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Max-E-Therm Owner`s Manual

1. A thermal regulator and an internal bypass regulate the water flow t through the heat exchanger to maintain the correct outlet t v ue Q temperature The heater operator control panel board assembly is B D AMAL KM lt p p p y 1 4 d ene EE located on top of the heater aes E 3 tm Tn E A SEQUENCE OF OPERATION Lj um Outlet 1 Waten Burner Heating Coils An electronic temperature sensing thermistor in the manifold 1 adapter inlet controls the heater operation When the inlet water y temperature drops below the temperature set on the operating Figure 1 control the burner controller supplies power to the combustion air blower through a series of safety interlocks The interlocks consist of e the pressure switch PS which senses that the pump is running e 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 480 F 249 C 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 h
2. Go to BURNER TROUBLESHOOTING Page 44 Go to HEATER WILL NOT FIRE D Page 41 Repl Igniti Check for 24 VAC Module mee YES between TH and GND terminals on Ignition Control Module SEE NOTE 1 A NO Check for 24 VAC between VAL and GND terminals on Ignition Control Module SEE NOTE 2 Check for 24 VAC between TH and GND terminals on Control Check for 24 VAC between YES Board SEE NOTE 1 VAL and GND terminals on Control Board SEE NOTE 2 Check for 24 VAC between GAS termi nals on Control Board SEE NOTE 2 Fix wiring between VAL and GND terminals of Ignition Control Module and Control Board Replace Control Board MAX E THERM Pool and Spa Heater Installation and User s Guide Section 4 Troubleshooting 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 combus tion premature extinction of flame evidence of boiling or operation of any diagnostic LED Go to pertinent trou bleshooting section if any malfunction is observed NO 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 2 Replace Gas Valve with identical part
3. Fix wiring between TH and GND terminals of Ignition Control Module and Control Board Replace Control Board Fix wiring between GAS ter minals on Control Board and Gas Valve NOTE 1 Voltage appears immedi ately 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 P N S794 Rev H 8 11 14 Section 4 Troubleshooting 41 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 240 VAC 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 digital meter If the ICM is bad your volt 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 Start Gas flows during igni NO Go back to chart HEATER WILL tion try but burner NOT FIRE C Page 40 does not fire Check voltage across o igniter leads OK Check gas pressure OK Replace Ignition Increase gas flow into heater Control Module On a Replace gas line with larger YE LES Replace HSI Igniter 120
4. 474200 77707 0014 77707 0117 6 77707 0120 42001 0060S 77707 0017 77707 0010 38000 0007S 35505 1313 U178 920P U78 60ZPS 473715Z SR333NA SR333LP SR333HD 77707 0233 41406044 77707 0243 47406449 474200 77707 0015 77707 0118 10 77707 0120 42001 00608 77707 0017 77707 0010 38000 00078 35505 1313 U178 920P U78 60ZPS 473715Z SR400NA ASNE SR400LP SR400HD 460763 NA400 1460767 NA250 460764 LP400 13460768 LP250 77707 0234 47406194 77707 0244 41406544 4609404 4740964 4749560 9 9 11460941 4 1147409744 114749550044 474200 474200 77707 0016 77707 0119 12 77707 0120 460923 4737162 472648Z 42001 00608 77707 0017 77707 0010 460924 38000 0007S 38000 0007S 35505 1313 U178 920P U78 60ZPS 4737152 4131152 PIN S794 Rev H 8 11 14 MAX E THERM HEATERS REPLACEMENT PARTS Seen REPAIR PARTS ELECTRICAL SYSTEM Part Description Display Cover Retainer Cap Kit Cap and CPSC Warning Label Heater Display Cover Igniter Bracket Igniter Igniter Gasket Kit Incl Key Nos 4 and 5 Igniter Gasket Manifold Switch Cover Automatic Gas Shutoff Switch AGS High Limit Switch Thermistor Terminal Board Fireman s Switch Fuse 1 25A 1 1 4 Ignition Control Module Transformer 115 230V Air Flow Switch Control Board Kit HD Series Control Board Kit NA LP Series Heater Wiring Harness 115 2
5. For minimum exhaust vent clearances for all building openings including but not limited to vented eaves doors windows gravity air inlet see Figure 10 3 ft 1 M or more 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 see Figure 11 page 17 Orient the heater for convenient access to the water connections and the gas and electrical connections Note Check local building codes for installing the heater from any property line set back requirements A CAUTION If installing the heater next to or near an air conditioning unit or a heat Figure 9 pump allow a minimum of 36 in between the air conditioning unit and the heater MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 17 OUTDOOR INSTALLATION VENTING GUIDELINES m From window or door X A A 3 SIDE VIEW Y From building wall Air Inlet Building Exhaust Grill Vent Vent Termination Must be at least 3 ft above any forced E DED air inlet located within a 10 ft radius Must be located 6 in away from the building wall and the following distances away from any building wall openings included but not limited to vented eaves doors windows gravity air inlet gt 4ft below Aft horizontally Figure 10 OUTDOOR INSTALLATION V
6. Set 3 way valves on inlet and outlet to pool or spa as appropriate Turn on all electric power to the appliance Press either the POOL ON or SPA ON button switch on the operating control Set the thermostat to desired setting NOTICE Set point must be above actual water temperature or burner will not fire See OPERATING the CONTROL PANEL 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 28 Toggle Style Valve Gas control is shown ON 3j Pull toggle toward you i to turn OFF An Figure 29 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 If the appliance will not operate follow the instructions below TO TURN OFF GAS TO TH
7. 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 running IMPORTANT READ ME FIRST NOTICE Installing the black120 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 FOLLOWING CAREFULLY 1 Check the line voltage to your heater This heater will operate 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 BLACK plug is for 120 volts the RED plug is for 240 volts Start here for directions to specific Troubleshooting Chart Is green POOL or SPA LED on Is red SERVICE SYSTEM LED on Go to chart HEATER WILL NOT FIRE A Page 38 Go to chart HEATER WILL NOT FIRE B Page 39 Are any red diagnos tic LED s on back of board AGS AFS SFS HLS PS or Is red SERVICE HEATER LED on Go to specific saf
8. 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 page 18 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 5 ft 1 5M of the inside surface of a pool or spa unless it is separated by a solid fence wall or other permanent barrier CONSUMER INFORMATION AND SAFETY A WARNING The U S Consumer Product Safety Commission warns that carbon monoxide is an invisible killer Carbon monoxide is a colorless and odorless gas l 2 LL X dn ue Carbon monoxide is produced by burning fuel including natural gas and propane Proper installation operation and maintenance of fuel burning appliances in the home is the most important factor in redu
9. S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide C 4 N TES MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 O1 2 N TES P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide gt PENTAIR 1620 HAWKINS AVE SANFORD NC 27330 e 919 566 8000 10951 WEST LOS ANGELES AVE MOORPARK CA 93021 e 805 553 5000 WWW PENTAIRPOOL COM All Pentair trademarks and logos are owned by Pentair or one of its global affiliates Pentair Aquatic Systems Sta Rite Max E Therm IntelliTouch EasyTouch 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 countries Saf T Vent is a registered trademark of Selkirk Corporation Unless expressly noted names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners 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 third parties Because we are continuously improving our products and services Pentair reserves the right to change specifications without prior notice Pentair is an equal opportunity employer 2014 Pentair Water Pool and Spa Inc All rights reserved This document is subject to change without notice P N S794 REVH
10. V installation line check the ignitor for Replace regulator damage if it has seen Replace meter or 240 VAC All of the above P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 42 Section 4 Troubleshooting Diagnostic LED s AGS AFS HLS PS THERMISTOR Verify that water flow rate is NO above minimum required for heater Shutoff AGS Y YES Verify that inlet water temper ature is below 104 F CONTINUE If problem persists verify proper operation of Internal Bypass Valve and Thermal Governor and check for Heat Exchanger blockage Verify that water flow rate is NO above minimum required for heater Replace High Limit Switch HLS or Automatic Gas YES Verify that wiring is OK and pressure tap is not blocked Re place Pressure Switch YES NO YES Disconnect Blower and check for line voltage between pins 1 and 3 of Blower Connector on ignition try Replace Blower Verify that wires BM and F1 are correctly connected at the terminal strip see Heater Connection Diagram Page 30 Check for 24 VAC between 24 VAC and GND terminals on Ignition Control Module on ignition try Check that IND wire is correctly connected Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board Connect correctly and retry Disconnect wires F1 Does Blower st
