDOOR INSTALLATION (U.S.) OR OUTDOOR SHELTER (CANADA)

The following clearances must be maintained from combustible surfaces:

TOP ..............................6 in. (15 cm)

EXHAUST SIDE .......... 6 in. (15 cm)

HEADER SIDE ............6 in. (15 cm)

DOOR PANELS† ........6 in. (15 cm)

For service access, it is advisable to allow for sufficient clearance on at least one door

anel

6 in.

Note (†) For service access it is advisable to allow for sufficient clearance on at least one door panel. 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

6 in.*

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

6 in.

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.

Figure 10.

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.

P/N 472592 Rev. C 10-5-07

Section 3. Installation

COMBUSTION AIR SUPPLY

For indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area.

The minimum requirements for the air supply specify that the room in which a heater is installed should be provided with two permanent air supply openings; one within 12 inches (30cm) of the ceiling, the other within 12 inches (30cm) of 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 .. These openings shall directly , or through duct, connect to outdoor air .

Pentair W ater Pool and Spa, Inc. does not r ecommend indoor installations that do not provide combustion air from outside the building.

CAUTION

Air Supply Requirements Guide

for MasterT emp Heaters

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Table 8.

Chemicals should not be stored near the heater installation. Combustion air can be contaminated by corrosive chemical fumes which can void the warranty.

Corrosive Vapors and Possible Causes

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Table 9.

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Section 3. Installation

VENT INSTALLATION –

(Category I)

Always vent the heater to the outdoors, see Note*.

• Vent it vertically using Type “B” double wall vent connector pipe.

INDOOR INSTALLATION (U.S.) OR OUTDOOR SHELTER (CANADA)

NOTE *: 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.

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 it is recommended to have a condensate drain as described in the venting installation instructions.

VERTICAL VENTING

(See

Figures 11, 12 and 13)

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. T ype “B” Double-wall vent connector is recommended; however single-wall pipe is

- NEGATIVE PRESSURE

lean the Interior Surface

4" x 8" Metal Flue Collar

Vent Pipe

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 .

T o connect a negative pressure metal gas vent to the heater, order the appropriate Metal Flue Collar from the chart below:

lean and RTV

ralloCeulFlateM.oNtraP

"6x46700-70777

"8x47700-70777

hambe

Flue Collar

This Surface

Figure 11.

1. See Table 10, to determine allowable vent sizes for your heater. NOTICE:

T able 10 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).

Read “VERTICAL VENTING – NEGATIVE PRESSURE” before using this table.

Table 10.

– Permitted Minimum and Maximum Vent Heights By Size and Heater Model

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P/N 472592 Rev. C 10-5-07

Section 3. Installation

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 high temperature 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 V ent Body using the RTV supplied with the kit, following the vent manufacturer’s instructions (included with kit).

3. Attach the vent pipe to the metal Flue Collar with sheet-metal screws.

Min. 10 Ft.

6" Minimum Clearance to Combustible

Materials

Class B Double Wall

Metal Vent Pipe

Metal Flue

Vent

Body

Collar

Listed Termination Cap

Storm Collar

Flashing

Firestop

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

WARNING

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.

Figure 12. – Typical Metal Vent Pipe Installation - U.S.

(Vertical – Negative Pressure)

Listed Termination

Min. 2 Ft.

(.7 M)

6" (15 cm) Minimum Clearance to Combustible Materials

Min. 10 Ft. (3.3 M)

Type B Double Wall

Metal Vent Pipe

Vent

Body

Metal Flue

Collar

Condensate Drain w/trap

Cap

Storm Collar

Flashing

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.

Rev. C 10-5-07 P/N 472592

Figure 13. – Typical Metal Vent Pipe Installation - Canada

(Vertical – Negative Pressure)

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 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.

5. Use Listed fire stop 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 fire stop) 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.

Section 3. Installation

WARNING

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.

WARNING

Risk of fire, carbon monoxide poisoning, or asphyxiation. It is recommended to use a CO Monitor and Fire Alarm in rooms that contain gas fired appliances.

P/N 472592 Rev. C 10-5-07

Section 3. Installation

HORIZONTAL OR VERTICAL VENTING

- POSITIVE PRESSURE

(See Figures 14, 15, and 16)

(Category III)

V ent the heater either horizontally or vertically using an optional vent adapter of the 4-inch special gas approved Category III vent pipes. 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. 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

T able 1 1 for maximum permissible vent lengths.

NOTE

The allowable vent runs for each vent pipe diameter are different and can not be exceeded.

Each 90-degree elbow reduces the maximum horizontal vent run by 12 feet and each 45-degree elbow in the vent run reduces the maximum vent run by 6 feet. See the table below for the maximum vent lengths using 90-degree and 45-degree elbows.

The MasterTemp is a “Category III” appliance and is a forced-draft pool and spa heater which uses positive pressure to push flue gases through the vent pipe to the outside. Flue gases under positive pressure

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may escape into the dwelling with any cracks or loose joints in the vent pipe, or improper vent installation. The vent pipe must be of a

sealed-seam construction, such as those listed for use with “Category

0)M3.12(.tf07

1)M7.71(.tf85

III Appliances”, and for operating temperatures less than 400° F. Vent pipe construction will be of UL 1738 approved non-corrosive material, such as stainless steel, aluminum, galvanized. A condensate trap may

2)M0.41(.tf64

3)M4.01(.tf43

be needed. The use of “Approved” thimbles, roof jacks and/or side vent terminals are required; and the proper clearances to combustible materials must be maintained in accordance with type of vent pipe employed—in the absence of a clearance recommendation by the vent

4)M7.6(.tf22

pipe manufacturer, the requirements of the Uniform Mechanical Code should be met. The ventilation air requirements for the MasterTemp

heater can be found on

18 feet may need to be insulated to reduce condensation related problems

page 19. It is recommended that vent runs over

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and/or the use of a condensate trap in the vent run close to the heater may be necessary in certain installations such as cold climates. Horizontal vents 3’ (1M) or less in length do not require a condensate tee. The MasterTemp heater is suitable for through-the-wall venting.

