Sta-Rite 200HD Installation Manual

1

1

1

MasterTemp

Pool & Spa Heater (Outdoor use only)

OPERATION & INSTALLATION MANUAL

240 VAC NATURAL GAS/LP GAS

MODELS Natural Propane

200HD (200 MJ/h) 460946 460949

300HD (300 MJ/h) 460945 460948

400HD (400 MJ/h) 460944 460947

FOR YOUR SAFETY – This product must be installed and serviced

by authorized personnel, qualified in pool/spa heater installation.
Improper installation and/or operation can create carbon monoxide
gas and flue gases which can cause serious injury, property damage,
or death. As an additional measure of safety, Pentair Water Pool and
Spa, Inc. strongly recommends installation of suitable Carbon Monoxide
detectors in the vicinity of this heater. Improper installation and/or
operation will void the warranty.

™

(Australia)

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 1800 664 266 – AUS.

Pentair Water AU/NZ –

10951 W. Los Angeles Ave., Moorpark, CA 93021, USA • [phone] • [phone]

Rev. B 04-30-10 P/N 474131

Head Office

1620 Hawkins Ave., Sanford, NC 27330, USA • [phone] • [phone]

– 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • [phone] • 1800 664 266

Pentair Water Pool and Spa, Inc.

2

Customer Service

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

Customer Service and Technical Support, AUS (AEST Time)

Phone: [phone]

Fax: [phone]

Notting Hill, Victoria, AUS (AEST Time)

Phone: [phone]

Customer Service and Technical Support, USA (8 A.M. to 4:30 P.M. Eastern/Pacific Times)

Phone: [phone]

Fax: [phone]

Sanford, North Carolina, USA (8 A.M. to 4:30 P.M. — Eastern Time)

Phone: [phone]

Fax: [phone]

Moorpark, California, USA (8 A.M. to 4:30 P.M. — Pacific Time)

Phone: [phone]

Fax: [phone]

Web site

visit

www.pentairpool.com

products

© 2010 Pentair Water Pool and Spa, Inc. All rights reserved.

or

www.staritepool.com

or

www.onga.com.au

to find information about Pentair

Pentair Water AU/NZ – Head Office – 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • [phone]
1620 Hawkins Ave., Sanford, NC 27330 – USA • [phone] or [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 – USA • [phone] or [phone]

This document is subject to change without notice.

Trademarks and Disclaimers: MasterTemp™, IntelliTouch™, EasyTouch™, and Pentair Water Pool and Spa® are trademarks and/or

registered trademarks of Pentair Water Pool and Spa, Inc. and/or its affiliated companies in the United States and/or other counties.
Unless noted, names and brands of others that may be used in this document are not used to indicate an affiliation or endorsement
between the proprietors of these names and brands and Pentair Water Pool and Spa, Inc. Those names and brands may be the
trademarks or registered trademarks of those parties or others.

P/N 474131 Rev. B 04-30-10

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

Sequence of Operation ......................................................................................................................................................................... 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

Gas Pipe Sizing ................................................................................................................................................................................... 13

Sediment Trap/Drip Leg ....................................................................................................................................................................... 13

Testing Gas Leaks and Gas Pressure .................................................................................................................................................. 14

Gas Pressure Requirements ................................................................................................................................................................ 14

Outdoor Installation .............................................................................................................................................................................. 15

Heater Clearances ................................................................................................................................................................................ 16

Outdoor Installation Venting Guidelines ................................................................................................................................................ 16

Corrosive Vapors and Possible Causes ................................................................................................................................................ 17

Control Panel Indexing ......................................................................................................................................................................... 17

Final Installation Check ........................................................................................................................................................................ 17

Electrical Connections .......................................................................................................................................................................... 18

Fireman’s Switch Connection/Remote Control Connections .................................................................................................................. 19

MasterTemp Wiring Diagram ................................................................................................................................................................. 20

Electrical Schematic Ladder Diagram ................................................................................................................................................... 21

Section 4. Operation ............................................................................................................... 22

Basic System Operation ...................................................................................................................................................................... 22

HSI (Hot-Surface Ignition) Lighting/Operation ....................................................................................................................................... 22

Operating Instructions .......................................................................................................................................................................... 23

To Turn Off Gas to Appliance ............................................................................................................................................................... 23

Safety Controls .................................................................................................................................................................................... 24 - 26

Section 5. Troubleshooting ................................................................................................... 27

Initial Troubleshooting and Troubleshooting Chart ................................................................................................................................. 27

Heater Will Not Fire Troubleshooting .................................................................................................................................................... 28 - 31

LED Diagnostics .................................................................................................................................................................................. 32 - 33