11. 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 A 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 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 8 Section 1 Introduction 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
12. can determine the disinfectant residual of your pool water with a reliable test kit available from your local pool supply store You 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 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 48 Section 5 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 Table 12 Muriatic Acid has a pH of about 0 Pure water is 7 neutral Weak Lye 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
13. card after filling in the serial number from the rating plate inside the heater The high standards of excellence of Pentair Aquatic Systems includes 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 ACAUTION 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 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 1 Introduction 5 CODE REQUIREMENTS Installation must be in accordance with all local codes and or the latest edition of the National Fuel Gas Code ANSI Z223 I NFPA54 and the National Electrical Code ANSI NFPA 70 U S
14. gt PENTAIR STA RITE MAX E THERM POOL AND SPA HEATER INSTALLATION AND USER 5 GUIDE FOR YOUR SAFETY READ BEFORE OPERATING Warning f you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life For additional free copies of this manual call 800 831 7133 120 240 VAC NATURAL GAS LP GAS MODELS Natural Propane HD 200K BTU HR SR200NA SR200LP SR200HD 250K BTU HR ASME 460767 460768 333K BTU HR SR333NA SR833LP SR333HD 400K BTU HR SR400NA SR400LP SR400HD 400K BTU HR ASME 460763 460764 OWNER FOR YOUR SAFETY This product must be Retain For installed and serviced by authorized personnel Future qualified inpool spa heater installation Improper Reference installation and or operation can create carbon monoxide gas and flue gases which can cause serious injury property damage or death For indoor installations as an additional measure of safety Pentair Aquatic Systems strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance P and in any adjacent occupied spaces Improper installation and or operation will void the warranty Ceri Warning 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 WHAT
15. have an effect Exhaust may affect shrubbery and some ABE Listed building materials Keep shrubbery away from Condensate Terminal termination To prevent staining or deterioration sealing Tee Mn Metal or shielding exposed surfaces may be required Vent Body Saach z Slope at least Fire Hazard Do not run the heater vent into a common D 1 A per o vent with any other appliance Do not run the Special Gg ee 3 7 6 cm Min Gas Vent into through or within any active vent such Optional condensate drain Ge on Max as a factory built or masonry chimney Figure 19 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 26 Section 2 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 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 Risk of explosion if a unit burning propane gas is installed in a pit or other low spot Propane
16. installed more than 1 above or below the water pressure switch must be adjusted by a qualified service technician See page 34 Figure 32 FLOW SWITCH 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 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 13 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 page 14 show which size pipe is required for the distance from the gas meter to 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 shoul
17. 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 c as the temperature changes Support the vent pipe Vent Cap and _ Chimney or Gas Vent according to applicable codes and vent manufacturer s P ede 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 mi 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 installat
18. other volatile flammable liquids near heater or in the same room with heater A WARNING 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 A WARNING 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 A 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 See Page 23 for Part Numbers for Conversion Kits is available for installations 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
19. valves isolation valves flow nozzles or therapeutic pool valving must have a relief valve installed as described above P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 46 Section 5 Maintenance AFTER START UP CHECKING WATER FLOW 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 A 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 Wa
20. 0 in 3 5 Check Thermal minutes Regulator Open at 120 Replace Heater Membrane Pad Correct problem Heater should fire DONE Heater starts after several tries exhaust temperature stays below 250 OR Heater doesn t start at all exhaust stays cold Check Thermal Regulator Seats correctly Replace Heater Check pressure and volume oT oy Control Board of fuel supply DONE Correct Fuel Supply reset Heater and retry Heater Disconnect the sensor and should fire correctly check continuity across its terminals Resistance should be 3 5 4 0 mega ohms mE NO Reset power to Heater and open circuit Replace Stack Flue Sensor retry Heater should fire NO Does sensor check OK Reset power to Heater and YES retry Heater should fire Check Heat Exchanger Coil for leaks liming soot or low flow Repeat checks on fuel Replace Heater Control Board supply Thermal Regulator Check continuity in wiring NO harness between Control Board and Probe Continuity OK check for correct orifices DONE Check the J3 and J6 He Reset power to Heater and connectors for corrosion NO looseness on the male DONE pins Does the Digital Reset power to Heater and retry Heater should fire Temperature Display show NO Error Code E05 or E06 Basic Clean tighten pins as needed Reset power to Heater and retry Heater should fire P N S794 Rev H 8 11 14 MAX E TH
21. 30V 120 240 Volt Plug Kit Junction Box Cover Kit Control Board Enclosure Membrane Panel Kit HD Series Includes Key Nos 17 and 18 Control Board Enclosure Membrane Panel Kit NA LP Series Includes Key Nos 17 and 18 Control Board Enclosure Membrane Pad HD Series Membrane Pad NA LP Series Stack Flue Sensor sch sch sch sch NM sch sch ch oL n SR200NA SR200LP SR200HD 77707 0009 42001 0008S 42001 0030S 77707 0054 42001 00668 42001 00078 42002 00258 42001 00638 42001 00538 42001 00568 32850 0099 42001 00528 42001 01078 42001 00618 42001 00968 42002 00078 42001 01048 42001 01058 77707 0022 77707 0004 77707 0013 42002 00248 SR333NA SR333LP SR333HD 77707 0009 42001 0008S 42001 00308 77707 0054 42001 0066S 42001 00078 42002 00258 42001 00638 42001 00538 42001 00568 32850 0099 42001 00528 42001 01078 42001 00619 42001 00968 42002 00078 42001 01048 42001 01058 77707 0022 77707 0004 77707 0013 42002 0024S SR400NA SR400LP SR400HD 460763 NA 460764 LP 77707 0009 42001 0008S 42001 00308 77707 0054 42001 0066S 42001 0007S 42002 0025S 42001 0063S 42001 00538 42001 00568 32850 0099 42001 00528 42001 01078 42001 0061S 42001 0096S 42002 00078 42001 01048 42001 01058 77707 0022 77707 0004 77707 0013 42002 0024S 53 e Not available separately A Kit parts not available separately P N
22. 8 14
23. Clamp Assembly O Ring and Silicon Tube For heater manufactured AFTER 10 31 2013 New 9 bolt lid tub design 444 For heater manufactured BEFORE 1 12 2009 P N S794 Rev H 8 11 14 SR200NA SR200LP SR200HD 42001 00515 38404 40978 77707 0008 42001 00748 SR333NA SR333LP SR333HD 42001 00515 38404 40978 77707 0421 77707 0451 77707 1451 77707 1421 77707 0252 77707 0255 77707 0112 42001 01149 77707 0011 77707 0203 77707 0002 474095 47495749 42001 02008 446 42001 0200S 604 42001 0001S 77707 3333N 77707 3333L 77707 0008 42001 00748 4740944 41495804 42001 021454046 474201 47495244 42002 00058 475002 SR400NA SR400LP SR400HD 460763 NA 460764 LP 42001 00515 38404 40978 77707 0411 77707 0441 77707 1441 77707 1411 77707 0253 77707 0256 77707 0113 42001 01149 77707 0011 77707 0204 77707 0002 4740954 4749574 42001 0200Se0 42001 0001S 77707 3400N 77707 3400L 77707 0008 42001 00748 4740944 41495844 42001 0214S5446 4742014 47495240 42002 00058 475002 MAX E THERM Pool and Spa Heater Installation and Users Guide 52 MAX E THERM Pool and Spa Heater Installation and User s Guide MAX E THERM HEATERS REPLACEMENT PARTS REPAIR PARTS WATER SYSTEM Part Description Tube Sheet Coil Assembly Kit NA LP Series Includes Key No 3 Tube Sheet Coil Assembly Kit NA HD Series Includes Key No 3 Tube P
24. DE 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 toxic levels of 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 NEVER use this pool heater indoors without specified ventilation system and properly installed vent pipe NEVER use this pool heater in the home or in partly enclosed areas such as garages unless the specified ventilation system is used If used outdoors install far from open windows doors vents and other openings Pentair strongly recommen