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Table 11.

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Do NOT combine exhaust vent pipes to a common exhaust vent in multiple unit installations. Run separate vent pipes.

CONNECTING SPECIAL GAS VENT TO THE HEATER

Metallic:

1. Order an optional 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 V ent Cover). Before connecting

the Appliance Adapter to the V ent 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.

Rev. C 10-5-07 P/N 472592

CAUTION

(Pentair offers optional appliance adapter kits, call our Customer Service dept.):

Section 3. Installation

WARNING

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

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. It is recommended to slope the horizontal pipe runs up from the heater at least 1/4" per foot (2cm/M). Install “Approved” 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.

5. Use an “Approved” firestop for floor and ceiling penetrations. Use an “Approved” thimble for wall penetrations. Use an “Approved” 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. Vent Termination – Vertical (See

Figures 14 and 15),

for height of vent termination above the roof. Use an “Approved” 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.

Vent Cap and Riser Furnished by Installer

Side

Wall Vent

Vent Cap and Riser Furnished by Installer

Chimney or Gas Vent

Heater

Chimney or Gas Vent

Outlet Air Opening

Inlet Air Opening

Figure 14.

Outlet Air Opening

7. Make sure entire installation is sealed according to approved standard.

P/N 472592 Rev. C 10-5-07

Side

Wall Vent

Heater

Inlet Air Opening

Figure 15.

Section 3. Installation

Max. 12" Min. 3"

Vent Terminatio

At least 7' above grade adjacent to public walkways

Figure 16.

Vent Termination

1' Minimum above snow or finished grade (whichever is higher)

Forced Air Inlet

4' Min.

Gas Meter

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

4' Min.

Vent Terminatio

1' Min.

8. Vent Termination – Horizontal The terminal must be located (U.S. – See

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

Figure 16):

Figure 17), 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

The terminal must be located (Canada – See

Figure 16):

• 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. T o prevent staining or deterioration, sealing or shielding exposed surfaces may be required.

WARNING

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.

Rev. C 10-5-07 P/N 472592

Metal Vent Body

Metal Special Gas Vent requires Appliance Adapter

Condensate drain w/Trap

(Optional)

Support weight of pipe

Condensate Te e

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

Listed Termina

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

Figure 17.

Leave 6 in. (15 cm) of clear space between heater and combustible surface.

Leave 3 ft. (1 m) or more of clearance above heater

RAISE AT LEAST 18 in. (46 cm) above floor

to avoid flammable vapors

18 in.

Section 3. Installation

OUTDOOR SHELTER INSTALLATION

In Canada, 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.

WARNING

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.

WARNING

Risk of explosion if a unit burning propane gas is installed in a pit or other low spot. Propane is heavier than air. Do not install the heater using propane in pits or other locations where gas might collect. Consult your local building code officials to determine installation requirements and specific installation restrictions of the heater relative to propane storage tanks and filling equipment. Installation must meet the requirements for the Standard for the Storage and Handling of 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.).

GARAGE OR UTILITY ROOM INSTALLATION

In Canada, the heater must be installed in a room that is not normally occupied and has no openings directly to occupied areas.

WARNING

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 any utility room or residential garage installation, install the heater with the base at least 18 inches (.5M) above the floor, see Figure 18. 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 8, page 19).

Choose a location that will avoid contamination by chemical fumes.

CAUTION

A Propane (LPG) fired heater must not be installed in a garage in Massachusetts, by order of the Massachusetts State Fire Marshal. For more information, call the Massachusetts State Fire Marshal’s office.

NOTICE: Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty (See Table 9, page 19).

P/N 472592 Rev. C 10-5-07

Figure 18.

Section 3. Installation

CONTROL PANEL INDEXING

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, see

Figure 19.

Top Panel

Door Access Panel

1. Remove the bolts from the door panels. Remove both door access panels.

2. Remove the four corner screws that secure the top panel. Lift the top

panel upward to remove the top panel.

3. Rotate the top panel to the desired position located at 90° angles. Note

that the control panel must NOT be located on the side where the vent is located.

4. Replace the top panel down onto the side panels. Be sure that there are no

Door Access Panel

wires caught under the panel.

5. Secure the top panel using the four corner screws.

Figure 19.

6. Reattach the door access panels.

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. In Florida, building codes require that the heater be anchored to the equipment pad or platform to

withstand high wind pressures created during hurricanes. A Bolt Down Bracket Kit, P/N 460738, is available with anchor clamps designed to hold the unit to the equipment pad in high wind conditions. Installation of the anchor clamps are recommended in all installations and are required in Florida,

For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No.

460738.

(See Florida Building Code 301.13).

Lead Anchor

Rev. C 10-5-07 P/N 472592

Section 3. Installation

ELECTRICAL CONNECTIONS

Electrical Rating 60 Hz 120 / 240 Volts AC, single phase

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.

CAUTION

This heater is designed to operate at 120 or 240 VAC. It is not recommended to be connected to OR operate on a 208 VAC.

NOTE

• 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).

