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Max-E-Therm Manual - parts4heating.com

1. 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 HORIZONTAL OR VERTICAL VENTING POSITIVE PRESSURE See Figure 13 Vent the heater either horizontally or vertically using one of the 4 inch Special Gas Vent Pipes listed on Page 14 Table 5 Install the vent pipe in accordance with local codes and the provisions of the National Fuel Gas Code ANSI Z223 1 U S or the standards CSA B149 1 Natural Gas and Propane Installation Codes Canada and the vent manufacturer s instructions Do not use a draft hood with this heater Use one of the special gas vents specified in Table 5 Page 14 for positive pressure venting of this heater do not use any other vent with it 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 mate rials around the vent or inside the required clear air space surrounding the vent See Table 6 Page 15 for maximum permissable vent lengths See Table 7 Page 15 for Listed vent components CONNECTING SPECIAL GAS VENT TO THE HEATER Metallic
2. 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 quali fied service technician check the system For deck level heater installations the Pressure Switch is factory set at 3 psi 20 6 kPa If the pressure switch is one to two feet 3 6M below or one to five feet 3 1 5M above the pool water level reset the switch so that it is 2680 1096 1 Set Manua Bypass Valve 2 Remove de Outlet to A Pool Switch Settings Aio am The water pressure switch turns off the burner if the water Filter flow is interrupted If the water flow is restricted the water FIGURE 17 Manual bypass valve Table 9 Water Chemistry Parameters Disinfectant levels Minimum Ideal Maximum Free Chlorine ppm 1 0 2 0 4 0 10 0 Combined Chlorine ppm None None 0 2 Bromine ppm 2 0 4 6 10 0 Other Sanitizers Levels not established Consult local health department before use Chemical Values pH 7 2 7 4 7 6 7 8 Total Alklinity Buffering ppm 60 80 100 180 as CaCO3 Total Dissolved Solids ppm N A N A 1 500 ppm gt TDS at startup Calcium Hardness ppm as CaCO3 150 200 400 500 1 000 Heavy Metals None None None Biological Values Algae None None None Bacteria None None Refer to Local Code NOTICE Failure to adhere to the listed water chemistry parameters may result in premature failure of the heat exchanger
3. 10 in Not Rec Not Rec Not Rec Not Rec Not Rec Not Rec Use Listed firestops for floor and ceiling penetrations Use Listed thimble for wall penetrations Use a Listed roof flashing roof jack or roof thimble for all roof pen etrations Do not fill the space around the vent that is the clear air space in the thimble or firestop with insulation The roof opening must be located so that the vent is vertical Do not run the heater vent into a common vent with any other appliance lt Listed Termination Cap g a Ft mM Min 10 Ft 3 3 M Storm Collar 6 15 cm Minimum Clearance to Combustible Materials Type B Double Wall etal Vent Pipe Metal Flue Collar Firestop Yt e B Double Wall Vent etal Vent Tee Body Vertical Vent Pipe so adapter does not take weight of pipe Dispose of condensate according to local codes Condensate Drain w trap FIGURE 12A Typical Metal Vent Pipe Installation Canada Vertical Negative Pressure Listed Termination Ca Min 8 Ft See Table 4 For Min Hght Storm Collar 6 Minimum Clearance to Combustible Materials Class B Double Wall Metal Vent Pipe Metal Flue Vent Body i Collar FIGURE 12B Typical Metal Vent Pipe installation U S Vertical Negative Pressure Firestop Support Vertical Vent Pipe so adapter does not take weight of pipe
4. 31 62M 62 92M 200 3 4 1 1 1 1 4 1 1 4 333 i 4 4 4 1 4 4 1 4 2 1 1 2 400 1 1 4 4 1 1 4 1 1 2 2 18 24 of 3 4 Manual Gas Line Shut off Valve a aJ bo Union A Sediment Trap FIGURE 22 Gas line and Trap PRESSURE TESTING Before operating the heater the heater and its gas connec tions must be leak tested Test all gas connections for leaks with soapy water 44 WARNING Risk of fire or explosion Do not use an open flame to test for leaks 20 The heater and its individual shutoff valve must be discon nected from the gas supply piping system during any pres sure 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 shutoff valve during any pres sure testing of the gas supply at test pressures equal to or less than 1 2 psig 3 5 kPa SUPPLYING POWER TO THE HEATER The heater requires a 120 or 240V 60Hz 1Ph power sup ply Enclose the line to the heater in an approved flexible conduit connected directly to the junction box on the inside of the heater jacket Line voltage field wiring should be 14 gauge with a circuit capacity of 15 amps ELECTRICAL WIRING NOTICE Before making any electrical connections to the power supply remove the covers open the control box remove the 12 pin plugs from their bag and plug in the correct plug
5. E parts heating STA RITE info parts4heating com A SR POOL AND SPA HEATER 120 240 VAC NATURAL GAS LP GAS OWNER S MANUAL INSTALLATION OPERATION amp PARTS MODELS 200K BTU HR SR200NA SR200LP SR200HD 333K BTU HR SR333NA SR333LP SR333HD 400K BTU HR SR400NA SR400LP SR400HD SPECIAL INSTRUCTIONS TO OWNER Retain this manual for future reference This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation Its use will reduce service calls and chance of injury and will lengthen product life If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Pentair Water Pool and Spa 1620 Hawkins Ave Sanford NC 27330 919 566
6. and will void the warranty Start up TDS includes source water TDS and any other inorganic salt added at start up open when the pump is off and closed when the pump is running Turn the star wheel on the switch clockwise DV to raise setting heater below the pool and counterclock wise N to lower the setting heater above the pool see Figures 18 and 19 Test the switch after resetting NOTICE When the heater is mounted more than five feet 1 5M above or two feet 6M below the deck level a Pressure Switch is no longer adequate A Flow Switch must be installed instead NOTICE Heater operation with incorrect Pressure Switch setting may cause operation with no water flow Operation of the heater without sufficient water flow may severely damage it Verify proper operation of the water pressure switch at the start of every season and every six months thereafter by the following steps 1 Lower the thermostat setting to turn off the heater 2 Wait at least 15 minutes after the burner is off and then turn off the filter pump 3 Turn up the thermostat as though to fire the burner FIGURE 18 Remove cover for access to Switch Raise Pressure Turn star wheel to raise pressure set point if pressure switch is more than 2 feet 6 M below water level 7 2734 1296 Turn star wheel to lower pressure set point if pressure switch is more than 5 feet 1 5 M above water level