25. E APPLIANCE and call your service technician or gas supplier TOTURN OFF GAS TO APPLIANCE A ee HE P N S794 Rev H 8 11 14 Press the OFF button on operating control Switch off all electric power to the unit Remove the jacket cover s see Figure 28 Toggle Style Valve Pull toggle toward you to turn gas off see Figure 29 Replace the jacket cover s MAX E THERM Pool and Spa Heater Installation and Users Guide 34 Section 3 Operation SAFETY CONTROLS Figure 30 AIR FLOW SWITCH AFS The air flow switch see Figure 30 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 Air Flow Switch Hazardous pressure Do not bypass the Water Pressure Switch or render it inoperable The water pressure switch see Figure 31 If the water flow is restricted the Figure 31 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 p
26. E 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 Hlectrical 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 5 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 I e S ST 228 A Lg Green Ground 7 Do not wire single pole switches including protective to devices into a grounded line The hea
27. ENTING GUIDELINES F SE EE FOR CANADA s h 10 3M 7 9 A 59 SIDE VIEW E Property uc 15 24cm d i From building wall Exhaust S SO en Grill bc D gt Vent A V Air Inlet e eov Building Exhaust k Grill Vent Vent Termination Must be at least 3 ft 9M above any forced air inlet located within a 10 ft 3M radius Must be located 6 in 15 24cm away from the building t wall and the following distances away from any building wall openings included but not limited to vented eaves doors windows gravity air inlet 10 ft 3M below 10 ft 3M horizontally Figure 11 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and Users Guide 18 Section 2 Installation INDOOR VENTING General Requirements The heater may be installed as a Category or Category III appliance 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 pages 20 22 Vented Appliance Category lll 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 appropriat
28. ERM Pool and Spa Heater Installation and User s Guide 44 Section 4 Troubleshootin Burner Troubleshooting SYMPTOM CAUSE REMEDY Loud high pitched whine Flame is too rich Verify pressure tap between gas valve and blower inlet See page 16 and verify that the gas regulator setting is 0 2 0 5cm wc Contact a qualified technician or service agency to replace the gas orifice Flame is fluttery Flame is too lean See page 16 and verify that the gas Exhaust may have acrid regulator setting is 0 2 0 5cm wc smell or burner may fail D l y Contact a qualified technician or service ESCH agency to replace the gas orifice Burner pulsates or Exhaust vent is too long Reduce length of exhaust vent and or surges especially on number of elbows ignition Combustion appears Flame current is not Checkfor wet or damaged igniter with normal but flame does being sensed low resistance to ground Replacewith not stay lit new igniter Verify burner flameholder is properly grounded Replace Ignition Control Module Heat Exchanger Troubleshooting SYMPTOM CAUSE REMEDY Boiling in heat exchanger Low water flow to heater Service pump and or filter May be accompanied by Heat exchanger plugged Service heat exchanger Correct water bumping sounds chemistry Bypass valve stuck open Service bypass valve Thermal governor stuck Replacethermal governor closed Sweating Thermal governor failed Rep
29. Lid purchase separately Bolt Down Bracket Kit Part No 42001 00858 A Operating Control Assy U CC Lead Anchor E N N KR Combustion Chamber cGMP up THE DESIGN Cover Assy Vent C CLAMP LID TUB DESIGN amp Vent Elbow 24 2 Combustion z Chamber Clamp ASSY Combustion Chamber Gasket Electrical Control Box w Index Plate Tube Sheet Coil Assy Combustion Heat Exchanger Chamber ning 15 if attached not required For heaters manufactured between 1 12 2009 and 10 31 2013 clamp lid tub design Note Kits also include O Ring and Enclosure Kit Jacket Covers MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 KO NM A N O 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 09 51 MAX E THERM HEATERS REPLACEMENT PARTS REPAIR PARTS BURNER SYSTEM Part Description Combination Gas Control Valve Kit 3 4 Union Gas Orifice Gas Orifice O Ring AQ N Gas Orifice Kit NG Incl Key Nos 3 and 4 T 77707 0431 Gas Orifice Kit Propane Incl Key Nos 3 and 4 Tt 77707 0461 NG to Propane Conversion Kit Incl Key Nos 3 and 4 T 77707 1461 Propane to NG Conversion Kit Incl Key Nos 3 and 4 T 77707 1431 Air Blower Kit Natural Gas Units 1 77707 0251 Propane Units 1 77707 0254 Air Orifice Kit Includes Key Nos 6 and 7 1 77707 0111 Air Orifice 1 Air Ori
30. N adjacent gie See Forced Air EN Ger inished grade whichever s Inlet 3 Minimum clearance if higher horizontal distance to exhaust opening is less than 10 feet Figure 18 5 Vent Termination Horizontal The terminal must be located U S See Figure 18 at least 3 and at most 12 out from the wall see Figure 19 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 18 e 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 Metal Special Gas Vent Support Avoid corners or alcoves where snow or wind could requires GE
31. OT 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 Pentair offers optional appliance adapter kits call our Customer Service dept 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 Vent Cover Before connecting the Appliance Adapter 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 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 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 24 Section 2 Installation AWARNING 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 AWARNING Risk of fire or asphyxiation if vent
32. Section 2 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 ACAUTION 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 his heater is configured for a 240V application If it is to be installed in a 120V application remove the Jacket halves C open the control box remove the 240V plug from the receptacle and replace it with the 120V plug The 120V plug is m located within the control box This procedure is to be performed prior to making any electrical connection to the heater ECH Jam 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 ACAUTION 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 M
33. THERMISTOR SENSOR STACK FLUE SENSOR NOTES 1 er Eoo Ft Fe st 24 vac ARE CONNECTED ON THE IGNITION MODULE 2 a DIN 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 Figure 27 MAX E THERM Pool and Spa Heater Installation and Users Guide 32 Section 3 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 MAX E THERM HEATER HSI ELECTRONIC IGNITION LIGHTING OPERATION FOR YOUR SAFETY READ BEFORE LIGHTING 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 E Do not operate the pool heater unless the pool or spa is an ignition device which automatically lights the burner
34. TO DO IF YOU SMELL GAS Do not try to light any appliance For Your Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Safety Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances Pentair Water Pool and Spa Inc 1620 Hawkins Ave Sanford NC 27330 e 800 831 7133 or 919 566 8000 10951 W Los Angeles Ave Moorpark CA 93021 e 800 831 7133 or 1805 553 5000 Customer Service and Technical Support If you have questions about ordering Pentair Aquatic Systems replacement parts and pool products please call Phone 800 831 7133 Fax 800 284 4151 8 A M to 4 30 P M Eastern Time Pacific Time Web sites www pentairpool com www staritepool com P N S794 REVH 8 14 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Contents vecilol JIRUTOGUC ON ge ae H lies UIE E Te ors E 4 EAE aS T E e E A DhE E E E E 4 Beeler CN 5 Consumer Information and Safety InfOFTlallORi ssa theres dh P R PEE RAS S nda Uh S Ee eoa EbR Ret Fx p rd s TR eka ra UHR Rr d sth eie ode 6 8 Genci ee 8 Section Te UE d e ME H Peder D SONDUON e es e E E e 9 Sequence of Operation Putting the Heater into Servi
35. als 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 25 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 connect a 3 Wire Control Connect wires between the control board terminals on the heater and the external relays as shown in Figure 26 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 Figure 26 to enable 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 and bolt up the jacket halves To control heaters that are operated in parallel connect wiring at same locations on heater as 2 Wire or 3 Wire Control I
36. an 1 2 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 AWARNING DO NOT INSTALL THE GAS LINE UNION INSIDE THE HEATER CABINET THIS WILL VOID YOUR WARRANT Y 18 24 of 3 4 Manual Gas line from Shut off Valve Valve SEDIMENT TRAPS 1 Dia or larger See Recommended Pipe Sizes Chart Bell Reducer 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 A either a tee fitting with a capped nipple in the bottom outlet Pe At er 9 which can be removed for cleaning as illustrated in Figure 6 or an other device recognized as an effective sediment t E 2 trap All gas piping should be tested after installation in A B At least 3 accordance with local codes 4 Sediment Trap Figure 6 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 14 Section 2 Installation GAS PIPE SIZING Table 2 PIPE SIZING FOR GAS LINE CONNECTIONS MAXIMUM EQUIVALENT PIPE LENGTH Ft Natural Gas at 1000 B T U per Cubic Foot Propane Gas at 2500 B T U per Cubic Foot 12 34 d tt 1427 27 212 wee NAT PRO NAT PRO nar e