• If any of the original wiring supplied with this heater must be replaced, installer must supply (No. 18 AWG, 600V, 105° C. U.L. approved AWM low energy stranded) copper wire or it’s equivalent.

CAUTION

The heater ships from the Factory with the 240V plug installed. 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 37 and 41 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 .

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.

Always use crimp type connectors when connecting two wires.

P/N 472592 Rev. C 10-5-07

AC Plug 120 Volt

240 Volt

Figure 20.

Section 3. Installation

CONNECTION OF FIREMAN’S SWITCH OR REMOTE CONTACT

CAUTION

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 immediately destroy the control board and void the warranty.

REMOTE CONTROL CONNECTIONS

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

2. Unbolt and remove the access door panels.

3. Open control box cover (see 4a. To connect a 2-Wire Control (such as Pentair’s IntelliTouch or EasyTouch) or a

timer:

- Remove the factory installed jumper from the Fireman’s Switch terminals.

- Connect wires between the Fireman’s Switch terminals on the heater and the relay. Connect wires from the controller or timer to the Fireman’s Switch. Controller, timer or relay should be sized to handle 24VAC at 0.5 Amp (because it will be completing the 24VAC control board circuit on the heater as shown in

Figure 22). DO NOT apply line voltage to the Fireman’s Switch terminals. Use

18 gauge wire with a minimum 3/64” (1.2mm) thick insulation rated for a temperature rise of at least 105°C.

- Knock-outs are provided to route the wires through the bottom of the control box and past the junction box.

4b. To connect a 3-Wire Control:

- Connect wires between the control board terminals on the heater and the external relays, as shown in

Figure 23. Use at least 2 relays per heater, to allow

for an “OFF setting” on each heater mode. Select relays that can handle logic level switching. DO NOT apply line voltage to control board terminals.

- Move jumper (as shown on external control and to disable the heater membrane pad’s “Pool ON” and “Spa ON” buttons (the “OFF” key on the membrane pad remains functional).

- Knock-outs are provided to route the wires through the bottom and the top of the control box and past the junction box.

5. Close control box cover.

6. Re-install the access door panels. T o control heaters that are operated in parallel, connect wiring

at same locations on heater as 2-Wire or 3-W ire Control. It is imperative that each control circuit is isolated from the other control circuits, to avoid that current will flow from one heater to another through the control circuits.

NOTICE: The fuse for the Fireman’ s Switch is a 1.25 Amp 1¼ x ¼” fast blow fuse, which is commonly available.

Figure 21).

Figure 23) to enable

Figure 22.

Figure 21.

FUSE

24VAC

TRANS

GND

24VAC

THERMISTOR

MEMBRANE PAD

CONNECTION

IND

VAL

OPERATING CONTROL

ENABLE TOGGLE DISABLE TOGGLE

TERMINAL BOARD

TRANS

Time Clock or Remote

(Purchase Separately –

Supplies Power to

Circulator Pump)

Fireman's Switch Completes the heater 24 Volt AC Control Board Circuit. DO NOT connect this circuit to Line Voltage!

12 Pin

Receptacle

GROUND (GND )

GND

24VAC

F I

X BO

JUNCTION

TRANS

S W I

T C H

Rev. C 10-5-07 P/N 472592

MASTERTEMP WIRING DIAGRAM

(3-WIRE SYSTEM)

CONNECTION DIAGRAM

AGS Switch

Stack Flue Sensor

Gas Valve

Y/W

External Control Interface Circuit Disabled, Heater Membrane Pad Enabled

JMP

Air Flow Switch

Extra Switch 1

Hi-Limit Switch Pressure Switch

HLS

ES1

AFS

AGS

SFS

GAS

OPERATING CONTROL

JMP3

External Control Interface

VAL

Spa Line

IND

GND

Common Line

Section 3. Installation

Y/R

Y/BL

Y/O

Y/W

Y Y Y Y

BR BR

24VAC

MEMBRANE PAD CONNECTION

Pool Line

THERMISTOR

NA/LP Models Only

Y/BL

Y/W

Y/R

Y/O

YYYYY

JMP

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

Plug –12 pin

120V – Black 240V – Red

12 Position Receptacle

JUNCTION BOX

Line 1

Line 2

Ground

GND

F1 F2

VAC

DIAGNOSTIC INDICATOR

IGNITION CONTROL

MODULE

S1/

120

L2S2TH IND

240

GYGYBK

120 VAC IGNITER

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.

VAL G ND

GND

24VAC

SEC

Y/W

Y/O

Y/BL

Y/R

Y/W

F I

GND

BLOWER

R E

M A N S

S W I T C H

TRANS

RRW

Replace jumper with

leads to Fireman"s

Switch (field installed)

Figure 23.

P/N 472592 Rev. C 10-5-07

Section 3. Installation

MASTERTEMP ELECTRICAL SCHEMATIC LADDER DIAGRAM

LADDER DIAGRAM

L1 L2

120/240

VAC

IGNITER

S1 S2 L2

24V

COM NO

24 VAC

F2 BLOWER

120/240

24 VAC

OPERATING

CONTROL

24 VAC

LOGIC

WATER

PRESSURE

SWITCH

HI LIMIT SWITCH

GND

CLASS II

TRANSFORMER

GND

AIR

FLOW

SWITCH

IND

THERMISTOR

Rev. C 10-5-07 P/N 472592

AGS

SWITCH

VAL

STACK FLUE

SENSOR

NOTES:

1.)

L1 L2 F1 F2 S1 24 VAC

S2 GND IND VAL

AND TH

ARE CONNECTED ON THE IGNITION MODULE.