Burner / Heat Exchanger Troubleshooting ............................................................................................................................................ 34

Section 6. Maintenance ..........................................................................................................35

Care and Maintenance .......................................................................................................................................................................... 35

Pressure Relief Valve ........................................................................................................................................................................... 35

After Start-Up ...................................................................................................................................................................................... 36

Spring, Fall and Winter Operation ......................................................................................................................................................... 36

Maintaining Pool Temperature ............................................................................................................................................................... 37

Energy Saving Tips .............................................................................................................................................................................. 37

Chemical Balance ................................................................................................................................................................................ 37 - 38

Replacement Parts .............................................................................................................................................................................. 39 - 43

3

Rev. B 04-30-10 P/N 474131

4

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

a. Heater Identification Number (HIN)

The following example simplifies the identification system:

1) MT : MasterTemp

2) Model Size : (200, 300 or 400) : Input rating (Mega Joule [MJ]/hr)

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

4) Construction :(HD = Heavy Duty Model)

HEATER IDENTIFICATION INFORMATION — (HIN)

Model Number and the other is the Heater Identification Number (HIN).

H. I. N.

HEATER IDENTIFICATION NUMBER

ID DESIGNATOR FOR PENTAIR WATER POOL & SPA MASTERTEMP HEATERS

Example:

1 2 3 4

MT 200 NA

HD

CONSTRUCTION =

FUEL TYPE =

MODEL SIZE = MJ INPUT = Mega Joule [MJ] / HR

HD = HEAVY DUTY MODEL

NA = NATURAL GAS

LP = PROPANE GAS

MT = MASTERTEMP

P/N 474131 Rev. B 04-30-10

Section 2. Introduction

Introduction

5

MasterTemp

Pool and Spa Heater

Congratulations on your purchase of a MasterTemp 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 MasterTemp
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 Water Pool and Spa
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 MasterTemp requires an external power source (240 VAC

SPECIAL INSTRUCTIONS TO OWNER: Retain this manual for future reference. This instruction manual provides
operating instructions, installation and service information for the MasterTemp high performance heater. The information in
this manual applies to all MasterTemp models. READ AND REVIEW THIS MANUAL COMPLETELY, 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.

™

(Australia)

(Outdoor use only)

50 Hz) to operate.

®

IMPORTANT NOTICES

THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED
IN POOL HEATER INSTALLATION.

...For the installer and operator of the MasterTemp 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 Water AU/NZ, AUS – at 1800 664 266 • [phone] or Pentair Water Pool and Spa, Inc., USA – at
[phone] • [phone] • [phone].

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 20°C. 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 20°C., as this will cause condensation
related problems.

Rev. B 04-30-10 P/N 474131

6

Section 2. Introduction

CODE REQUIREMENTS

Installation must be in accordance with all local codes and ordinances/or the latest edition of the National
Fuel Gas Code, AS 5601 and the National Electrical Standards, or standards and/or local codes.

The heater, when installed, must be electrically grounded and bonded in accordance with local codes.

DANGER

CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains toxic levels of carbon monoxide, a dangerous,
poisonous gas you cannot see or smell.

CONSUMER INFORMATION AND SAFETY

WARNING

The U.S. Consumer Product Safety Commission warns that carbon monoxide is an "invisible killer". Carbon monoxide
is a colorless and odorless gas.

1. Carbon monoxide is produced by burning fuel, including natural gas and propane.

2. Proper installation, operation and maintenance of fuel-burning appliances in the home is the most important factor in reducing
carbon monoxide poisoning.

3. Be sure that fuel burning appliances such as heaters are installed by professionals according to manufacturer's instructions and codes.

4. Always follow the manufacturer's directions for safe operation.

5. Have the heating system (including vents) inspected and serviced annually by a trained service technician.

6. Examine vents regularly for improper connections, visible cracks, rust or stains.

7. Install battery-operated carbon monoxide alarms. The alarms should be certified to the requirements of the most recent UL, IAS,
CSA and IAPMO standard for carbon monoxide alarms. Test carbon monoxide alarms regularly and replace dead batteries.

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 40° C. A temperature of 37° C. 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 37° C. can cause fetal damage during the first three months of pregnancy
(resulting in the birth of a brain-damaged or deformed child). Pregnant women should stick to the 37° C. 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 -15° C.

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.

WARNING

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 474131 Rev. B 04-30-10

Section 2. Introduction

7

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.

DANGER — CARBON MONOXIDE GAS IS DEADLY

• • READ OWNERS MANUAL COMPLETELY BEFORE OPERATING. • •

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.