7. 1 Order an Appliance Adapter kit Sta Rite Part No 77707 0086 for Saf T Vent or Saf T Vent Cl Sta Rite Part No 77707 0087 for Z Vent Remove the outside vent cover 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 alco hol rubbing alcohol and vigorously wipe the socket of the Vent Body Immediately wipe the cleaned sur faces 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 fol lowing the vent manufacturer s instructions 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 Table 4 Vent Termination Height vs Roof Pitch U S Minimum Height Roof Pitch Above Roof Flat to 6 12 1 Ft 6 12 to 7 12 1 Ft 3 in gt 7 12 to 8 12 1 Ft 6 in gt 8 12 to 9 12 2 Ft gt 9 12 to 10 12 2 Ft 6 in gt 10 12 to 11 12 3 Ft 4 in gt 11 12 to 12 12 4 Ft gt 12 12 to 14 12 5 Ft gt 14 12 to 16 12 6 Ft gt 16 12 to 18 12 7 Ft gt 18 12 to 20
8. 120 volt or 240 volt Note that installing the 120V plug and then connecting the heater to 240V line current will immediately destroy the transformer control board and ignition control module and will void warranty If you install the 240V plug and connect the heater to 120 volts line current the heater will not operate Please read the boxes headed IMPORTANT READ ME FIRST on pages 23 and 27 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 jacket under the vent for this purpose 3 Electrical power circuits to the pool heater must follow local codes and National Electrical Code or Canadian Electrical Code as applicable 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 jacket The conduit or cable connector at the field wiring box should con tain an insulating bushing or its equivalent to prevent abrasion of the wires as they enter the box The filter pump should run c
9. 240V plug in 120V circuit Replace with correct plug 120V plug in 240V circuit Replace trans former control board and ignition control module see HEATER WILL NOT FIRE C and D Pages 26 and 27 Check fuse and all other 24V components for damage GOTO HEATER WILL NOT FIRE B Page 25 Depress POOL or SPA ON button on Membrane Pad Does POOL or SPA LED come on YES Heater should fire on demand for heat y NO Check for line voltage to heater NO Restore power to heater Po for 24 VAC at sec ondary of Transformer y NO Check for Line Voltage between L1 and L2 terminals on Terminal Board NO gt Check wiring connections between power supply and Junction Box and between Junction Box and Terminal Board restore continuity YES 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 NO Check wiring connections between Terminal Board and Transformer primary and restore continuity YES Replace Transformer _ Jumper Fireman s Switch at Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on YES Check Fireman s Switch circuit connection
10. 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 Pregnant women beware Soaking in water above 102 F 39 C can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should follow the 100 F 38 C maximum rule Before entering the spa or hot tub users should check the water temperature with an accurate thermometer spa or hot tub thermostats may err in regulating water temperature Persons with medical history of heart disease circula tory problems diabetes or blood pressure problems should obtain their physician s advice before using spas or hot tubs Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs OPERATING INSTRUCTIONS BRWN STOP Read the safety information above 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 FIGURE 3 Removal of Jacket Covers Remove the jacket cover s by unfastening the screws connecting both halves of the top jacket See Figure 3 Toggle Style Valve Pull toggle toward you to turn gas o
11. For complete Electrical System parts breakdown Key Nos 1 through 4 See Page 35 For compete Burner System parts breakdown Key Nos 5 through 9 See Pages 32 and 33 4 Sk s For complete Water System parts breakdown Key Nos 10 through 13 see Page 34 Repair Parts are available from your Sta Rite dealer If your dealer cannot supply you call Sta Rite Customer Service at 1 800 831 7133 31 LE 00000 cm For Heater mounting bolts and clamps purchase separately Bolt Down Bracket Kit Part No 42001 0085S 0 a aT Laa gt 5029 0505 32 REPAIR PARTS BURNER SYSTEM Model SR200NA SR333NA SR400NA Key Part SR200LP SR333LP SR400LP No Description Qty SR200HD SR333HD SR400HD 1 Combination Gas Control Valve Kit 1 42001 0051S 42001 0051S 42001 0051S 2 3 4 Union 2 38404 4097S 38404 4097S 38404 4097S 3 Gas Orifice 1 4 Gas Orifice O Ring 1 e Gas Orifice Kit NG Incl Key Nos 3 and 4 t 77707 0431 77707 0421 77707 0411 Gas Orifice Kit Propane Incl Key Nos 3 and 4 t 77707 0461 77707 0451 77707 0441 NG to Propane Conversion Kit Incl Key Nos 3 and 4 t 77707 1461 77707 1451 77707 1441 Propane to NG Conversion Kit Incl Key Nos 3 and 4 t 77707 1431 77707 1421 77707 1411 5 Air Blower Kit Natural Gas Units 1 77707 0251 77707 0252 77707 0253 Propane Units 1 77707 0254 77707 0255 77707 0256 e Air Orifice Kit
12. Includes Key Nos 6 and 7 1 77707 0111 77707 0112 77707 0113 6 Air Orifice 1 TA Air Orifice Grill 1 42001 0114S 42001 0114S 42001 0114S Blower Adapter Plate Gasket Kit Includes Key Nos 8 9 10 12 1 77707 0011 77707 0011 77707 0011 Flameholder Kit Includes Key Nos 10 11 12 13 and on 333 8 400 models only Flameholder Insert 77707 0202 77707 0203 77707 0204 8 Blower Adapter Plate Gasket 1 9 Blower Adapter Plate 1 10 Flameholder Adapter Plate Gasket 1 11 Flameholder Assembly 1 12 Flameholder Combustion Chamber Gasket 1 13 Flameholder Insulation Cap 1 e Flameholder Insert 1 14 Enclosure Kit Upper Right Hand 1 77707 0002 77707 0002 77707 0002 15 Condensate Evaporator Plate 1 16 One Piece Metal Chamber Combustion Chamber Assembly 1 42001 0200S 42001 0200S 42001 0200S 17 Lower Enclosure 1 42001 0001S 42001 0001S 42001 0001S 18 Upper Enclosure Fastener 12 11x2 1 2 Type AB Hex Washer Head S S Sheetmetal Screw 4 19 Enclosure Kit Upper Left Hand Natural Gas 1 77707 3200N 77707 3333N 77707 3400N 19 Enclosure Kit Upper Left Hand LP Gas 1 77707 3200L 77707 3333L 77707 3400L 20 3 8 Washer S S 4 21 3 8 Lock Washer S S 4 22 3 8 Hex Nut Brass 4 Insulation Kit Includes Key Nos 13 15 23 24 25 and 26 1 77707 0008 77707 0008 77707 0008 23 Bottom Outer Insulation Blanket 1 24 1 Bottom Inner Insulation 1 25 1 Top Insulation 1 26 Top Outer Insulation Blanket 1 Lower Enclosure Insulation 1 42001 0074S 42001 0074S