2. )

PIN AND SOCKET CONNECTOR.

3. )

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

GAS VALVE

Figure 24.

Section 4. Operation

Operation Instructions

BASIC SYSTEM OPERATION

Start pump, make sure the pump is running and is primed, to close the water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. Follow the Lighting/Operating instructions

below.

MASTERTEMP HSI ELECTRONIC IGNITION LIGHTING/OPERATION

FOR YOUR SAFETY: READ BEFORE LIGHTING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not attempt to light the heater if you suspect a gas leak. Lighting the heater can result in a fire or explosion which can cause personal injury, death, and property damage.

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 burners. Do not try to light the burners by hand.

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas 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.

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. Forced or attempted repair may result in a 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.

P/N 472592 Rev. C 10-5-07

Section 4. Operation

OPERATING INSTRUCTIONS

1. STOP! Read the safety information on (page 32).

2. Set both pool and spa thermostats to the lowest settings.

Water Pressure Switch

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 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

6. Toggle-Style Valve: Pull toggle toward you to turn gas off , see

Figure 25.

Figure 26.

Figure 25.

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the “Before Start-up” instructions (

page 32). If you don’t smell

gas, go to the next step.

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.

Gas control is shown OFF. Push toggle switch away from you to switch ON.

10. Set 3-way valves on inlet and outlet to pool or spa, as appropriate.

1 1 . 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: Setpoint must be above actual water temperature or burner will not fire). See “OPERATING the CONTROL PANEL”.

You

are

here.

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.

Figure 26.

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 below “TO TURN OFF GAS TO THE APPLIANCE”, and call your service technician or gas supplier.

TO TURN OFF GAS TO 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

4. Toggle-Style Valve: Pull toggle toward you to turn gas off, see

5. Replace the Access Door Panels.

Rev. C 10-5-07 P/N 472592

Figure 25.

Figure 26.

SAFETY CONTROLS

AIR FLOW SWITCH (AFS)

The air flow switch, (see Figure 27), is a safety device used to insure that the combustion air blower (fan) is operating and has been designed to monitor the vacuum (negative) pressure within the blower housing. The air flow switch is factory set and is connected upstream of the ignition module. The ignition module does not operate unless the air pressure switch and all safety switches are closed.

WATER PRESSURE SWITCH

WARNING

Section 4. Operation

Figure 27.

Air Flow Switch

Hazardous pressure. Do not bypass the Water Pressure Switch or render it inoperable.

The water pressure switch, (see Figure 28). 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 Water Pressure Switch is factory set at

3.00 psi (20.6 kPa). NOTE: See, Below Pool Level Installation instructions on

page 12. If the pressure switch is one feet (.3M) below or 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 Figure 29. T est the switch after resetting.

NOTICE: When the heater is mounted more than five feet (1.5M) above or four feet (1.2M) 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

Turn star wheel clockwise to raise pressure set point if pressure switch is more than 4 feet (1.2M) below water level

with no water flow. Operation of the heater without sufficient water flow may severely damage it.

Water Pressure Switch

Figure 28.

HIGH LIMITS

A “High Limit”, is a safety device that opens the electrical circuit and shuts off the heater based on a water temperature set point within the “High Limit Device”. The MasterTemp series of heaters contains two (2) high limit devices which are located on the main inlet / outlet header.

P/N 472592 Rev. C 10-5-07

A reference scale is on the back of pressure switch

Turn star wheel counterclockwise to lower pressure set point if pressure switch is more than 5 feet (1.5M) above water level

Star Wheel

Figure 29.

Section 4. Operation

SAFETY CONTROLS, (cont’d.)

Flame Current

OPERATION OF IGNITION MODULE

The Ignition Module, (see Figure 30), is microprocessor based and operates on 24VAC supplied by the transformer. The control utilizes a microprocessor to continually and safely monitor, analyze, and control the proper operation of the gas flame holder. The module with the presence of the flame sensor, using flame rectification, allows the heater to operate.

OPERATING THE CONTROL PANEL

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.

▲▲

Check Point

Diagnostic LED

1 Flash - Air Flow Fault 2 Flashes - Flame No Call for Heat 3 Flashes - Ignition Lockout

Figure 30.

Temperature

Up and Down

Digital Temperature

Display

▼▼

▼ 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.

System Operation

Indicator Lights

Dual Temperature

Controls

Heater "OFF"

Switch

Figure 31.

2. Press ▲ TEMP or ▼ TEMP for 5 seconds. The display will flash once and change modes (°C to °F or vice versa).

3. Turn the Operating Control ON.

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.

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 back-washing). 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 TURN OFF GAS TO THE APPLIANCE” on

page 33), 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.

Rev. C 10-5-07 P/N 472592

WARNING

Door Access Panel

Top Panel

Door Access Panel

Section 4. Operation

TEMPERATURE SETTING

The heater comes factory set at 78° F. for the pool mode and 100° F. for the spa mode. Using the up and down arrows, you can set the thermostats to a minimum temperature of 65° F ., or a maximum of 104° F. If you desire to heat only one body of water, the thermostat is capable of an of f mode. As an example, if you only wish to heat the spa and not the pool, simply depress and hold the pool down arrow , and the thermostat will lower its setting to 65° F. then go to an off mode.

MAXIMUM TEMPERATURE SET POINT

1. Unbolt and remove the door panels (see Figure 32).

2. Access the control panel board on the underside of the top cover. Locate the yellow button on the corner of the control board.

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

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.

Figure 33).

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. T o override the time delay, push the Max. Temp. Set Point button again.

4. Reinstall the access door panels.

Figure 32.