37. and Users Guide Increase POOL SPA tempera ture setting on Membrane Pad above actual water tem perature Heater should fire on demand for heat If not and no other red LED s light replace Control Board Service pump filter and elimi nate other flow obstructions Heater should fire on call for heat Re verify that water flow is above minimum require ment Minimum Flow Requirements Model Flow 200 20 gal min 76 LPM 333 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 Model Flow 200 20 gal min 76 LPM 3393 30 gal min 114 LPM 400 40 gal min 151 LPM Go to Diagnostic LED s Pages 42 and 43 S 40 Heater Will Not Fire C Start Is SERVICE HEATER LED on Turn off power to heater for 5 seconds and turn back on Make sure tempera ture setting is above water temperature Wait one minute If any red diagnostic LED s AGS AFS SFS HLS PS or THERMISTOR come on go to to Pages 42 and 43 Does heater fire and stay on CONTINUE NO Did Blower come on YES Verify that gas is flow ing to burner during ignition try Observe gas meter for move ment during ignition YES try wait for about 30 seconds after calling for heat Did burner fire at all
38. applies in your state be sure your contractor bears the appropriate license See Figure 2 for Outdoor and Indoor Installations DIMENSIONS IN INCHES ee Ce sd Ut Sa IT 30 03 SS SS N Ex E Auf TI CL IN eer EE CI RK A Je LI ER EE EID LA V1 E E NN D TWA L EE OUTLET Dem BACK VIEW TOP VIEW Figure 2 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 11 PLUMBING CONNECTIONS From Filter Outlet The Max E Therm heater has the unique capability of direct BEE g toHeater ZZ Sp schedule 40 PVC schedule 80 CPVC for ASME models zc en plumbing connections A set of bulkhead fittings is included r with the Max E Therm heater to insure conformity with lY b Sy f Pentair s recommended PVC plumbing procedure Other ih ay LI Warm Water e plumbing connections can be used See Figure 3 for plumbing pe AJ Ke PA E A connections je el E Sch se H ff ZAN TJ Corrosion Resistant S AN Positive Seal AD GE L o Spa Sanitizer gt l ACAUTION K v Check Valve Before operating the heater on a new installation turn on the circulation pump and bleed all the air from the filter using the air relief valve on top of the filter Water Cool Water In From Spa Co
39. art and F2 from Ignition Control Module and NO short them together Does Blower come on Replace Blower Does Blower NO start on ignition try Replace Ignition Control MES Module Verify Thermistor wiring If OK replace Thermistor y CAUTION Do not jumper a safety switch to remedy a failed switch Replace thermistor or Control Board to correct overheating Service pump and filter to restore proper flow Service pump and filter to restore proper flow After ser vicing verify proper operation of Pressure Switch PS CONTINUE CONTINUE Adjust Water Pressure Switch to close with pump running and open with pump off Verify that there is no block age in Blower intake Heat Exchanger and exhaust and that exhaust is not too long see Special Gas Venting 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 NOTE ES1 is a spare and should be jumpered MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 4 Troubleshootin 43 YES Diagnostic LED s SFS SS Check Heat Exchanger Coil for leaks liming soot or low flow Heater starts and runs OK but temperature of exhaust climbs to 450 50
40. 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 Total 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 You 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 Table 12 Disinfectant levels Minimum Ideal Maximum Free Chlorine ppm 1 0 2 0 4 0 507 Combined Ch
41. ce uuaaauaacacacncncncenenenenenenenene nene nene nene rere nene ne rere rene nt ete eee re eee tetit eee eee eee eee tetit 9 Deo ee ETT 10 xU teen CMCC NOMS NN Emm ti e 11 MANDI E E E E E ti MAU BE OT OT D EP 12 E nenene 12 DEENEN 13 nen eee 13 Ge RI eee 14 Testing Gas Pressure Gas Pressure Requirements vese seen eneve rere rere eee re nene rere nnne nnne nnne nennt eee meet 19 STAN NAS te EE EE 16 Outdoor Installation Vening 9 s m ECT 17 Indoor Venting General Requirements Category amp Category III clarification seen 18 Heater GATE NEEE nEn EnEn Ee Enae 18 KEE EE ee 18 Reuler UO E 19 SOMO SING Vapors and OS SINGS Se E ER ET EEEE E OE 19 Vent Installation Indoor Installation for U S or Outdoor Shelter for Canada 20 Vertical Venting Negative Pressure Direct Air Intake with 3 inch PVC Pipe indoor Installation s 20 22 Horizontal or Vertical Venting e ET 23 Sona ete peta Gas E 23 25 Outdoor Shelter Installation cceesseeq eint ter PFERENNH HERI EEHRU usa EURO HUI Utente DRE NE UH naranasan TANANAN RRNA eons 26 Garage or geeint AN ANON EE 26 Control Panel Inde XI IO E 27 Sue CNECK E 27 Elec CONE e E 28 Fireman s Switch Connection Remote Control Connections esses 29 esi e ER 30 Ree eelere Rat Te 31 vecio 9 Opera Le EE 32 Basic OS ODOFAHOH ee ne eer ree a heen eee er ee ee ee eh re 32 ase
42. cing carbon monoxide poisoning Be sure that fuel burning appliances such as heaters are installed by professionals according to manufacturer s instructions and codes Always follow the manufacturer s directions for safe operation Have the heating system including vents inspected and serviced annually by a trained service technician Examine vents regularly for improper connections visible cracks rust or stains 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 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 9 Installation Instructions HEATER DESCRIPTION Figure is a diagram of the heater showing how it operates Precisely matched orifice plates meter the air and gas into the mixer The 9 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 Two 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
43. d 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 Figure 6 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 The heater and any other gas appliances must be disconnected from the gas supply piping system during any pressure testing on that system greater th
44. djusting the regulator setting The correct gas regulator setting is required to maintain proper combustion and must NOT be altered ACAUTION 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 Tee E wem e inat Ja Je 4 4 Manifold 02401 0 2 0 1 NOTE All readings must be taken while heater is operating Any adjustments or readings made while heater is off will result in performance problems Table 7 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 16 Section 2 Installation OUTDOOR INSTALLATION U S and Canada For heaters located outdoors using the built in stackless venting system 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 sp
45. ds 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 A 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 A 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 attemp
46. e 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 Max E Therm heaters operate with a positive vent static pressure and with a vent gas temperature less than 400 F 204 C 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 re e 6 in 15 cm eec ALL SIDES 6 in 15 cm ZA VEN prre 6 in 15 cm Note 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 three inches 10cm beyond the base of the heater If the heater is installed in a li 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 operating control panel located on the top of the jacket can be rotated for convenient access to the control panel OUTSIDE VENT COVER REMOVAL The heater is supplied from the factory with a built in stackless outside vent for outdoor installati
47. ecific 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 To avoid damage to the electronic components in the heater take care to prevent Bolt Down Bracket Kit prolonged exposure to driving sources of water such as lawn sprinklers heavy P N 42001 0085S roof runoff hoses etc Avoid operation in persistent extreme moist or salty i environments v In extreme weather shut down the heater and disconnect the power to it until Z the weather has moderated In areas subject to hurricanes or very high winds purchase the Bolt Down Bracket Kit P N 42001 00858 see Figure 8 o DE ZN HEATER CLEARANCES OUTDOOR A N N N N 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 Figure 8 This unit shall not be operated outdoors at temperatures below 20 F If the heater is located under a roof 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 9 If the heater is under a roof overhang the space around the heater must be open on three sides DO NOT under any circumstances install the heater under ANY deck