Exhaust from this pool heater contains carbon monoxide, a dangerous, poisonous gas you cannot
see or smell. Symptoms of carbon monoxide exposure or poisoning include dizziness, headache,
nausea, weakness, sleepiness, muscular twitching, vomiting and inability to think clearly. IF YOU
EXPERIENCE ANY OF THE ABOVE SYMPTOMS, IMMEDIATELY TURN OFF THE POOL
HEATER, LEAVE THE VICINITY OF THE POOL OR SPA AND GET INTO FRESH AIR IMMEDIATELY.
THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE
RESUMING OPERATION.

EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR DEATH.

Install this pool heater far from open windows, doors, vents and other openings, see page 16 for
minimum distances.

Pentair strongly recommends that all vents, pipes and exhaust systems be initially and periodically
tested for proper operation. This testing can be accomplished by using a hand-held carbon monoxide
meter and/or by consulting with a gas professional.

Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool
heater. The carbon monoxide detectors must be periodically inspected for proper operation so as to
insure continued safety. Broken or malfunctioning carbon monoxide detectors must be replaced
immediately.

WARNING —

WARNING —

Rev. B 04-30-10 P/N 474131

This heater is equipped with an unconventional gas control valve that is factory set with a
manifold pressure of

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

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

Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a

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

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

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

11 ± 5 Pa. Improper installation, adjustment, alteration, service or maintenance

8

SAFETY INFORMATION, (cont’d.)

WARNING —

WARNING —

WARNING —

WARNING —

Ven t

Cover

Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, varnishes,
paints, or other volatile flammable liquids near 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 (latest edition).

Risk of fire. Do not place articles on, near or against the heater.

Risk of burn hazard. To reduce the risk of injury, do not touch the side heater vent cover when the

heater is operating. Side heater vent covers are HOT and can burn when touched causing personal
injury. Do not allow children to play on or around heater or associated equipment.

Section 2. Introduction

WARNING —

CAUTION —

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.

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 240 Volt, 50 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 IAPMO as complying with the Standard for Gas Fired Pool Heaters, 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 240 VAC
single-phase electric power source.

• 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 1.5M (5 ft.) of the inside surface of a pool or spa unless it is separated by a solid
fence, wall or other permanent barrier.

P/N 474131 Rev. B 04-30-10

Section 3. Installation

9

Installation Instructions

THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED IN POOL
HEATER INSTALLATION.

Pentair strongly recommends that all vents, pipes and exhaust systems be initially and periodically tested for proper operation. This
testing can be accomplished by using a hand-held carbon monoxide meter and/or by consulting with a gas professional.

Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool heater. The carbon monoxide
detectors must be periodically inspected for proper operation so as to insure continued safety. Broken or malfunctioning carbon
monoxide detectors must be replaced immediately.

HEATER DESCRIPTION

Gas

Figure 1 is a diagram of the heater showing how it operates. Precisely

Air

Blower

Exhaust

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.

Inlet
(Cold
Water)

Mixer

Five (5) cm PVC water piping connects directly to the manifold/
header on the heat exchanger using 5 cm 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

Outlet
(Mixed
Water)

Burner

Heating Coils

located on top of the heater.

SEQUENCE OF OPERATION

Figure 1.

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 57° C (135° F), 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 60° C (140° F).

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

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

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

PUTTING THE HEATER INTO SERVICE

If the heater is installed below the level of the pool, or more than 0.6 meters (2 feet) above pool level, the pressure switch
setting should be adjusted. See “WATER PRESSURE SWITCH” in the “SAFETY CONTROLS Section” (page 24) and
the “CAUTION” under “BELOW POOL INSTALLATION Section” (page 12).

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

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

Rev. B 04-30-10 P/N 474131

page 22) in

10

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 Installations.

DIMENSIONS IN CENTIMETERS & INCHES

58.5 cm
(23.02")

40.6 cm
(16")

71.5 cm
(28.15")

ELECTRICAL
CONDUIT PORT

82.8 cm
(32.61")

53.3 cm
(21.0")

TOPFRONT

71.6 cm
(28.2")

57.7 cm
(22.7")

40.6 cm
(16.0")

EXHAUST SIDE

Figure 2.

P/N 474131 Rev. B 04-30-10

PLUMBING SIDE

14.2 cm
(5.6")

25.7 cm
(10.13")

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 MasterTemp to insure conformity
with Pentair’s recommended PVC plumbing procedure. Other
plumbing connections can be used. See Figure 3 for plumbing
connections.

11

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

Figure 4.

Where the water flow rate exceeds the maximum 454 LPM, 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)MPG(MPL.niM*)MPG(MPL.xaM

002)02(67)021(454

003)03(411)021(454

004)04(251)021(454

dednemmocermumixamehtdeecxetonoD*

.gnipipgnitcennocehtrofetarwolf

Table 1.