SET

Figure 33.

P/N 472592 Rev. C 10-5-07

Section 5. Troubleshooting

Troubleshooting Instruction

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

NOTICE: Installing the black 120 volt plug in the control box and then connecting the heater to a 240 volt line will destroy the trans -

former, control broad, 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 FOLLOWINGCAREFULLY:

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

Start here for directions to specific Troubleshooting Chart

running.

IMPORTANT! READ ME FIRST!

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 is for 240 volts.

BLACK

plug is for 120 volts, the RED plug

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.

YES

Are any red diagnostic LED’s on back of

board (AGS, AFS, SFS, HLS, PS or THERMISTOR)

Does red “SERVICE HEATER” LED come “on”

YES

“on”

YES

Go to chart “HEATER WILL NOT FIRE - A” (Page 38)

Go to chart “HEATER WILL NOT FIRE - B” (Page 39)

Go to specific safety switch troubleshooting chart (Pages 41 and

Go to chart ‘HEATER WILL NOT FIRE -C” (Page 40)

42)

WARNING WARNING

Disconnect power before servicing any components.

Rev. C 10-5-07 P/N 472592

Hazardous voltage. Can shock, burn or kill.

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

switch terminals to remedy a failed safety switch.

Board.

Fire and Explosion hazard.

Do not jumper

Heater Will Not Fire - A Start

Section 5. Troubleshooting

Is green “SPA” or “POOL” LED

YES

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

If plug is not installed:

Install correct plug.

240V plug in 120V circuit: Replace with

correct plug.

120V plug in 240V circuit: Replace trans-

former, control board, and ignition control module (see “HEATER WILL NOT FIRE-C and

-D”, Pages 40 and 41). Check fuse and all other 24V components

damage.

for

“on”

120V)

YES

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

on?

come

YES

Check for line voltage to heater

Check for 24 VAC at secondary of Transformer

Check for Line Voltage between L1 and L2 terminals on Terminal

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.

Board.

YES

Heater should fire on demand

heat.

for

Restore power to heater.

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

Replace Transformer.

GO TO “HEATER WILL NOT FIRE - B” Page 39

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

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

ground.

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

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?

“on”?

YES

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

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

Heater should fire on demand for

Replace Membrane Pad.

Replace Control Board.

relay).

heat.

P/N 472592 Rev. C 10-5-07

Section 5. Troubleshooting

Heater Will Not Fire - B Start

Is red “SERVICE HEATER” LED “on”

YES

CONTINUE

Is red “SERVICE SYSTEM” LED on?

YES

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

YES

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.

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

YES

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

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

Heater should fire on call for

obstructions.

heat. Re-verify that water flow is above minimum requirement.

Minimum Flow Requirements

Model Flow

175 20 gal/min (76 LPM) 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

Rev. C 10-5-07 P/N 472592

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 40

Model Flow

175 20 gal/min (76 LPM) 200 20 gal/min (76 LPM) 250 25 gal/min (95 LPM) 300 30 gal/min (114 LPM) 400 40 gal/min (151 LPM)

Go to “Diagnostic LED’s”, (Pages 42 and 43)

Heater Will Not Fire - C Start

Section 5. Troubleshooting

Is “SERVICE HEATER” LED “on”?

YES

If any red diagnostic LED’s (AGS, AFS, SFS, HLS, PS, or THERMISTOR) come “on”, go to to Pages 42 and

Did burner fire at all?

Go to “BURNER TROUBLESHOOTING”

44)

(Page

Go to “HEATER WILL NOT FIRE-D” (Page

Replace Ignition Control Module.

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

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

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

43.

CONTINUE

YES

41)

YES

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

on?

stay

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

heat).

for

Check for 24 VAC between TH and GND

terminals on Ignition Control Module. SEE NOTE

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

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

Replace Control Board.

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

Replace Control Board.

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

Replace Gas Valve with identical p

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 Va

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.

lve.

observed.

YES

art.

P/N 472592 Rev. C 10-5-07

Section 5. Troubleshooting

Heater Will Not Fire - D

IMPORTANT! READ ME FIRST!

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 digita

l meter). If the ICM is bad, your volt-

Start

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.

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

Check voltage across igniter leads;

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

AC.

240 V

OK?

YES

Go back to chart “HEATER WILL NOT FIRE-C” (Page 40).

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

Replace HSI Igniter.

Rev. C 10-5-07 P/N 472592

Section 5. Troubleshooting

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

AGS or HLS "on"

Replace High Limit Switch (HLS) or Automatic Gas Shutoff

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

(AGS)

CONTINUE

YES

PS "on"

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

Switch

CONTINUE

AFS "on"

Replace Blower.

Verify that wires BM and F1 are correctly connected at the terminal strip (see Heater Connection Diagram, Page 30)

YES

Verify that water flow rate is above minimum required for heater

Verify that inlet water temperature is below 104˚

Verify that water flow rate is above minimum required for heater

Adjust Water Pressure Switch to close with pump running and open with pump of

Does Blower operate?

Disconnect Blower and check

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

Check for 24 VAC between

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

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

Board.

blockage.

YES

connected.

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

Replace thermistor or Control Board to correct

Service pump and filter to restore proper flo

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 23.

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

(PS).

overheating.

CONTINUE

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

THERMISTOR "on"

CAUTION

remedy a failed switch.

P/N 472592 Rev. C 10-5-07

Do not jumper a safety switch to

Connect correctly and retry. Does Blower st

Replace Blower. Does Blower start on ignition

Replace Ignition Control Module.

Verify Thermistor wiring. If OK, replace Thermistor

art?

try?