48. ect 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 ACAUTION A Propane LPG fired heater must not be installed in a garage in Leave 3 ft 1 m or more of clearance above heater 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 rere damage the heater and will void the warranty See Table 9 page 19 of clear space between heater and combustible surface RAISE AT LEAST 18 in 46 cm above floor 1g in to avoid flammable vapors Figure 20 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 27 CONTROL PANEL INDEXING On an outdoor shelter installation the exhaust discharges into a vent pipe The heater control panel assembly on top of the jacket can be turned to any of six positions for convenient access to the panel see Figure 21 1 Unbolt and separate the jacket halves 2 Pullhair pin clips 3 Depress plastic clips on the control panel assembly 4 Lift panel off of support plate 5 Turn the assembly to the desired position and snap in place 6 Make sure that the operating controls can be adjusted without having to lean over the e
49. en remove the valve handle or lock it in place to avoid tampering See Figure 4 Figure 4 Max GPM LPM 120 454 120 454 120 454 Bypass Valve 3 Do not exceed the maximum recommended flow 2 Remove handle id rate for the connecting piping Table 1 Outlet to Pool Inlet from See page 45 for Pressure Relief Valve Installations Filter P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 12 Section 2 Installation WATER CONNECTIONS The heater requires proper water flow and pressure for its operation See Figure 5 for the recommended installation The filter pump discharges to the filter the filter discharges to the heater and the heater discharges directly to the pool or spa Figure 5 3 Way Valve Chlorinator 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 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 installations 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 Ersm Boo 3 VVay 3 Way Valve Valve Install the chemical feeder downstream of the heater Instal
50. 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 AWARNING 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 S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 6 Section 1 Introduction IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS SAFETY INFORMATION The Max E Therm 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 4 symbol Be sure to read and comply with all of the warnings and cautions DANGER CARBON MONOXI
51. es 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 Table 11 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 Max E Therm heater may be installed as a Category III appliance which requires a four 4 inch special gas approved Category IIT vent pipe and is a forced draft pool and spa heater which uses positive pressure to push flue gases through the 4 in Special Gas Vent Vertical or Horizontal vent pipe to the outside Flue gases under positive pressure may escape into the dwelling with any cracks or loose joints in the vent Maximum Length in Feet M pipe or improper vent installation The vent p
52. ety switch troubleshooting chart Pages 41 and 42 THERMISTOR on Turn off power to heater for about 5 seconds and turn back on Make sure tempera ture 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 diag nostic LED s may come on momentarily when you turn on the power to the heater on Does red SERVICE HEATER LED come Go to chart HEATER WILL NOT FIRE C Page 40 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 Board WARNING Fire and Explosion hazard Do not jumper switch terminals to remedy a failed safety switch AA WARNING Hazardous voltage Can shock burn or kill Disconnect power before servicing any components P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 38 Section 4 Troubleshooting Heater Will Not Fire A Start Is green SPA or NO Depress POOL or SPA ON button on Membrane Pad Does POOL or SPA LED YES Heater should fire on demand for heat POOL LED on come on YES Check that correct 12 pin plug is installed red is 240V black is 120V If plugis notinstalled Install correct plu
53. fice Grill 1 42001 01148 Blower Adapter Plate Gasket Kit Includes Key Nos 8 9 10 12 1 77707 0011 Flameholder Kit Includes Key Nos 10 11 12 13 and on 333 amp 400 models only Flameholder Insert 77707 0202 Blower Adapter Plate Gasket 1 Blower Adapter Plate 1 Flameholder Adapter Plate Gasket 1 Flameholder Assembly 1 Flameholder Combustion Chamber Gasket 1 Flameholder Insulation Cap 1 Flameholder Insert 1 Enclosure Kit Upper Right Hand 1 77707 0002 Condensate Evaporator Plate 1 One Piece Metal Chamber Combustion Chamber Assembly 1 4740954 47495704 Lovver Enclosure 1 42001 00015 Upper Enclosure Fastener 12 11x2 1 2 Type AB Hex Washer Head S S Sheet Metal Screw 4 Enclosure Kit Upper Left Hand Natural Gas 1 77707 3200N Enclosure Kit Upper Left Hand LP Gas 1 77707 3200L Insulation Kit Includes Key Nos 13 15 23 24 25 and 26 Bottom Outer Insulation Blanket 1 Bottom Inner Insulation 1 Top Insulation Top Outer Insulation Blanket wesch sch sch sch Il Lower Enclosure Insulation One Piece Metal Eloow Combustion Chamber Cover Assembly 1 4740944 41495846 42001 02145444 Combustion Chamber O Ring Kit 1 474201 41495246 Metal Vent Cover 1 42002 0005S Combustion Air Intake Duct Connection Kit 1 475002 Not available separately Not included with heater Order separately For heaters manufactured between 1 12 2009 and 10 31 2013 clamp lid tub design Note Kits also include
54. for a standing pilot The Max E Therm heater 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 Max E Therm heater high performance heater The information in this manual applies to all Max E Therm heater 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 Max E Therm heater 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 Max E Therm 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 Aquatic Systems at 800 831 7133 WARRANTY INFORMATION The Max E Therm 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
55. g 240V plugin 120V circuit Replace with correct plug 120V plugin 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 for damage YES NO YES Check for line voltage to NO heater YES Check for 24 VAC at sec YES ondary of Transformer NO Check for Line Voltage between L1 and L2 terminals on Terminal Board 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 Jumper Fireman s Switch at YES Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on Leaving jumper in place NO check for 24 VAC between Fireman s Switch terminals and ground Hemove 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 on YES YES 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 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 p
56. hat 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 AWARNING 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 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and Users Guide 36 Section 3 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 off 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 setti
57. heck 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 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 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 ACAUTION Heat exchanger damage resulting from chemical imbalance is not covered by the warranty WHAT A DISINFECTANT DOES Two 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
58. igital Temperature isplay To toggle the display between degrees Centigrade C and degrees Fahrenheit F 1 Turn the Operating Control OFF 2 Press V TEMP or lt TEMP for 5 seconds The display will flash once and change modes C to F or vice versa STA RITE SIMPLY SMARTER System Operation Temperature Up Down Indicator Lights C C SERVICE SERVICE HEATING SPA POOL WV HEATER SYSTEM ON 3 Turn the Operating Control ON When either the V TEMP or lt TEMP buttons are depressed the digital TUR display will indicate the temperature setting After five seconds the display operating Control for all models except HD models will return to the actual pool spa temperature See page 30 for the External Control Interface for HD models In addition to the digital temperature display there are five indicator lights Figure 34 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 t
59. im m parts from more than one manufacturer may cause Min 2 Ft leaks or damage to vent When assembling a vent 7 M pick one manufacturer and be sure that all vent parts 1 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 7 Min 10 Ft 3 3 M NA Storm Collar 6 15 cm Minimum Clearance to Combustible Materials Type B Double VVall etal Vent Pipe Metal Flue Collar Firestop s B Double Wall u etal Vent Tee Vent EOS Support Vertical Vent Pipe so adapter does not take weight of pipe Dispose of condensate according to local codes Condensate Drain w trap Figure 15 Typical Metal Vent Pipe Installation Canada Vertical Negative Pressure P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide SS Section 2 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 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 ru