13. NOTICE Set point must be above actual water temperature or burner will not fire See OPERATING CONTROL below 14 The blower should come on immediately and after about 20 seconds the burner should fire When oper ating 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 15 The burner should fire until the pool spa temperature reaches the desired temperature set on the thermostat The blower will continue to run for about 45 seconds after the burner shuts off If any of the safety interlocks should open during burner operation the burner shuts off immediately but the blower continues to run for about 45 seconds Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance 16 If the appliance will not operate follow the instruc tions TO TURN OFF GAS TO THE APPLIANCE and call your service technician or gas supplier TO TURN OFF GAS TO THE APPLIANCE 1 Depress OFF button on operating control 2 Turn off all electric power to the unit 3 Remove jacket cover s See Figure 3 A CAUTION HEATER PARTS MAY BE HOT 4 Toggle Style Valve Pull toggle toward you to turn gas off Knob Style Valve
14. Re place Pressure Switch Verify that water flow rate is above minimum required for heater NO lt gt Service pump and filter to restore proper flow IO ES CONTINUE CONTINUE r Adjust Water Pressure Switch to close with pump running and open with pump off MA Does Blower operate YES y No Replace Blower YES Verify that wires BM and F1 are correctly connected at the terminal strip see Heater Connection Diagram Page 36 Disconnect Blower and check for line voltage between pins 1 and 3 of Blower Connector on ignition try NO YES Check for 24 VAC between 24 VAC and GND terminals on Ignition Control Module on ignition try Check that IND wire is correctly connected NO Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board Disconnect wires F1 and F2 from Ignition Control Module and short them together Does Blower come NO NO Connect correctly and retry Does Blower start DEM Replace Blower Does Blower start on ignition try on YES THERMISTOR on Replace Ignition Control Module Verify Thermistor wiring If OK replace Thermistor Verify that there is no block age in Blower intake Heat Exchanger and exhaust and that ex
15. 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 In the U S and Canada The heater is certified for installation on combustible flooring The following clearances must be maintained from combustible surfaces O onneen 3 FEET 1M ALL SIDES 6 INCHES 15cm Orient the heater for convenient access to the water connections and the gas and electrical connections Install the heater at least 18 inches 45cm from any property line Outdoor installations must have at least 3 1 M of clearance above vent Space around unit must be open on three sides when under roof or overhang leave 6 in 15 cm of clear space between unit and y combustible surfaces TOP VIEW FIGURE 8 Combustible clearances CONTROL PANEL INDEXING The exhaust discharges vertically from outside the vent cover The heater control panel assembly on top of the jacket can be turned to any of six positions for convenient access to the panel as follows 1 Unbolt and separate the jacket halves 2 Pull hair 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 exhaust vent 7 Replace hair pin clips 8 Replace jacket halves and bolts
16. Turn the knob on the gas control clockwise to the black line depress slightly and turn to OFF position See Figure 4 5 Replace jacket cover s OPERATING CONTROL Digital Temperature Display a _ Dual Temperature Controls FIGURE 6A Operating Control for model 400HD See Page 36 for External Control Interface Digital Temperature Display System Operation Indicator Lights Dual Temperature Controls FIGURE 6B Operating Control for all models except HD models The five operating switches are POOL ON Press this button to govern heater operation by the pool temperature setting SPA ON Press this button to govern heater operation by the spa temperature setting OFF Press this button to switch off the heater ATEMP Press this button to raise the temperature setting WTEMP Press this button to lower the temperature setting To toggle the display between degrees Centigrade C and degrees Farenheit F 1 Turn the Operating Control OFF 2 Press ATEMP or WTEMP for 5 seconds The display will flash once and change modes C to F or vice versa When either the ATEMP or WTEMP buttons are depressed the digital display will indicate the temperature setting After five seconds the display will return to the actual pool spa temperature In addition to the digital temperature display there are five indicator lights The POOL ON light indicates that the pool water
17. surfaces AS TOP VIEW FIGURE 10 Minimum outdoor shelter clearances Canada or minimum garage or utility room clearances U S HEATER CLEARANCES OUTDOOR SHELTER Canada or INDOOR U S The following clearances must be maintained from com bustible surfaces TOP ascos 6 INCHES 15cm ALL SIDES 6 INCHES 15cm VENT 3 os sccccecsssssevesetanss 6 INCHES 15cm The heater is design certified by CSA International for installation on combustible flooring For installation on car peting 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 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 top of the jacket can be rotated for convenient access to the control panel Table 1 Corrosive Vapors and Possible Causes Area Likely Contaminants CSA B149 1 Natural Gas and Propane Installation Codes as applicable and any local codes that may apply The minimum net free area in square inches shall be as follows Table 2 Combustion and Ventilation Air Requirements Chlorinated swimming pools and spas Pool or spa cleaning chemicals Acids such as hydrochloric or muriatic a
18. 0007S 38000 0007S 17 Thermal Regulator Spring 1 18 Thermal Regulator Cap O Ring 1 35505 1313 35505 1313 35505 1313 G Thermal Regulator Spring Clip 1 19 Thermal Regulator Cap 1 20 Drain Plug 1 U178 920P U178 920P U178 920P 21 3 4 Pipe Plug 1 U78 60ZPS U78 60ZPS U78 60ZPS 22 Pressure Relief Valve Recommended Purchase Separately 1 38674 0719 38674 0719 38674 0719 Not available separately e Not illustrated 34 5028 0505 REPAIR PARTS ELECTRICAL SYSTEM Model SR200NA SR333NA SR400NA Key Part SR200LP SR333LP SR400LP No Description Qty SR200HD SR333HD SR400HD 1 Display Cover Retainer Cap Kit Cap and CPSC Warning Label 1 77707 0009 77707 0009 77707 0009 2 Heater Display Cover 1 42001 0008S 42001 0008S 42001 0008S 3 Igniter Bracket 1 42001 0030S 42001 0030S 42001 0030S 4 Igniter Igniter Gasket Kit Incl Key Nos 4 and 5 1 77707 0054 77707 0054 77707 0054 5 Igniter Gasket 1 42001 0066S 42001 0066S 42001 0066S 6 Manifold Switch Cover 2 42001 0007S 42001 0007S 42001 0007S 7 Automatic Gas Shutoff Switch AGS 1 42002 0025S 42002 0025S 42002 0025S 8 High Limit Switch 1 42001 0063S 42001 0063S 42001 0063S 9 Thermistor 1 42001 0053S 42001 0053S 42001 0053S 10 Terminal Board 1 42001 0056S 42001 0056S 42001 0056S 11 Fireman s Switch Fuse 1 25A 1 1 4 1 32850 0099 32850 0099 32850 0099 12 Ignition Control Module 1 42001 0052S 42001 0052S 42001 0052S 13 Transformer 115 230V 1 42001 0107S 42001 0107S 42001