1. Set Manual By-Pass Valve.

2. Remove Handle.

Warm water out

See page 35 for Pressure Relief Valve Installations.

Rev. B 04-30-10 P/N 474131

Cool water

Outlet to pool

Inlet to heater

12

Section 3. Installation

WATER CONNECTIONS

3-Way

The heater requires proper water flow and pressure for its
operation. See

Figure 5 for the recommended installation. The

Valve

filter pump discharges to the filter, the filter discharges to the
heater, and the heater discharges directly to the pool or spa.

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

page 11 - Table 1 for setting of

the manual by-pass valve.

Make sure that the outlet plumbing from the heater contains

Main

Drain

Pool

Heater

Spa

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

Install the chemical feeder downstream of the heater. Install

From Pool

3-Way

Valve

Figure 5.

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 5 cm 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.

Local codes may require the installation of a pressure relief valve (PRV), see

page 35 for “PRESSURE

RELIEF INSTRUCTIONS”.

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.

CAUTION

BELOW OR ABOVE POOL INSTALLATION

The water pressure switch is set in the factory at 21 kPa (± 5 kPa). This setting is for a heater installed at pool level. If
the heater is to be installed more than 0.3 m above or below, the water pressure switch must be adjusted by a
qualified service technician. See page 24, Figure 22.

FLOW SWITCH

If the heater is installed more than 1.5 m above the pool or more than 1.2 m 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 474131 Rev. B 04-30-10

Section 3. Installation

13

GAS CONNECTIONS

GAS LINE INSTALLATIONS

The gas supply must be installed in accordance with the Gas Installation Code, AS5601, as applicable and all applicable local codes.

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 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 0.9 additional meters 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. Insufficient gas supply will cause the heater to operate below its designed performance or not at
all. 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. Gas supply
companies are increasingly supplying natural gas to new installations with 2.75 kPa; this means if the gas pressure is not
adjusted to the correct working pressure, the heater will be over gassed and cause serious damage within minutes. This
damage is not covered under the heater warranty.

Install a manual shut-off valve that conforms with Type 1 or Type 2 as per AG201 and/or AS4617 standards, and a sediment
trap/drip leg and union located outside the heater panels, see

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 6.0 kPa). 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.

Table 2 below shows the recommended gas inlet pipe sizes required for the distance from the gas meter to

Figure 6. Do not use a restrictive gas cock.

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.

GAS PIPE SIZING

Table 2.

eziSretaeH

m51ot0m03ot61m06ot13

002mm52mm23mm23

003mm23mm23mm04

004mm23mm04mm05

SEDIMENT TRAP/DRIP LEG

Install a sediment trap/drip leg and union located outside the
heater panels in accordance with National code
requirements. Do not use a restrictive gas cock. The sediment
trap/drip leg 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/drip leg. All gas piping should be
tested after installation in accordance with local codes.

reteMehtmorfecnatsiD

46-61 cm of 1.91 cm

(18–24" of 3/4")

Gas line from

Valve

2.54 cm (1") Dia. or larger
(See "Recommended

Pipe Sizes" Chart

Bell
Reducer

Union

Sediment
Trap/Drip Leg

Manual
Shut-off
Val ve

)

At least 22.9 cm (9")

At least 7.6 cm (3")

Figure 6.

Rev. B 04-30-10 P/N 474131

14

Section 3. Installation

TESTING GAS LEAKS AND 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 6.0 kPa (.87 psig).

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 6.0 kPa (.87 psig).

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 11 ± 5 Pa.
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 negative­pressure regulator. For

To

Air Flow

Switch

proper operation, the
regulated pressure at the
outlet manifold of the valve
must be 11 ± 5 Pa 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 in Figure 7.

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.

Connection

for Service

To
Gas
Valve
Vent

To Air Flow
Switch

To Gas

Valve Vent

To Low Side
of Differential
Pressure Gauge

Connection

for Test

To High Side
of Differential
Pressure Gauge

Ven t

Pressure

Ta p

Figure 7.

CAUTION

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

erusserPsaGmuminiMmumixaM

saGlarutaN

saGenaporP

:ETON .tnemtsujdatupnirofdetsileulavm

P/N 474131 Rev. B 04-30-10

uminimehT

.smelborpecnamrofrep

aPk0.1aPk0.6

aPk0.1aPk0.6

.erusserpylppusmumixamehtdeecxetonoD

ynA.gnitareposiretaehelihwnekatebtsumsgnidaerllA

lliwffosiretaehelihwedamsgnidaerrostnemtsujda

nitluser

Table 3.