60. ing five 5 feet or more above the roof must be braced or guyed Vent it vertically using Type B double wall vent connector pipe 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 NEGATIVE PRESSURE See Figures 13 14 and 15 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 4 x 8 Metal CSA B149 1 Natural Gas and Propane Installation Codes and local codes Type Lado B Double wall vent connector is recommended however single wall pipe is 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 a a To connect a negative pressure metal gas vent to the heater order the appropriate p a 4 ye Metal Flue Collar from the chart below y A m ER and RTV Seu Combustion This Surface Chamber 4 x 6 77707 0076 Flue Collar l Figure 13 4x9 11107 0077 1 See Table 10 to determine allowable vent sizes for your heater NOTICE Table 10 i
61. ion instructions 5 Use an Approved firestop for floor and ceiling arnt GC 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 Figure 16 thimble or firestop with insulation The roof opening must 2 MN BSG be located so that the vent is vertical Muere Sr by Installer 6 Vent Termination Vertical See Figures 16 and 17 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 Outlet Air Opening Heater 7 Make sure entire installation is sealed according to approved standard F i wallvent 7 T E metArOpenng LL Figure 17 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 25 Max 12 Min 3 Vent Vent Termination Termination uz Vent V E Termination 4 Min mE f 23 above grade 1 Minimum GET E
62. ipe must be of a sealed 0 Tota seam construction such as those listed for use with Category III Appliances and for operating temperatures less than 400 F 204 C Vent pipe construction will be of UL 1738 approved non corrosive material such as stainless steel A condensate trap may be needed The nu 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 pipe manufacturer Minimum vent length is one foot 34M or in accordance the requirements of the Uniform Mechanical Code should be met The with vent manufacturer s instruction and local and ventilation air requirements for the Max E Therm heater can be national codes Horizontal vents 3 1M or less in length found on page 19 It is recommended that vent runs over 18 feet may do not require a condensate tee but must slope down need to be insulated to reduce condensation related problems and or the toward the outlet at 1 4 to the foot 2cm M to allow use of a condensate trap in the vent run close to the heater may be necessary CON ensate to drain in certain installations such as cold climates Horizontal vents 3 1M or Table 11 less in length do not require a condensate tee The Max E Therm heater is suitable for through the wall venting A CAUTION Do N
63. 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 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 20 In a garage install a rail or wall to prot
64. justment by the user Call a qualified service technician if you suspect that the burner may require maintenance PRESSURE RELIEF VALVE nor Factory INSTALLED Some U S local codes may require installation of a pressure relief valve PRV Purchase separately P N 460925 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 reliefvalve p Es must be installed horizontality To install the valve use a 3 4 x 3 1 2 brass nipple Y S atthe manifold and one brass elbow and nipple supplied asshown in Figure 37 fc LC No valve is allowed to be placed between the manifoldadapter and the relief KE Q j N valve a gt To avoid water damage or scalding from operation of the relief valve install a zy Ti e SC A drain pipe in the outlet of the pressure relief valve that will direct water discharging j Td from the valve to a safe place for disposal Do not install any reducing couplings li Ro or valves in the drain pipe The drain pipe must be installed so as to allow guns Valve 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 37 Explosion hazard Any heater installed with restrictive devices in the piping system downstream from the heater including check
65. l 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 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 A CAUTION 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
66. l Interface Circuit Disabled Heater Membrane Pad Enabled d External Control Interface Common Line Pool Line W Y 24 DIAGNOSTIC INDICATOR IGNITION CONTROL MODULE Y Y 24VAC SEC External Control Interface Circuit Enabled Pool On and Spa On Keys Disabled OFF Key on peo H Y W Membrane Pad Remains Functional all GY GY BK G E Y BL Y R 120 VAC IGNITER LJ W EM MM Plug 12 pin E o 120V Black 388 e 240V Red i DOE IA Ww bd d SES NC R DJON NNN R 12 Position Receptacle s Sg 25 HE Evo BL S9 JUNCTION BOX NOTICE Touching any 24VAC wire including gic inet AS Xi the Fireman s Switch wire to any 120 240V age Line 1 BK o terminal while the heater is connected to line c 2 0 eee ME power will immediately destroy the control Ground EA mi board and void the vvarranty Fi 26 E d 1 igure 26 GND MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 31 MAX E THERM HEATERS ELECTRICAL SCHEMATIC LADDER DIA GRAM P N S794 Rev H 8 11 14 L1 LADDER DIAGRAM ME 1POP0 gt VAC Le IGNITER BLOWER 120 240 VAC CLASS II TRANSFORMER OPERATING CONTROL 24 VAC Wee oe e ee ee AIR 24V M s LOGIC FLOW e SWITCH PRESSURE LIMIT e e e WATER HI SWITCH e SWITCH COM NO SG ee ee ee eg AGS SWITCH Le LX GAS VALVE
67. l 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 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 S ection 3 Operation OPERATING INSTRUCTIONS pe E D qx 10 11 12 13 14 15 16 STOP Read the safety information on page 32 Set both pool and spa thermostats to the lowest settings Turn off all electric power to the appliance 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 Remove the jacket cover s by unfastening the screws connecting both halves of the top jacket see Figure 28 Toggle Style Valve Pull toggle toward you to turn gas off see Figure 29 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 Toggle Style Valve Push toggle away from you to turn gas on Replace the jacket cover s All jacket covers must be in place when operating the heater
68. lacethermal governor MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 5 Maintenance 45 Maintenance Instructions CARE AND MAINTENANCE 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 jacket covers 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 Test the operation of the pressure relief valve by lifting the valve lever if installed Test for proper operation of the water pressure switch See WATER PRESSURE SWITCH page 34 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 ad
69. le 8 Pentair Aquatic Systems does not recommend indoor installations that do not provide combustion air from outside the building A CAUTION 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 Area Likely Contaminants Chlorinated swimming Pool or spa cleaning chemicals Acids pools and spas such as hydrochloric or muriatic acid Glues and cements construction adhesives paints varnishes and paint and varnish strippers Waxes and cleaners containing calcium or sodium chloride New construction and remodeling areas Permanent wave solutions bleaches Beauty parlors aerosol cans containing chlorocarbons or fluorocarbons Refrigeration plants or various industrial finishing and processing plants Refrigerants acids glues and cements construction adhesives Bleaches detergents or laundry soaps Dry cleaning and laundry containing chlorine Waxes and cleaners areas containing chlorine calcium or sodium chloride Table 9 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 20 Section 2 Installation VENT INSTALLATION INDOOR INSTALLATION U S OR OUTDOOR SHELTER CANADA Category l NOTE Vent must be at least eight 8 feet away from Always vent the heater to the outdoors see Note nearest vertical surface Vents extend
70. lorine 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 io Total Alkalinity Buffering ppm 60 80 100 180 as CaCO3 Salt pom 3200 5000 Total Dissolved Solids ppm N A 1 500 ppm gt TDS at startup Calcium Hardness ppm as CaCO3 200 400 500 1 000 Heavy Metals None None Biological Values Algae None None Bacteria None Refer to Local Code Start up TDS includes source water TDS and any other inorganic salt added at start up NOTE Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger and will void the heater warranty MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 49 MAX E THERM HEATER REPLACEMENT PARTS S794 revC 11 19 10 For complete Electrical System parts breakdown Key Nos 1 through 4 oee Page 53 For complete Burner System parts breakdown Key Nos 5 through 9 see Pages 51 and 52 For complete Water System parts breakdown Key Nos 10 through 12 oee Page 52 Repair Parts are available from your Pentair dealer If your dealer cannot supply you call Customer Support at 1 800 831 7133 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and Users Guide 50 MAX E THERM HEATERS REPLACEMENT PARTS For Heater mounting bolts and clamps
71. nd Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 21 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 EN i I ermination Body with two 10 sheet metal screws Use Cap 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 6 Minimum of the Vent Body Immediately wipe the cleaned GE surfaces dry with a clean cloth or paper towel Materials Repeat for the exterior of the 4 end of the metal Flue Collar Attach the metal Flue Collar to the Class B Double Wall Vent Body using the RTV supplied with the kit Metal Vent Pipe following the vent manufacturer s instructions Metal Flue included with kit Vent S J Support Vertical Vent Pipe so adapter does not take weight of Body 3 Attach the vent pipe to the metal Flue Collar with sheet metal screws pipe AWARN NG Figure 14 Typical Metal Vent Pipe Installation U S a Vertical Negative Pressure 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 e