19. 12 7 Ft 6 in gt 20 12 to 21 12 8 Ft Vent must be at least eight 8 feet away from nearest vertical surface Vents extending five 5 feet or more above the roof must be braced or guyed Consult your local code officials for detailed information AWARNING 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 interchange able 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 manufac turer for your system Follow manufacturer s instructions and local and National Fuel Gas Code U S or CSA B149 1 Natural Gas and Propane Installation Codes Canada requirements carefully during assembly and installation 4 Install vent pipe so that it can expand and contract freely as the temperature changes Support the vent pipe according to applicable codes and vent manufac turer s instructions Pipe support must allow the vent pipe free movement out and back from side to side or up and down as necessary without putting a strain on the heater or vent body Slope horizontal pipe runs up from the heater at least 1 4 per foot 2cm M Install Listed condensate drains at low points where conden sate might collect
20. 42001 0074S 27 One Piece Metal Elbow Combustion Chamber Cover Assembly 1 42001 0214S 42001 0214S 42001 0214S 28 Metal Vent Cover 1 42002 0005S 42002 0005S 42002 0005S Not available separately t Not included with heater Order separately 33 REPAIR PARTS WATER SYSTEM 5122 0805 Model SR200NA SR333NA SR400NA Key Part SR200LP SR333LP SR400LP No Description Qty SR200HD SR333HD SR400HD 1 Tube Sheet Coil Assembly Kit NA LP Series Includes Key No 3 1 77707 0232 77707 0233 77707 0234 1 Tube Sheet Coil Assembly Kit HD Series Includes Key No 3 1 77707 0242 77707 2043 77707 0244 2 Manifold Kit Includes Key Nos 3 14 21 and Key Nos 7 9 in Electrical System Page 35 1 77707 0014 77707 0015 77707 0016 3 Coil Tubesheet Sealing O Ring Kit 77707 0117 6 77707 0118 10 77707 0119 12 4 Manifold Bottom Plate 1 5 Manifold O Ring 1 O Ring Kit Incl Key Nos 3 5 1 77707 0120 77707 0120 77707 0120 6 Manifold Insert 1 7 Manifold Baffle Plate 1 8 Manifold Bypass Valve 1 9 Water Pressure Switch 1 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16x18x2 3 4 Hex Capscrew 10 13 Connector Tube O Ring 2 14 Connector Tube Kit Includes 1 Connector Tube and 1 O Ring 2 77707 0017 77707 0017 77707 0017 15 Thermal Regulator Kit Incl Key Nos 16 17 18 19 and Spring Clip 1 77707 0010 77707 0010 77707 0010 16 Thermal Regulator Includes Spring Clip 1 38000 0007S 38000
21. FLUE THERMISTOR SENSOR SENSOR 37 NOTES HEA ew ARE CONNECTED ON THE IGNITION MODULE 2 4 PIN AND SOCKET CONNECTOR 3 IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED THEY MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT STA RITE LIMITED WARRANTY Pumps filters skimmers underwater lights excluding bulbs accessories and fittings manufactured by Sta Rite are warranted to be free of defects in material and or workmanship for one 1 year from the original date of installation The foregoing warranties relate to the original consumer purchas er Purchaser only Sta Rite Industries shall have the option to repair or replace the defective product at its sole discretion Purchasers must pay all labor and shipping charges necessary to replace the product covered by this warranty Requests for war ranty service must be made through the installing dealer This warranty shall not apply to any product that has been subject to negligence misapplication improper installation or maintenance or other circumstances which are not in Sta Rite s direct control Failure to have product installed by a professional in compliance with local codes will void any and all manufacturers warranty This warranty sets forth Sta Rite s obligation and Purchaser s exclusive remedy for defective products STA RITE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDENTAL OR CONTINGENT DAMAGES
22. 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 manu facturer s installation instructions 5 Use Listed firestops for floor and ceiling penetrations Use Listed thimble for wall penetrations Use a Listed roof flashing roof jack or roof thimble for all roof pen etrations Do not fill the space around the vent that is the clear air space in the thimble or firestop with insulation The roof opening must be located so that the vent is vertical 6 Vent Termination Vertical See Figures 12A and 12B Page 13 for height of vent termination above the roof See Table 7 Page 15 for Listed terminations Use a Listed vent terminal specified by local and national codes and your manufacturer s instructions A roof ter mination 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 7 Vent Termination Horizontal See Table 7 Use a list ed wall thimble and vent terminal from Table 7 The terminal must be located U S See Figure 13 e at least 3 and at most 12 out from the wall see Figure 14 following the vent manufacturer s instructions e at least 12 above finished grade or the normally expect ed snow accumulation level whichever is higher e at least 4 f
23. Remember that all parts of the system affect heater operation Before starting this troubleshooting procedure make sure that the pump is running correctly that there are no blockages in the system that the valves are correctly set and that the time clock is correctly set and is running IMPORTANT READ ME FIRST NOTICE Installing the black 120 volt plug in the control box and on either 120 Volts AC or 240 Volts AC then connecting the heater to a 240 volt line will destroy the 2 Remove the covers and check the 12 pin plug in the back of the transformer control board 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 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 READ THE FOLLOWING CAREFULLY and plug it in The BLACK plug is for 120 volts the RED 1 Check the line voltage to your heater This heater will operate plug is for 240 volts Start here for directions to specific Troubleshooting Chart Y Is green POOL or SPA LED on YES Is red SERVICE SYSTEM LED on no Is red SERVICE HEATER NO Go to chart HEATER WILL NOT FIRE A Page 24 YES Go to chart HEATE