NOTE: ES1 is a spare and should be jumpered.

Section 5. Troubleshooting

Diagnostic LED's: SFS

SFS "on"

Heater starts and runs OK,

but temperature of exhaust climbs to 450˚–500˚ in 3–5 minutes.

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

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

Check pressure and volume of fuel

supply

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

= open circuit;

0 = shorted.

Does sensor check

YES

Check continuity in wiring harness between Control Board and Probe.

YES

Continuity

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

Clean/tighten pins as needed.

Reset power to Heater and retry. Heater should fire.

OK?

DONE

YES

Check Heat Exchanger Coil for leaks, liming, soot,

correctly?

DONE

or low flo

Check Thermal Regulator: Open at 120˚?

Correct problem; Heater should fire

Check Thermal-Regulator: Seats

NOT OK

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

Replace Stack Flue Sensor

Reset power to Heater and retry. Heater should

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

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

YES

fire.

(HD )

(Basic)

Replace Heater Membrane

Replace Heater Control

Reset power to Heater and retry. Heater should

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

Replace Heater Control Board.

Reset power to Heater and retry. Heater should

Replace Heater Membrane Pad.

Reset power to Heater and retry. Heater should

Pad.

DONE

Board.

DONE

fire.

DONE

fire.

DONE

fire.

Rev. C 10-5-07 P/N 472592

Section 5. Troubleshooting

Burner Troubleshooting

SYMPTOM CAUSE REMEDY

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

and blower inlet. See page 15 and verify t hat the gas

regulator setting is

Contact a qualified technician or service agency to replace the gas orifice.

Flame is “fluttery.” Flame is too lean. See page 15 and verify t hat the gas Exhaust may have acrid regulator setting is –0.2" (–0.5cm) wc. smell or burner may f to stay lit.

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

ignition.

Combustion appears Flame current is not Check for wet or damaged igniter with normal, but flame does being sensed. not stay lit.

ail

Contact a qualified technician or service agency to replace the gas orifice.

number of

low resistance to ground. Replacewith new igniter.

Verify burner flameholder is properly grounded.

Replace

elbows.

Ignition Control Module.

–0.2" (–0.5cm) wc.

Heat Exchanger Troubleshooting

SYMPTOM CAUSE REMEDY

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

“bumping” sounds.

Sweating. Thermal governor failed. thermal governor

Heat exchanger plugged. Service

Bypass valve stuck open. Service bypass valve. Thermal governor stuck Replace

closed.

Service

heat exchanger. Correct water

chemistry.

thermal governor

Replace

P/N 472592 Rev. C 10-5-07

Section 6. Maintenance

Drill thru the NPT Port, then use a 3/4" Brass Nipple and Elbow (user supplied) for a PRV Installation.

Maintenance Instructions

CARE AND MAINTENANCE

WARNING

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. T est the operation of the pressure relief valve by lifting the valve lever.

4. Test for proper operation of the pressure switch. (See “WATER PRESSURE SWITCH” for testing instructions).

5. On enclosed installations with high-temperature Special Gas Vent systems, repeat the “Final Installation Check,”

page 27. 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.

PRESSURE RELIEF VALVE

Canadian code requires and some U.S. local codes may require installation of a pressure relief valve (PRV). 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.

The relief valve must be installed vertically. To install the valve, use a 3/4" x 2” brass nipple at the manifold, the two brass elbows and nipples are (user supplied), as illustrated in 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.

Figure 34. No valve is allowed to be placed between the manifold

WARNING

Figure 34.

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.

Rev. C 10-5-07 P/N 472592

Section 6. Maintenance

AFTER START-UP

CHECKING WATER FLOW

WARNING

Fire or flooding hazard. If the unit overheats and the burner fails to shut off, follow instructions under “To Turn Off Gas to the Appliance”, page 33, 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 68° F (20° 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.

WINTER OPERATION

CAUTION

• Operating this heater continuously at water temperatures below 68° F. (20° C) will cause harmful condensation and will damage the heater and void the warranty.

• If the heater has been drained for freezing condition, do NOT turn "ON" until the system is circulating water.

• Water trapped in the heat exchanger can result in freeze damage to the exchanger or headers. Freeze damage is specifically not covered by the warranty.

• 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 68° F (20° 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.

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). T urn switch on heater gas valve to OFF. 3 . In northern climates where they may be required, 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 dr aining the pool (isolation valves are not required and should not be used on heaters installed above pool water level except when needed for winterizing valves). 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).

WARNING

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 ST AR T -UP” (page 32) and “CARE AND MAINTENANCE” (page 45).

(See additional notes under Important Notices in Introduction.)

P/N 472592 Rev. C 10-5-07

Section 6. Maintenance

MAINTAINING POOL TEMPERATURE

T o 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). This is accepted as

being the most healthy temperature for swimming by the American Red Cross.

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.

CHEMICAL BALANCE

POOL AND SPA WATER

Your Pentair pool heater was designed specifically for your spa or pool and will give you many years of trouble-free service, provided you keep your water chemistry in proper condition.

W ater chemistry should follow good swimming pool water chemistry practices. When using a chlorinator , install it down stream from the heater and at a lower level than the heater outlet. Install a corrosion resistant positive seal “Check Valve”, (P/N R172288), 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 dif ferential. 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.

Three major items that can cause problems with your pool heater are: improper pH, disinfectant residual, and total alkalinity. These items, if not kept properly balanced, can shorten the life of the heater and cause permanent damage.

CAUTION

Heat exchanger damage resulting from chemical imbalance is not covered by the warranty.