72. ng to 65 F then go to an off mode MAXIMUM TEMPERATURE SET POINT 1 Unbolt and remove the upper jacket halves see Figure 35 2 Pullhairpin clips 3 Pressthe clips and remove the control panel board dome Locate the yellow button on the corner of the control board 4 Push the Max Temp Set Point button on the back of the control board see Figure 36 The following sequence should happen Fi 35 A The unit will come on and the POOL ON light will come on Clips dd B Press the V TEMP or lt TEMP pad on TOP of the panel to set N Se maximum pool temperature 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 D Press the V TEMP or lt 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 To override the time delay push the Max Temp Set Point button again 5 Reinstall and bolt up the upper jacket halves Figure 36 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 4 Troubleshooting 37 Troubleshooting Instructions 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
73. ns up from the heater at least 1 4 per foot Zcm 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 AWARNING 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 AWARNING 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 DIRECT AIR INTAKE DUCT WITH 3 INCH PVC PIPE INDOOR INSTALLATION Note Combustion Air Intake Duct Connection Kit Part Number Combustion 3 in PVC Pipe 475002 for all Max E Therm hea
74. ol Water x should flow freely through the heater Do not operate In From Pool Figure 3 the heater unless water in the pool spa is at the proper Typical Installation 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 Back siphoning 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 ACAUTION 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 Th
75. on Remove the outside vent cover for outdoor Figure 12 shelter installation Ze Ke MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 19 COMBUSTION AIR SUPPLY Air Supply Requirements Guide for Max E Therm Heaters For indoor installation the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area Minimum Net Free Open Area for Each Opening Square Inches Centimeters The minimum requirements for the air supply specify that All Air From Inside Building All Air From Outside Building the room in which a heater is installed should be provided with two permanent air supply openings one within XE Ns E 200 sq in 200 sq in 50 sq in 50 sq in 12 inches 30cm of the ceiling the other within 12 inches 200 4591 sq cm 323 sq cm 30cm of the floor for combustion air in accordance with URS T m Seege the latest edition of ANSI Z223 1 or the National Fuel Gas 333 12149 a dei 542 i cm code the CSA B149 1 Natural Gas and Propane Installation 400 400 sq in 400 sq in 100 sq in 100 sq in Codes as applicable and any local codes that may apply 2581 sq cm 2581 sq cm 645 sq cm 645 sq cm These openings shall directly or through duct connect to Area indicated is for one of two openings one at floor level and one at the ceiling outdoor air Tab
76. or standards CSA B149 INSTALLATION 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 CERTIFIED ADANGER 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 AWARNING 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
77. ot 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 PUTTINGTHE 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 page 32 in 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 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 10 Section 2 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
78. ressure Vessel Kit ASME Series Basic Manifold Kit includes Key No 3 5 10 14 Manifold Kit Includes Key Nos 3 12 15 22 Key Nos 7 9 in Electrical System Page 53 Coil Tubesheet Sealing O Ring Kit Manifold Bottom Plate Manifold O Ring O Ring Kit Incl Key Nos 3 5 Manifold Insert Manifold Baffle Plate Manifold Bypass Valve Manifold Bypass Valve Kit Includes Install Tool Water Pressure Switch Bypass Access Plug Manifold 5 16 Washer S S 5 16x18x2 3 4 Hex Cap screw Connector Tube O Ring Connector Tube Kit Includes 1 Connector Tube and 1 O Ring Thermal Regulator Kit Incl Key Nos 16 17 18 19 and Spring Clip Thermal Regulator Kit Includes Spring Clip and Install Tools Thermal Regulator Includes Spring Clip Thermal Regulator Spring Thermal Regulator Cap O Ring Thermal Regulator Spring Clip Thermal Regulator Cap Drain Plug 3 4 Pipe Plug Pressure Relief Valve Recommended Purchase Separately Not available separately Not illustrated For ASME heater manufactured BEFORE 4 2009 original tub design For heaters manufactured between 4 2009 and 10 31 2013after 1 12 2009 clamp lid design Note Kits also include Clamp Assembly O Ring and Silicon Tube 444 For ASME heater manufactured AFTER 10 31 2013 new 9 bolt lid tub design 1 1 1 1 1 1 1 1 1 1 10 10 2 h h ss SS Ll SR200NA SR200LP SR200HD 77707 0232 41405844 77707 0242 41406244
79. rimary and restore continuity Replace Transformer Check Fireman s Switch circuit connections time clock wiring external controller relay 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 heat Replace Membrane Pad NO Replace Control Board GO TO HEATER WILL NOT FIRE B Page 39 MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 S P ection 4 Troubleshootin Heater Will Not Fire B Start Is red SERVICE HEATER LED on CONTINUE N S794 Rev H 8 11 14 Is red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above the minimum requirement With pump running adjust Water Pressure Switch to lower pressure until SER VICE SYSTEM LED goes out Then verify that SER VICE SYSTEM LED goes on with pump off Check that water pressure is within the adjustment range of the Pressure Switch 0 5 psig Verify that switch wiring is OK and Pressure Switch port is not blocked and replace water Pressure Switch 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 MAX E THERM Pool and Spa Heater Installation
80. ro nar PRO NAT ero NAT PRO nar PRO m 2 se posae aso fool L 1 3 TJ pu par o 19 2 35 9 99 poo TIT Ew po eo 09 9o 2o 6 99 Pf 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 Stage One High Pressure Gas Pipe Sizing 10 PSI 2500 B T U Per CU FT MAXIMUM EQUIVALENT PIPE LENGTH ed oto So Ft 50 to too Fe 100 to 150 F modei oto10Ft 1010207 20 trough 400 20 rough 400 Table 3 Table 4 Stage Two Low Pressure Gas Pipe Sizing Stage 2 set at 14 in W C MAXIMUM EQUIVALENT PIPE LENGTH RESIDENTIAL NATURAL 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 a
81. s properly filled with water Do not try to light the burners by hand F Before operating the appliance for the first time or after B BEFORE OPERATING smell all around the it has been off for an extended time perform the appliance area for gas Be sure to smell next to the floor following checklist because some gas is heavier than air and will settle on 1 Remove debris or other articles from inside the heater the floor and the area around the heater and its exhaust vent WHAT TO DO IF YOU SMELL GAS 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 Do not try to light any appliance Donottouch any electrical switch do not use any phone in your building 2 Keep heater area clear and free from combustibles Immediately call your gas supplier from a neighbor s bierger phone Follow the gas supplier s instructions 3 Check that all wat ti tieht If you cannot reach your gas supplier call the Fire SE Department 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 C Use only your hand to turn the gas contro
82. s 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 Metal Flue Collar PartNo Type B Double Wall Vent with Type B Double Wall Connector in Feet Meters Vent Size Model 200 Model 333 Model 400 Height min max Height min max Height min max 6 ft 1 8 100 ft 30 5 30 ft 9 100 ft 30 5 7 in 6 ft 1 8 100 ft 30 5 10 ft 3 100 ft 30 5 15 ft 4 6 100 ft 30 5 8 in 6 ft 1 8 100 ft 30 5 6 ft 1 8 100 ft 80 5 8 ft 2 4 100 ft 30 5 9 and 10 in 6 ft 1 8 50 ft 15 3 6 ft 1 8 100 ft 30 5 6 ft 1 8 100 ft 30 5 Type B Double Wall Vent with Single Wall Connector in Feet Meters Height min max Height min max Height min max sin 6f 8 151 46 1 8 15 ft NotRec Rec NotRec Rec 7 in 6 ft 1 8 8 ft 2 4 15 ft 4 6 50 ft 15 3 SH L820 6 st4y201 MAX E THERM Pool a
83. si 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 Y to raise setting heater below the pool and counterclockwise W to lower Water Pressure the setting heater above the pool see Figure 32 Test the switch after resetting A O Switch NOTICE When the heater is mounted more than five feet 1 5M above or i O 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 Turn star wheel clockwise to raise i pressure set point if pressure switch is more Pressure Switch setting may cause operation than 4 feet 1 2M below water level with no water flow Operation of the heater without sufficient water flow may severely damage it HIGH LIMITS Star Wheel 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 Max E Therm series of heaters contains two 2 high limit devices which are located on the main inlet outlet header A reference scale is on the back of pressure switch SA Figure 32 Turn star wheel counterclockwise to lower pressure set poin