24. WHATSOEVER THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WAR RANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE APPLICABLE EXPRESS WARRANTIES PROVIDED HEREIN Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Supersedes all previous publications Product Specific Warranties from date of installation Product Limited Family Warranty Exceptions Filters 1 Year System 3 Tank Bodies 10 Yrs Filter Valves 1 Year Pumps 1 Year Heaters 2 Years Commercial Application 1 Yr Controls 1 Year Above Ground Systems 1 Year Lights and Niches 1 Year Lamps and Bulbs 90 Days White Goods 1 Year Maintenance Equipment 90 Days Drainer Utility Pumps 90 Days Replacement Parts 90 Days Cleaners Lil Shark 1 Year Cleaners Calypso 1 Year Cleaners Pool Shark 2 Years Footpad and Seal Flaps 1 Yr Cleaners Great White 2 Years Commercial and multi family application Retain this warranty certificate in a safe and convenient location for your records For
25. adjustment range of the Pressure Switch 0 5 psig YES j YES 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 YES NO GO TO HEATER WILL NOT FIRE C Page 26 25 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 GPM 76 LPM 333 30 GPM 114 LPM 400 40 GPM 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 GPM 76 LPM 333 30 GPM 114 LPM 400 40 GPM 151 LPM Go to Diagnostic LED s Pages 28 and 29 Heater Will Not Fire C Start Is SERVICE HEATER LED on YES If any red diagnostic LED s NO Turn off power to heater for 5 seconds and turn back on Make sure tem
26. and tighten FIGURE 9 Indexing Control Panel OUTDOOR SHELTER INSTALLATION INSTRUCTIONS 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 correct ly 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 A WARNING Risk of explosion if a unit burning propane gas is installed in a pit or other low spot Propane is heavier than air Do not install the heater using propane in pits or other locations where gas might collect Consult your local build ing code officials to determine installation requirements of heater relative to propane storage tanks and filling equip ment Installation must meet the requirements for the Standard for the Storage and Handling of Liquified 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 INSTALLATION IN A GARAG
27. inspect the heater and to replace any part of the control system and any gas control which has been under water Do not operate the pool heater unless the pool or spa is properly filled with water Before operating the appliance for the first time or after it has been off for an extended time perform the fol lowing checklist 1 Remove debris or other articles from inside the heater and the area around the heater and its exhaust vent Make sure the ventilation openings are clear of debris or obstruction For installations in an enclosed space make sure openings for combustion and ventilation air are unobstructed 2 Keep heater area clear and free from combustibles flammable liquids and chemicals Check that all water connections are tight 4 Water must be flowing through the heater during operation Make sure that pool spa is filled with water and have pump operating Check that water flow is unobstructed from the appliance When operating for the first time or after an extended shut down run filter pump for several minutes to clear all air from the system Un SPA TEMPERATURE CAUTION All safety rules recommended by the U S Consumer Product Safety Commission should be observed when using a spa or hot tub including 1 Spa or hot tub water temperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is con sidered safe for a healthy adult Special caution is sug gested for young children
28. mixer Remove the barbed fit ting and replace the plug in the PRESSURE TAP port of the gas valve using a thread sealant approved for use with natural gas and propane Replace the heater covers and cycle the heater to check for proper operation GAS CONNECTIONS 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 inlet pressure of 4 10 2cm wc is required to maintain input rating The gas supply must be installed in accordance with the National Fuel Gas Code ANSI Z223 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 out side the heater jacket Figure 22 Do not use a restrictive gas cock The following gas pipe sizes are recommended for natural gas supply piping For low pressure LP gas pipe size may be reduced by 1 4 with a minimum pipe size of 3 4 Check for compliance with local codes NOTICE DO NOT use a corrugated flexible gas line to supply the heater it will not deliver enough gas at nominal diameter to supply heater Table 10 Recommended Pipe Size For Natural Gas 1 000 BTU ft 0 6 Sp Gr 0 5 wc Pressure Drop 0 25 26 50 51 100 101 200 201 300 Model 0 7 6M 7 6 15M 15 31M
29. or e Vent it vertically using Type B double wall vent con nector pipe Locate the heater so as to minimize the length of horizon tal 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 must have a condensate drain as described in the venting installation instructions Metal Special Gas Vent Supren requires of nip e Appliance N Listed Adapter Terminal Condensate Tee Metal Vent JE Body n F Slope at least 1 4 per foot otk Santis 2 cm per Meter 3 7 6 cm Min down towards 1E 42 30 5 cm Max condensate drain Clearance FIGURE 14 Typical Special Gas Vent Pipe Installation Table 7 Listed Thimbles and Vent Terminals for OUTSIDE VENT COVER REMOVAL The heater is supplied from the factory with a built in stackless outside vent for outdoor installation Remove the outside vent cover for outdoor shelter installation Table 6 Maximum Vent Length 4 Special Gas Vent Vertical or Horizontal No of 90 Elbows Maximum Length in Feet M 0 70 Ft 21 3M 1 57 Ft 17 4M 2 45 Ft 13 7M 3 32 Ft 9 8M 4 20 Ft 6 1M Minimum vent length is one foot 34M or in accordance with vent manufacturer s instructions and loc
30. other safety information contained in this manual prior to operating this pool heater GENERAL SPECIFICATIONS REQUIREMENTS NOTICE Combustion air contaminated by corrosive chemi cal fumes can damage the heater and will void the warranty NOTICE The Combination Gas Control Valve on this appliance differs from most appliance gas controls If it must be replaced for safety reasons replace it only with an identical gas control NOTICE The jacket covers must be in place to provide proper ventilation Do not operate the heater for more than five 5 minutes with the jacket covers removed This heater is design certified by CSA International as com plying with the Standard for Gas Fired Pool Heaters ANSI Z21 56 CSA 4 7 and is intended for use in heating fresh water swimming pools or spas NOTICE Do not use this heater as a heating boiler water heater or for heating salt water pools This heater is intended for use in heating fresh water swimming pools or spas only 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 Installation Instructions Pages 9 and 10 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