WHAT A DISINFECTANT DOES

T wo pool guests you do not want are algae and bacteria. To get rid of them and make pool water sanitary for swimming

- as well as to improve the water's taste, odor and clarity - some sort of disinfectant must be used. Chlorine and bromine are universally approved by health authorities and are accepted disinfecting agents for bacteria

control.

WHAT IS A DISINFECTANT RESIDUAL?

When you add chlorine or bromine to the pool water, a portion of the disinfectant will be consumed in the process of destroying bacteria, algae and other oxidizable materials. The disinfectant remaining is called chlorine residual or bromine residual. You can determine the disinfectant residual of your pool water with a reliable test kit, available from your local pool supply store.

Y ou must maintain a disinfectant residual level adequate enough to assure a continuous kill of bacteria or virus introduced into pool water by swimmers, through the air, from dust, rain or other sources.

Rev. C 10-5-07 P/N 472592

Section 6. Maintenance

CHEMICAL BALANCE, (cont’d.)

It is wise to test pool water regularly. Never allow chlorine residual to drop below 0.6 ppm (parts per million). The minimum level for effective chlorine or bromine residual is 1.4 ppm.

pH - The term pH refers to the acid/alkaline balance of water expressed on a numerical scale from 0 to 14. A test kit for measuring pH balance of your pool water is available from your local pool supply store; see T able 12.

Muriatic Acid has a pH of about 0. Pure water is 7 (neutral). Weak L ye solution have a pH of 13-14.

RULE: 7.4 to 7.6 is a desirable pH range. It is essential to maintain correct pH, see Table 12.

If pH becomes too high (over alkaline), it has these effects:

1 . Greatly lowers the ability of chlorine to destroy bacteria and algae.

2. Water becomes cloudy.

3 . There is more danger of scale formation on the plaster or in the heat exchanger tubing. 4 . Filter elements may become blocked.

If pH is too low (over acid) the following conditions may occur:

1 . Excessive eye burn or skin irritation. 2 . Etching of the plaster . 3 . Corrosion of metal fixtures in the filtration and recirculation system, which may create brown, blue, green, or sometimes almost

black stains on the plaster.

4 . Corrosion of copper tubes in the heater , which may cause leaks. 5 . If you have a sand and gravel filter, the alum used as a filter aid may dissolve and pass through the filter.

CAUTION: Do not test for pH when the chlorine residual is 3.0 ppm or higher, or bromine residual is

6.0 ppm or higher. See your local pool supply store for help in properly balancing your water chemistry.

RULE: Chemicals that are acid lower pH. Chemicals that are alkaline raise pH.

ALKALINITY High or Low:

"T otal alkalinity" is a measurement of the total amount of alkaline chemicals in the water, and control pH to a great degree. (It is not the same as pH which refers merely to the relative alkalinity/acidity balance.) Your pool water's total alkalinity should be 100 - 140 ppm to permit easier pH control.

A total alkalinity test is simple to perform with a reliable test kit. Y ou will need to test about once a week and make proper adjustments until alkalinity is in the proper range. Then, test only once every month or so to be sure it is being maintained. See your local pool dealer for help in properly balancing the water chemistry.

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 Alkalinity (Buffering), ppm 60 80-100 180 as CaCO3 Total Dissolved Solids, ppm N/A N/A 1,500 ppm > TDS at startup* Calcium Hardness, ppm, as CaCO3 150 200-400 500-1,000 Heavy Metals None None None

Biological Values

Algae None None None Bacteria None None Refer to Local Cod

Table 12.

NOTICE:

*Start-up TDS includes source water TDS and any other inorganic salt added at start-up.

P/N 472592 Rev. C 10-5-07

Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger and will void the warranty.

For complete Electrical System parts breakdown (Key Nos. 1 through 4), See Page 53

MASTERTEMP REPLACEMENT PARTS

For complete Burner System

parts breakdown (Key Nos. 5 through 7), See Page 51

For complete Water System parts breakdown (Key Nos. 8 through 9), see Page 52

Repair Parts are available from your Pentair dealer.

If your dealer cannot supply you, call Customer Support at 1-800-831-7133.

Rev. C 10-5-07 P/N 472592

For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No.

460738.

MASTERTEMP REPLACEMENT PARTS

Lead Anchor

P/N 472592 Rev. C 10-5-07

MASTERTEMP REPLACEMENT PARTS

REPAIR PARTS – BURNER SYSTEM

Model

Key Part 200NA 250NA 300NA

No. Description

1 Combination Gas Control Valve Kit 42001-0051S 42001-0051S 42001-0051S 42001-0051S 2 3/4" Union 3 Gas Orifice 4 Gas Orifice O-Ring

• 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 77707-0251 460743 460757 77707-0253 Propane Units 77707-0254 460744 460758 77707-0256

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

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

• Blower/Adapter Plate Gasket Kit (Includes Key Nos. 8, 9, 10, 12) 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 9 Blower Adapter Plate 10 Flameholder/Adapter Plate Gasket 11 Flameholder Assembly 12 Flameholder/Combustion Chamber Gasket* 13 Flameholder Insulation Cap

• Flameholder Insert

14 Condensate Evaporator Plate 15 One Piece Metal Chamber/Combustion Chamber

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

• Insulation Kit (Includes Key Nos. 13, 14, 16, 17, 18 and 19) 77707-0008 77707-0008 77707-0008 77707-0008

16 Bottom Outer Insulation Blanket* 17 1" Bottom Inner Insulation 18 1" Top Insulation 19 Top Outer Insulation Blanket*

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

20 One Piece Metal Elbow/Combustion Chamber

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

21 Metal Vent Cover 42002-0005S 42002-0005S 42002-0005S 42002-0005S

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

22 Heater Top 42002-0034Z 42002-0034Z 42002-0034Z 42002-0034Z

Side Panel {Service Panel} 42002-0039 42002-0039 42002-0039 42002-0039

23 24 Side Panel {Manifold} 42002-0033 42002-0033 42002-0033 42002-0033

Heater Bottom 42002-0031 42002-0031 42002-0031 42002-0031

Side Panel {Flue Stack} 42002-0032 42002-0032 42002-0032 42002-0032

26 27 J-Box Cover 42002-0041 42002-0041 42002-0041 42002-0041 28 Screw Kit, Panel XXXXXX

Qty.