84. si saananira aeeai iranat rasina VEe dda aea aitaa daki eioi 32 Eo AE tel E 33 T0 Tum Off Gas to e 33 Salon OIE EE 34 36 Section 4 Troubleshooting gett 37 initial Troubleshooting and Troubleshooting LEE 3 Heater Will Not Fire e e rennene 38 41 LEDD ONOI E 42 43 Burner Heat Exchanger Troubleshooting E 44 Se 45 Gar and dE a 45 aiiis SO RSS V mm 45 EL le EE 46 SEN EE EIE E ODORE 46 Maintaining Pool Temperature Em Em 47 Energy e avigd TIDS oues nuce v tette M E een ne keen uS M UC MU UM MM PU eee 47 ema A INC NRI 47 48 Be sies MS BH RE RN a E ARA E E TRE 49 53 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and Users Guide 4 Section 1 Introduction introduction Max E Therme Pool and Spa Heater Congratulations on your purchase of a Max E Therm 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 Max E Therm heater is a lightweight efficient induced draft gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe schedule 80 CPVC for ASME models only The Max E Therm heater also comes equipped with the Pentair multifunction temperature controller which shows at a glance the proper functioning of the heater AII Max E Therm heaters are designed with a direct ignition device HSI hot surface ignition which eliminates the need
85. ssist 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 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 START UP page 32 and CARE AND MAINTENANCE page 45 See additional notes under Important Notices in Introduction MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 5 Maintenance 47 MAINTAINING POOL TEMPERATURE To maintain pool temperature make sure
86. t 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 Stage One High Pressure Gas Pipe Sizing 2 PSI 1000 B T U Per CU FT MAXIMUM EQUIVALENT PIPE LENGTH 0 to 50 Ft 50 to 100 Ft 100 to 150 Ft Stage Two Low Pressure Gas Pipe Sizing Stage 2 set at 7 in W C MAXIMUM EQUIVALENT PIPE LENGTH Table 5 Table 6 200 trough 338 a asin MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 15 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 or another non flammable method see page 14 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
87. t if pressure switch is more than 5 feet 1 5M above water level MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 3 Operation 35 SAFETY CONTRO LS cont d Diagnostic LED Check Point 1Flash Air Flow Fault 2 Flashes Flame No Call for Heat OPERATION OF IGNITION MODULE 3 Flashes lgnition Lockout The Ignition Module see Figure 33 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 Figure 33 The five operating switches are Digital Temperature isplay STA RITE e BOOSTER PUMP POOL ON Press this button to govern heater operation by the pool temperature setting SIMPLY SMARTER HIGH SPEED Temperature Up Down SPAON Press this button to govern heater operation by the System Operation FILTER AUX AUX spa temperature setting eA MM mw ab HEATER OFF Press this button to switch off the heater m Msn bs B i HEATER SYSTEM ON V TEMP Press this button to raise the temperature setting Dual Temperature 4 TEMP Press this button to lovver the temperature setting Operating Control for HD models didi D
88. t 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 1 x 4 fast blow fuse which is commonly available P N S794 Rev H 8 11 14 BK O Y Horte lee Y oc O 5 gt t OPERATING CONTROL MEMBRANE PAD CONNECTION BK O 9 ENABLE TOGGLE DISABLE TOGGLE TERMINAL BOARD sL Z w Time Clock or Remote Purchase Separately Supplies Power to Circulator Pump Fireman s Switch Completes the heater 7 24 Volt AC Control j Board Circuit e DO NOT connect this circuit to Line Voltage LL RENE o ANNE L1 S S BK L2 9 n GROUND GND mS T 7 JUNCTION 12 Pin Receptacle Figure 25 MAX E THERM Pool and Spa Heater Installation and Users Guide 30 Section 2 Installation MAX E THERM HEATERWIRING DIAGRAM 3 WIRE SYSTEM CONNECTION DIAGRAM AGS Switch Air Flow Switch Stack Flue Sensor d Extra Switch 1 Gas Valve Hi Limit Switch Pressure Switch me U Yw III BL O LI W BL 5 Y Q V BR al IT al eye Y R E eo y tc de m e NA LP Tol Y 2 Models Only Hee B J6 is YW vie I I I I E AFSYS OPERATING CONTROL e pui me E Y YO vn v v v Y MEMBRANE PAD AGSy CONNECTION E Hej T SE CO GAS External Contro
89. t to adjust the gas flow by adjusting the regulator setting MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 1 Introduction 7 SAFETY INFORMATION contd A 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 e f a fuel conversion is necessary refer this work to a qualified service technician or gas supplier before putting the heater into operation A WARNING Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or
90. ter is not sensitive MEAN aon e Cutout for 4 to polarity Sech Conduit from Fireman s Switch 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 see Figure 23 View From Above Interior Always use crimp type connectors when connecting Wire into bottom of Junction box two Wires EMEND in Flexible Conduit Figure 23 View From Below MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 29 CONNECTION OF FIREMAN S SWITCH OR REMOTE CONTACT ACAUTION 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 I 2 2 4a 4b Switch off power to heater at main circuit breaker panel Unbolt and remove the upper jacket halves see Figure 24 Open control box cover To connect a 2 Wire Control such as Pentair Aquatic Systems IntelliTouch or EasyTouch controll systems or a timer To Remove the factory installed jumper from the Fireman s Switch termin
91. ter models can be purchased separately See page 51 for parts list Inlet Air Intake Duct Requirements Combustion Air Intake 3 in Pipe Vertical or Horizontal No of 90 Elbows Maximum Length in Feet M 36 MIN Combustion Air Intake OO OTL 213M 3 PVC Pipe a Ge A NN 4 Alternate seston 08 ft 17 7 M i ne 46 ft 14 0 M provided by installer Rm 34 ft 10 4 M Chimney a or Gas Vent Category I or III NOTE Flue Exhaust Vent Cap Each 90 degree elbow reduces the Alternate Location maximum horizontal PVC air intake E MEM set duct run by 12 feet and each 45 aaa Lee degree elbow in the PVC air intake Chay Se SEH duct run reduces the maximum run S PVCFIpe so vin by 6 feet See the Table 5 above for the maximum lengths using 90 degree elbows AWARNING Side SES 12 MIN DO NOT USE PVC PIPE FOR FLUE EXHAUST Wall Vent VENT FLUE EXHAUST VENT TEMPERATURES CAN BE IN EXCESS OF 400 F FLUE EXHAUST VENT MUST BE CATEGORY or CATEGORY III METAL VENT MAX E THERM Pool and Spa Heater Installation and User s Guide P N S794 Rev H 8 11 14 Section 2 Installation 23 HORIZONTAL OR VERTICAL VENTING POSITIVE PRESSURE See Figures 16 17 and 18 Category III Vent 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 cod
92. ter trapped in the heat exchanger can result in freeze damage to the exchanger or headers Freeze damage is specifically not covered by the S oe Gas Control Valve ZW Throw switch AA to OFF 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 minimumsetting 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 Pelcock temperatures are expected to drop below freezing 32 F 0 C shut down the heater and winterize it open o Puos For outdoor heaters in freezing climates shut the heater down and DS drain it for winter as follows see Figure 38 Figure 38 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater Turn switch on heater gas valve to OFF 3 Innorthern 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 draining 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 A
93. 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 Useatime 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 Water 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 C
94. to or less than 1 2 psig 3 5 kPa CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE AWARNING 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 l valve incorporates dual To Air Flow Valve Vent for Test Figure 7 Connection shut off valves and a ToAirFlow Switch To High Side CIC for Service negative pressure regulator adici For proper operation the regulated pressure at the outlet manifold of the valve 5 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 in Figure 7 Pressure Tap To Low Side of Differential Pressure Gauge Do not attempt to adjust the gas input by a
95. xhaust vent 7 Replace hair pin clips Replace jacket halves and bolts and tighten 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 42001 00858 see Figure 22 is available with anchor clamps designed to hold the unit to the equipment pad in high wind conditions Insert the Bolt Down Brackets in the knockouts in the Lower Enclosure and bolt them solidly to the pad Installation of the anchor clamps are recommended in all installations and are required in Florida See Florida Building Code 301 13 Bolt Down Bracket Kit P N 42001 0085S Figure 22 P N S794 Rev H 8 11 14 MAX E THERM Pool and Spa Heater Installation and User s Guide 28

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