31. power to Heater and retry Heater should fire Check continuity in wiring harness between Control Board and Probe Continuity OK jo Repeat checks on fuel no supply Thermal Regulator check for correct orifices Check the J3 and J6 connectors for corrosion looseness on the male pins m Does the Digital etc YES NO yes Temperature Display show NO Clean tighten pins as needed DONE Error Code E05 or E06 Basic Reset power to Heater and retry Heater should fire NO 29 Change Low Level Board Programming to SF1 See Page 4 11 in S5066 Sta Rite Pool Spa Heater Training and Service Manual Were you able to change the device code SFO to SF1 NO YES Replace Heater Membrane Pad DONE Reset power to Heater and try again to change code SFO to SF1 no Replace Heater Control Board Reset power to Heater and try again to change code SFO to SF1 Yes Reset power to Heater and retry Heater should fire No Check Heat Exchanger Coil for leaks liming soot or low flow Replace Heater Control Board DONE Reset power to Heater and retry Heater should fire No Replace Heater Membrane Pad DONE Reset power to Heater and retry Heater should fire Burner Troubleshooting
32. sq cm OUTDOOR SHELTER VENT INSTALLATION Canada or INDOOR INSTALLATION U S Always vent the heater to the outdoors e Vent it horizontally or vertically using a Special Gas Vent see Table 4 Page 14 or e Vent it vertically using Type B double wall vent con nector pipe Locate the heater so as to minimize the length of horizon tal 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 must have a condensate drain as described in the venting installation instructions Clean the Interior Surface Vent Body S 4 x 8 Metal Flue Collar y Vent Pipe N ES a N Eo rx A E Si VA Pa A i j gt lean and RTV Su laca This Surface hamber Flue Collar 2855 0597 RTV FIGURE 11 Flue Collar OUTSIDE VENT COVER REMOVAL The heater is supplied from the factory with a built in stackless outside vent for outdoor installation Remove the outside vent cover for outdoor shelter installation VERTICAL VENTING NEGATIVE PRESSURE See Figures 11 and 12 Vent the heater vertically in a negative pressure positive draft system in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 National Gas and Propane Installation Codes and local codes Type B Double wall vent connector is recommended however sin gle wall pipe is allowed
33. technical information about this product contact the installer or call at 800 831 7133 Visit www staritepool com e for more information about Sta Rite products listed above e to locate a Sta Rite dealer near you CREATE A RECORD OF YOUR WARRANTY AT STA RITE e Complete a warranty registration at www staritepool com by clicking on Register Products and selecting Sta Rite Pool OR STA RITE a OS e Complete bottom portion completely and mail within 10 days of installation to Sta Rite Attn Pool Warranty Dept 293 Wright St Delavan WI 53115 Warranty Registration Card Name New installation Replacement Address Years pool has been in service less than 1 J1 3 13 5 5 10 City State Zip This product was purchased from Installation or Purchase Date Company name Product Purchased Model Number Address City State Zip 4877PS Rev A 2 20 06 NOTES vartsNheating 800 536 1582 Fax 866 448 9304 info parts4heating com Pentair Water Pool and Spa 1620 Hawkins Ave Sanford NC 27330 919 566 8000 10951 W Los Angeles Ave Moorpark CA 93021 805 553 5000 www starite com and www pentairpool com 2006 Pentair Water Pool and Spa Inc All rights reserved 794 Rev A 2 20 06 This document is subject to change without notice Trademarks and Disclaimers The Pentair Water Pool and Spa logo is a trademark of Pe
34. tempera ture 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 burn er is firing This light should be on whenever the burner is on It blinks when the heater is calling for heat but not fir ing If this light is on but the burner fails to come on one of the service lights should come on indicating a fault in the system The SERVICE SYSTEM light indicates that there is insuffi cient 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 backwashing If the light remains on after the filter skimmers have been serviced the system should be checked by a qualified service tech nician 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 at left 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 Turn Off Gas to the Appliance at left and call a qualified service technician to repair unit AFTER START UP CHECKING WATER FLOW AWARNING Fire or floo
35. the Combination Gas Control Valve 2 Use a 3 16 hex key to remove the plug from the PRESSURE TAP port on the outlet side of the Combination Gas Control Valve 3 Install a 1 8 NPT barbed fitting into the PRESSURE TAP port Use a flexible tube to connect it to the low side of a differential pressure gauge or a slope gauge NOTICE If you are using a slope gauge or a differ ential pressure gauge of less than 3 capacity close the shutoff valve of the gauge to avoid pulling the liq uid out of the gauge when the blower starts Disconnect the tube from the Gas Valve VENT port Connect it to a tube with a tee running to the high side of a differential pressure gauge and to the blow ers air orifice grille See Figure 21 above Turn on the heater and verify the gas supply pressure Page 20 After the burner ignites open the shutoff valve of the gauge The pressure gauge should then read 0 2 wc 0 1 we 0 5cm we 0 25cm wc 0 0 to 0 1 wc 0 0 to 0 2 cm rich mixture 0 3 75 cm and above lean mixture Since the pressure tap is connected to the low side of the gauge the pressure is actually negative AWARNING Risk of fire or explosion if Combination Gas Control Valve is incorrectly adjusted If it is necessary to adjust the gas valve this must be done only by a qualified service agency Turn off the heater Replace the plastic hose between the VENT port and the inlet of blower
36. 0107S 14 Air Flow Switch 1 42001 0061S 42001 0061S 42001 0061S 15 Control Board Kit HD Series 1 42001 0096S 42001 0096S 42001 0096S 15 Control Board Kit NA LP Series 1 42002 0007S 42002 0007S 42002 0007S Heater Wiring Harness 115 230V 1 42001 0104S 42001 0104S 42001 0104S e 120 240 Volt Plug Kit 1 42001 0105S 42001 0105S 42001 0105S 16 Junction Box Cover Kit 1 77707 0022 77707 0022 77707 0022 Control Board Enclosure Membrane Panel Kit 1 77707 0004 77707 0004 77707 0004 HD Series Includes Key Nos 17 and 18 Control Board Enclosure Membrane Panel Kit 1 77707 0013 77707 0013 77707 0013 NA LP Series Includes Key Nos 17 and 18 17 Control Board Enclosure 1 18 Membrane Pad HD Series 1 18 Membrane Pad NA LP Series 1 19 Stack Flue Sensor 1 42002 0024S 42002 0024S 42002 0024S Not available separately Kit parts not available separately 35 Pool Heater Wiring Connection Diagram AGS Switch Stack Flue Sensor Gas Valve i i I Heater Membrane Pad Enabled External Control Interface Circuit Enabled Pool On and Spa On Keys Disabled OFF Key on Membrane Pad Remains Functional Plug 12 pin 120V Black 240V Red 12 Position Receptacle JUNCTION BOX Line 1 Ia gt BK Line 2 R Ground 2 gt al GND ars OPERATING CONTROL em Y El Ou n MEMBRANE PAD n AGS ZS CONNECTION Quim O en Quin mo tea is GAS HD M
37. 8000 MEMBER 10951 W Los Angeles Ave Moorpark CA 93021 805 553 5000 O www starite com and www pentairpool com pes INSTITUTE 794 Rev A 2 20 06 O 2006 Pentair Water Pool and Spa Inc All rights reserved INSTALLATION OPERATION AND SERVICE MANUAL Model SR Pool and Spa Gas Heater TO INSTALLER Affix these instructions adjacent to the heater TO CONSUMER Retain these instructions for future reference FOR YOUR SAFETY This product must be installed and serviced by a professional service technician qualified in pool heater installation Improper installation and or opera tion could create carbon monoxide gas and flue gases which could cause serious injury or death Improper instal lation and or operation will void the warranty FIGURE 1 For instructions on checking the gas pressure through the Combination Gas Control Valve See the sidebar on Page 19 Table of Contents Co a ee a ee ee ee ee eee eee 2 General Specifications Requirements 3 Description of the Heater 4 Sequence of Operation 04 4 Owner s Operating Instructions 4 Before SMUG is aaa 3 abe ninae ae Hewes 4 What To Do If You Smell Gas 04 4 Spa Temperature Caution 0 5 Operating Instructions 0 00 5 To Turn Off Gas To the Appliance 6 Operating Control 2 0 2 0 eee eee 6 After StartU
38. ANCES 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 SAFETY INSTRUCTIONS Continued AWARNING This appliance is equipped with an uncon ventional gas control valve that is factory set with a mani fold pressure of 2 inches wc Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Installation or service must be performed by a qualified installer service agency or the gas supplier If this control is replaced it must be replaced with an identical control Do not attempt to adjust the gas flow by adjusting the reg ulator setting AWARNING 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 qual ified 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 Sta Rite dealer Serious malfunction of the burner can occur which may result in loss of life Any additions changes or conversions requ
39. Back of pressure switch has a reference scale FIGURE 19 Water Pressure Switch Adjustment 4 Wait one minute The Service System light should go on but the burner should not fire and the blower should not start If the blower or burner do start or if the Service System light does not go on there is a pres sure switch malfunction Immediately press the OFF but ton on the operating control to turn the burner off and call a qualified service technician to check the system A CAUTION Live steam hazard If the Burner and the Pump stop at the same time wait at least 15 minutes before starting the filter pump to avoid severe damage to the heater PRESSURE RELIEF VALVE Canadian code requires and some U S local codes may require installation of a pressure relief valve Purchase sep arately and install a 3 4 pressure relief valve complying with the ANSI ASME Boiler and Pressure Vessel Code hav ing a capacity equal to the Btu hr rating of the heater The relief pressure of the valve MUST NOT EXCEED 50 PSI A 3 4 NPT connection is provided in the manifold for installing a pressure relief valve The relief valve must be installed vertically To install the valve use a 3 4 brass nipple and elbow user supplied as illustrated in Figure 20 No valve is allowed to be placed between the manifold adapter and the relief valve To avoid water damage or scalding from operation of the relief valve install a drain pi
40. E MAINTENANCE INSTRUCTIONS AWARNING 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 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 flam mable vapors and corrosive liquids 3 Test the operation of the pressure relief valve by lifting the valve lever 4 Test for proper operation of the pressure switch See SWITCH SETTINGS for testing instructions 5 On enclosed installations with high temperature Special Gas Vent systems repeat the Final Installation Check Page 15 Check for evidence of joint leakage Make sure that joints have not slipped partially or completely apart Check pipe and fittings for cracks or breaks The combustion air blower is permanently lubricated and does not require periodic lubrication The burner does not require maintenance or adjustment by the user Call a qualified service technician if you suspect that the burner may require maintenance WINTERIZING See Figure 7 For outdoor heaters in freezing cl
41. E OR UTILITY ROOM In Canada the heater must be installed in a room that is not normally occupied and has no openings directly to occu pied areas AWARNING Risk of fire and explosion if installed at floor level in an automotive garage or near gasoline or flamma ble 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 a utility room or residential garage installation install the heater with the base at least 18 inches 5M above the floor In a garage install a rail or wall to protect the heater from physical damage by a moving vehicle Provide an adequate ventilation air supply See Table 2 Page 11 Choose a location that will avoid contamination by chemical fumes NOTICE PROPANE LPG fired heaters must not be installed in garages in Massachusetts by order of the Massachusetts State Fire Marshall For more information call the State Fire Marshall s office NOTICE Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty See Table 1 Page 11 ES 1 6 in 15 cm Clear space t 18 5 M Raise at least 18 5 M above floor to avoid flammable vapors leave 6 in 15 cm of clear space between J unitand 15cm combustible