1 2 1 1

1 1 1 1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1

1 1 1 1 1 1 1 1

175NA

175LP

42001-0051S 38404-4097S

460794 460795

460794

460795

77707-0251 77707-0254

460798

42001-0114S

77707-0011

77707-0202

42001-0200S

77707-0008

42001-0074S

42001-0214S 42002-0005S 42001-0214S 42002-0034Z

42002-0039 42002-0033 42002-0031 42002-0032 42002-0041

XXXXXX XXXXXX XXXXXX XXXXXX

200LP 250LP 300LP 400LP

38404-4097S 38404-4097S 38404-4097S 38404-4097S

400NA

* Not available separately.

† Not included with heater. Order separately

Rev. C 10-5-07 P/N 472592

MASTERTEMP REPLACEMENT PARTS

REPAIR PARTS – WATER SYSTEM

Model

Key Part 175NA - 200NA 250NA 300NA No. Description Qty. 175LP - 200LP 250LP 300LP 400LP

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

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

1 Tube Sheet Coil Assembly Kit (NA – HD Series)

(Includes Key No.3) 1 473710 77707-0244

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

Key Nos. 5-7 in “Electrical System”, Page 53 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 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 8 Manifold Bypass Valve 1 9 Water Pressure Switch 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) 77707-0010 77707-0010 77707-0010 77707-0010 16 Thermal Regulator (Includes Spring Clip) 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 20 Drain Plug U178-920P U178-920P U178-920P U178-920P 21 3/4" Pipe Plug 1 U78-60ZPS U78-60ZPS U78-60ZPS U78-60ZPS 22 Pressure Relief Valve (Recommended -

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

1 1

––

400NA

77707-0234

38674-0719

* Not available separately.

• Not

illustrated.

P/N 472592 Rev. C 10-5-07

MASTERTEMP REPLACEMENT PARTS

REPAIR PARTS – ELECTRICAL SYSTEM

Model

Key Part 175NA - 200NA 250NA 300NA

No. Description Qty. 175LP - 200LP 250LP 300LP 400LP

1 Heater Display Cover 1 42002-0035 42002-0035 42002-0035 42002-0035 2 Igniter Bracket 1 42001-0030S 42001-0030S 42001-0030S 42001-0030S 3 Igniter/Igniter Gasket Kit Incl. Key Nos. 3 and 4) 1 77707-0054 77707-0054 77707-0054 77707-0054 4 Igniter Gasket 1 42001-0066S 42001-0066S 42001-0066S 42001-0066S 5 Automatic Gas Shutoff Switch (AGS) 1 42002-0025S 42002-0025S 42002-0025S 42002-0025S 6 High Limit Switch 1 42001-0063S 42001-0063S 42001-0063S 42001-0063S 7 Thermistor 1 42001-0053S 42001-0053S 42001-0053S 42001-0053S 8 Terminal Board 1 9 Fireman’s Switch Fuse (1.25A, 1-1/4") 32850-0099 32850-0099 32850-0099 32850-0099 10 Ignition Control Module 1 42001-0052S 42001-0052S 42001-0052S 42001-0052S 11 Transformer, 120/240V 1 42001-0107S 42001-0107S 42001-0107S 42001-0107S 12 Air Flow Switch 42001-0061S 42001-0061S 42001-0061S 42001-0061S 13 Control Board Kit (NA, LP Series) 1 42002-0007S 42002-0007S 42002-0007S 42002-0007S

• Heater Wiring Harness - 120/240V 1 42001-0104S 42001-0104S 42001-0104S 42001-0104S

• 120/240 Volt Plug Kit 42001-0105S 42001-0105S 42001-0105S 42001-0105S 14 Heater, Top 42002-0034Z 42002-0034Z 42002-0034Z 42002-0034Z 15 Membrane Pad (NA, LP Series) 472610Z 472610Z 472610Z 472610Z 16 Stack Flue Sensor 1 42002-0024S 42002-0024S 42002-0024S

1 1 1

42001-0056S 42001-0056S 42001-0056S 42001-0056S

400NA

42002-0024S

• Not available separately. * Kit parts not available separately

Rev. C 10-5-07 P/N 472592

NOTES

P/N 472592 Rev. C 10-5-07

NOTES

Rev. C 10-5-07 P/N 472592

SAVE THESE INSTRUCTIONS

Pentair Water Pool and Spa, Inc.

1620 Hawkins Ave., Sanford, NC 27330 • (800) 831-7133 or (919) 566-8000 10951 W. Los Angeles Ave., Moorpark, CA 93021

P/N 472592 Rev. C 10-5-07

• (800) 831-7133 or (805) 553-5000

Pentair Pool Products 175K BTU/HR, 400K BTU/HR ASME, 200K BTU/HR, 250K BTU/HR HD, 300K BTU/HR Operation & Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual