Sta-Rite MT2000 I Installation Manual

Installation and Operation Instructions for
MegaTherm
Pool Heating Boiler
Model MT
Sizes 2000-5000
TM
IMPORTANT: Store these instructions in the packet provided on the boiler
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
®
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
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 nearby phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency, or gas supplier.
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
P/N 472644 Rev A - 05/22/06
SAVE THESE INSTRUCTIONS
Page 2
Pentair Water Commercial Pool and Spa
TABLE OF CONTENTS
SECTION 1. General Information
1A. Introduction................................................... 3
SECTION 2. Installation
2A. Boiler Placement .......................................... 3
2B. Installation of Indoor Boilers ......................... 4
2B-1. Combustion Air Supply ................................. 4
2B-2. Venting ......................................................... 5
2C. Installation of Outdoor Water Units............... 5
2D. Freeze Protection ......................................... 6
2E. Gas Supply and Piping ................................. 6
2F. Electrical Wiring ............................................ 7
2G. Piping of System to Boiler ............................ 7
2H. General Water Piping ................................... 7
2I. Boiler By-Pass Piping ................................... 8
2J. Automatic Chlorinators ................................. 8
2K. Pressure Switch ........................................... 8
SECTION 3. Operation
3A. Initial Start Up ............................................... 9
3A-1. Initial Filter Cycle on a New Pool .................. 9
3A-2. Starting Instructions ...................................... 9
3A-3. Hi-Limit Checkout ....................................... 10
3B. To Start Up System
(See Section 3A for Initial Start Up) ............ 10
3C. To Turn Off Boiler ....................................... 10
3D. Spring and Fall Operation ............................ 10
3E. Winter Operation ......................................... 10
3E-1. Draining Boiler Before Freezing ................... 10
3E-2. Improper Use of the Boiler ........................... 10
3F. Time Clock Operation .................................. 11
3G. Spa (Hot Tub) Safety Rules ......................... 11
3H. Periodic Service .......................................... 11
3I. Pool Water Chemistry ................................. 11
SECTION 4. Maintenance
................................................................... 12
SECTION 5. Troubleshooting and Analysis of Service Problems
................................................................... 12
SECTION 6. Conversion of Model MT Pool Boilers From Indoor to Outdoor Models
6A. SECTION I ................................................. 14
6B. SECTION II ................................................ 14
SECTION 7. Parts Description and Order Numbers
................................................................... 16
Pentair Technical Support
Sanford, North Carolina (8 A.M. to 5 P.M.)
Phone: (800) 831-7133 Fax: (919) 566-8920
Moorpark, California (8 A.M. to 5 P.M.) Phone: (800) 831-7133 Fax: (800) 284-4151
Web sites: visit www.pentairpool.com and www.staritepool.com
MegaTherm Commercial Pool Heating Boiler
Page 3
SECTION 1. General Information
IMPORTANT WARNING:
The MegaTherm Model MT commercial pool boilers must be used with potable water only. For pools containing salt water, a specially equipped boiler must be used. Consult your distributor or factory representative. The pool boiler must be installed in accordance with the procedures in this manual, or the warranty could be voided. Consult local building codes and ANSI bulletin Z223.1 or in Canada CAN1­B149 before proceeding with the installation. Any modification to the boiler, its gas controls, gas orifices, wiring or draft diverter may void the warranty. Consult the factory before making any modifications.
1A. Introduction
This manual provides information for the installation and operation of Model MT Pool Boilers. It is strongly recommended that all application and installation procedures be reviewed completely before proceeding with the installation. Consult the Pentair Water Commercial Pool and Spa technical support
(see page 2), or your local representative, with any problems or questions regarding this equipment. Experience has shown that most operating problems are caused by improper installation.
Model MT boilers are offered in two configurations: an indoor version and an outdoor version. The indoor version is convertible for outdoor use with the installation of a conversion kit as described in Section 6 of this manual. The two configurations are shown in Figure 1.
Some accessory items are shipped in separate packages. Verify receipt of all packages listed on the packing slip. Inspect everything for damage immediately upon delivery, and advise the carrier of any shortages or damage. Any such claims should be filed with the carrier. The carrier, not the shipper, is responsible for shortages and damage to the shipment whether visible or concealed.
SECTION 2. Installation
2A. Boiler Placement
The Model MT boiler must be placed to provide clearances on all sides for maintenance and inspection. There must also be minimum distances maintained from combustible surfaces.
Figure 1. Boiler Configuration - Series MT.
Page 4
Pentair Water Commercial Pool and Spa
All boilers must be installed on a non-combustible floor. Under no circumstances can boilers be installed on carpeting. The National Fuel Code allows a boiler to be placed on other than a non combustible surface when such an installation complies with the local codes. This code specifies the surface under the boiler be protected with hollow masonry no less than 4" thick, covered with sheet metal at least 20 gage in thickness. Such masonry must be laid with ends unsealed, and joints matched in such a way as to provide a free circulation of air from side to side through the masonry (see Figure 2).
Clearance Indoor Outdoor
From (Inches) (Inches)
Top 24
Water Conn. Side 24 24
Opposite Side 24 24
Front 48 48
Rear 24 24 Vent 6
Table 1. Minimum Boiler Clearance
From Combustible Surfaces
cause accelerated deterioration of controls and electrical components.
3. Exhaust Fans or Vents: Any equipment which exhausts air from the boiler room can deplete the combustion air supply or reverse the natural draft action of the venting system. This could cause flue products to accumulate in the room. Additional air must be supplied to compensate for such exhaust. The information in Table 2 is not applicable in installations where exhaust fans or blowers of any type are used. Such installations must be designed by qualified engineers.
Blocks must provide solid base and be braced so they cannot slip out of place. Air openings in blocks must be arranged to provide unobstructed opening through entire width or length of base.
Figure 2. Non-Combustible Base.
2B. Installation of Indoor Boilers
2B-1. Combustion Air Supply
1. The boiler location must provide sufficient air supply for proper combustion, and ventilation of the surrounding area as outlined in the latest edition of ANSI standard Z223.1 or, in Canada CAN1-B149, and any local codes that may be applicable. Inadequate combustion air supply may result in incomplete combustion and consequent sooting of the heat exchange and unsafe operation of the boiler.
2. In general, (in the U.S.), these requirements specify that equipment rooms which represent confined spaces should be provided with two permanent air supply openings communicating directly through the wall to outside air; one within 12 inches of the ceiling, the other within 12 inches of the floor. Each opening should have a minimum free area of one square inch per 4,000 BTUH input of the total input rating of all appliances in the enclosed area. These requirements differ in Canada. Consult the National Standard of Canada CAN1-B149 for details. See Table 2 for recommended air supply for U.S. models. An improperly ventilated equipment room can get excessively hot and
Indoor Each Opening*
Size (Square Inches)
2000 500 2450 613 3050 763 3500 875 4050 1013 4500 1125 5000 1250
Net Free Area in Square Inches*
*Area indicated is for one of two openings: one at floor level and one at the ceiling, so the total net free area would be double the figures indicated. For all other conditions, refer to latest edition of ANSI A223.1.
NOTE: Check with louver manufacturers for Net Free Area of louvers. Correct for screen resistance to the Net Free Area if a screen is installed. Check all local codes applicable to combustion air.
Table 2. Minimum Recommended Air
Supply to Equipment Room.
4. If a blower or fan is used to supply air to the equipment room, the installer should make sure it does not create drafts which could cause nuisance shut-downs of the pilot. If a blower is necessary to provide adequate combustion air to the boiler, a suitable switch or equivalent must be wired into the boiler control circuit to prevent the boiler from firing unless the blower is operating.
5. The boiler must be completely isolated and protected from any source of corrosive chemical fumes such as emitted by trichlorethylene, perchlorethylene, chlorine, etc.
MegaTherm Commercial Pool Heating Boiler
Page 5
2B-2. Venting
1. Model MT boilers have built-in draft diverters for natural draft operation and must not be connected into any portion of a mechanical draft system under positive pressure. The flue outlet must be connected to a clear, unobstructed vent of adequate capacity terminating above the highest point of the building with an approved vent cap. The venting system should be installed according to the latest edition of ANSI Z223.1 (or CAN1-B149) and any local codes having jurisdiction. IMPORTANT NOTE: Do not use sheet metal
screws at the snap lock joints of Type B gas vents.
2. Do not weld or fasten the vent pipe to the boiler draft hood. The weight of the stack must not rest on the boiler. The draft hood and top must be easily removable for normal boiler service and inspection.
3. Avoid long horizontal runs of the vent pipe, and too many 90 degree elbows, reductions and restrictions. Horizontal runs should have at least a 1/4” rise per foot in the direction of flow. A vent connector shall be supported for the design and weight of the material employed to maintain clearances and prevent physical damage and separation of joints.
4. Avoid terminating boiler vents near air conditioning or air supply fans. The fans can pick up exhaust flue products from the boiler and return them inside the building, creating a possible health hazard. A minimum of 4 feet horizontal distance must be maintained from electric meters, gas meters, and relief equipment.
5. Always use double-wall or insulated vent pipe (Type B or equivalent). In cold weather, uninsulated outside vents can chill the rising flue products, blocking the natural draft action of the venting system. This can create a health hazard by spilling flue products into the boiler room.
6. Avoid oversize vent piping or extremely long runs of the pipe which may cause excessive cooling and condensation. Rule of Thumb: The total length of the vent, including the connector and any offset, should not exceed 15 feet for every inch of vent diameter. Longer total lengths shown in venting tables are based on maximum capacity, not condensation factors.
7. When the installation of a draft fan is necessary in the venting system to which a Model MT boiler is to be connected, the installation should be engineered by competent personnel following good engineering practices. The draft fan supplier should be consulted for correct size. The installation should be in accordance with the latest edition of ANSI Z223.1 and any local
codes having jurisdiction. When a draft fan is installed, a suitable draft switch must be used and wired into the boiler control circuit at terminal designated “Field Interlock,” to prevent firing of the unit unless a positive draft has been established (see Figure 3).
Figure 3. Draft Fan Wiring Diagram.
2C. Installation of Outdoor Units
1. Locate the boiler to provide the minimum clearances as listed in Section 2A, “Boiler Placement.”
2. Do not locate the boiler in an enclosure or wall recess. Avoid locations where wind deflection off structures might cause down draft. When such wind conditions are possible, locate the unit at least three (3) feet from the structures.
3. Never install the boiler under any kind of roof overhang. Do not locate the unit below or adjacent to any doors, windows, louvers, grills, etc. which communicate in any way with an inhabited area of a building. Even though such communication might be through another structure such as a garage or utility room (see Figure 4).
Figure 4. Incorrect Outdoor Installation.
Page 6
4. Liquified petroleum is heavier than air. Therefore, the pool boiler should not be installed in pits or other locations where gas could accumulate. The boiler should be located a safe distance from LP gas storage and filling equipment. Consult local codes and fire protection authorities for advice relative to specific installation restrictions.
2D. Freeze Protection
Boiler installations are not recommended in areas
where the danger of freezing exists unless proper precautions are made for freeze protection.
Pentair Water Commercial Pool and Spa
Figure 5. Tee Fitting Sediment Trap.
2E. Gas Supply and Piping
Review the following instructions before
proceeding with the installation.
1. Verify that the boiler is fitted for the proper type of gas by checking the rating plate. Model MT boilers are normally equipped to operate below a 2000 foot altitude. Boilers equipped to operate at higher altitudes have appropriate stickers or tags attached.
2. Use the figures in Table 3 to provide adequate gas piping (check local code for BTU capacity required).
Distance from Gas Meter or
Natural and LP Gas
0-100' 100-200' 200-300'
Indoor Outdoor
Size Size Nat. LP Nat. LP Nat. LP
2000 2 3 3 3 2450 2200 3 3 3 3050 2800 3 3 3 3500 3200 3 3 4 3½ 4050 3600 3 4 4 3½ 4500 4000 3 4 5 4 5000 4500 4 4 5 4
NOTES: These figures are based on ½" water column pressure drop. Check supply pressure and local code requirements before proceeding with work. Pipe fittings must be considered when determining gas pipe sizing.
must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig.
5. Provide gas supply pressure to the boiler as follows:
Natural Propane
Min. (inches water column) 7 11 Max. (inches water column) 9 14
Note: The boiler and all other gas appliances
sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. Low gas pressure could be an indication of an undersized gas meter and/or obstructed gas supply line.
6. The correct burner manifold gas pressure is stamped on the rating plate. The regulator is preset at the factory, and normally requires no further adjustment.
7. The gas manifold and control assembly was tested and conforms to the safe lighting and other performance criteria specified in the latest editions of ANSI Z21.13 and CGA 3.3 Low Pressure Boiler Standard.
8. Before operating the boiler, the complete gas supply system and all connections must be tested for leaks using a soap solution. Do not use raw flame.
3. A trap (drip leg) must be provided ahead of the gas controls (see Figure 5). Where required by code, provide a second manual gas shutoff valve. Do not remove manual valve furnished with the unit.
4. The boiler and its individual shutoff 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. The boiler
Caution
Since some leak test solutions, including soap and water, may cause corrosion or stress cracking, the piping must be rinsed with water after testing, unless it has been determined that the leak test solution is noncorrosive.
Loading...
+ 14 hidden pages