42. OTICE If the heater is plumbed in backwards it will cycle continuously Make sure piping from filter is not reversed when installing heater WATER PIPING Connect the heater directly to 2 PVC pipe using the inte 3 Way Chlorinator Valve pa 4 Pe pe S y y y Heater t gt gt gt gt From Pool 3 Way Valve FIGURE 16 Typical pool piping layout WATER FLOW RATE Maximum and minimum water flow rates required by the heater are listed below Table 8 Maximum and Minimum Flow Rate in GPM LPM f A f Model Minimum Flow Maximum Flow gral unions provided Heat sinks are not required The low 2 thermal mass of the heater will prevent overheating of the 00 20 76 120 454 piping connected to the pump even if the heater shuts 333 33 125 120 454 down unexpectedly 400 40 152 120 454 SYSTEM 3 a KA Modular Media E gt Inlet gt l A Si Warm Water PY Out to Pool or Spa To Pool Cool Water lt In From Pool FIGURE 15 Typical installation E Corrosion Resistant 5 Positive Seal se To Spa N Check Valve v Sanitizer 2735 1296 n Cool Water In From Spa If the water flow rate to the heater is above 120 GPM 454 LPM it must be reduced by installing a manual bypass valve Figure 17 After installing the valve adjust the valve to bring the flow rate within the acceptable range Then remove the v
43. R WILL J NOT FIRE B Page 25 Are any red diagnos A YES tic LED s on back of YES Go to specific safety switch board AGS AFS troubleshooting chart SFS HLS PS or Pages 28 and 29 LED on No 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 E YES NO Does red SERVICE YES Go to chart HEATER WILL m HEATER LED come NOT FIRE C on Page 26 NO 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 A WARNING Hazardous voltage Can shock burn or A WARNING Fire and Explosion hazard Do not kill Disconnect power before servicing any components jumper switch terminals to remedy a failed safety switch 23 Heater Will Not Fire A Start Is green SPA or NO POOL LED on YES Check that correct 12 pin YES plug is installed red is 240V black is 120V i NO If plug is not installed Install correct plug
44. SYMPTOM CAUSE REMEDY Loud high pitched whine Flame is too rich Verify pressure tap between gas valve and blower inlet Turn to Page 19 and verify that the gas regulator setting is 0 2 0 5cm wc below the blower inlet pressure Replace gas orifice with smaller size Flame is fluttery Exhaust may have acrid smell or burner may fail to stay lit Flame is too lean Turn to Page 19 and verify that the gas regulator setting is 0 2 0 5cm wc below the blower inlet pressure Replace gas orifice with larger size Burner pulsates or surges especially on ignition Combustion appears normal but flame does not stay lit Heat Exchanger Troubleshooting SYMPTOM Exhaust vent is too long Flame current is not being sensed CAUSE Reduce length of exhaust vent and or number of elbows Check for wet or damaged igniter with low resistance to ground Replace with new igniter Verify burner flameholder is properly grounded Replace Ignition Control Module REMEDY Boiling in heat exchanger May be accompanied by bumping sounds Low water flow to heater Heat exchanger plugged Bypass valve stuck open Thermal governor stuck closed Service pump and or filter Service heat exchanger Correct water chemistry Service bypass valve Replace thermal governor Sweating Thermal governor failed 30 Replace thermal governor
45. Y Board Circuit 200 DO NOT connect this 3 Circuit to Line Voltage GROUND GND gt FIGURE 25 Fireman s Switch Connections 6 Reinstall and bolt up the jacket halves The fuse for the Fireman s Switch is a 1 25 amp 1 1 4x1 4 fast blow fuse available locally MAXIMUM TEMPERATURE SET POINT 1 Unbolt and remove upper jacket halves see Figure 3 Page 5 2 Depress the clips and remove the control panel board dome see Figure 9 Page 10 3 Push the Max Temp Set Point button on the back of the control board see Figure 26 The following sequence should happen 3664 0200 BASIC FIGURE 26 Max Temperature Set Point Controls A B E The unit will come on and the POOL ON light will come on Press the WTemp or ATemp pad on TOP of the panel to set maximum pool temperature 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 but ton again Press the WIemp or ATemp pad on TOP of the panel to set maximum spa temperature set temper ature to 104 F 40 C or less 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 4 Reinstall and bolt up the jacket halves 22 Initial Troubleshooting Only qualified trained service technicians with appropriate test equipment should service the heater
46. al and national codes Horizontal vents 3 1M or less in length do not require a condensate tee but must slope down toward the outlet at 1 4 to the foot 2cm M to allow condensate to drain VERTICAL VENTING NEGATIVE PRESSURE See Figures 11 and 12 Vent the heater vertically in a negative pressure positive draft system in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 National Gas and Propane Installation Codes and local codes Type B Double wall vent connector is recommended however sin gle wall pipe is 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 To connect a negative pressure metal gas vent to the heater order the appropriate Metal Flue Collar from the chart below 1 See Table 3 below to determine allowable vent sizes for your heater NOTICE Table 3 is for installations in which the total later al 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 2 Install the metal Flue Collar i
47. alve handle or lock it in place to prevent tampering 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 WATER CHEMISTRY Water chemistry should follow good swimming pool water chemistry practices See Table 9 below for water chem istry parameters When using a chlorinator install it downstream from the heater and at a lower level than the heater outlet Install a corrosion resistant positive seal check valve see Figure 15 between the heater and the chlorinator to prevent concen trated 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 WATER PRESSURE SWITCH AWARNING Hazardous pressure Do not bypass the Water Pressure Switch or render it inoperable
48. bout 30 NO FIRE D Page 27 lt seconds after calling g for heat Repl laniti trol Check for 24 VAC Mea guion Conte YES between TH and GND l terminals on Ignition A NO Control Module Check for 24 VAC between SEE NOTE 1 VAL and GND terminals on NO YES Ignition Control Module gt SEE NOTE 2 Check for 24 VAC between TH and GND Y YES terminals on Control NO Check for 24 VAC between YES Board SEE NOTE 1 VAL and GND terminals on Control Board SEE NOTE 2 Check for 24 VAC Y NO between GAS termi YES Fix wiring between VAL and nals on Control _ GND terminals of Ignition Board SEE NOTE 2 Control Module and Control Board y NO Replace Control Board 26 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 Heater Will Not Fire D IMPORTANT READ ME FIRST IMPORTANT READ ME FIRST meter will read either O VAC or 240 VAC If your ICM is If your heater is correctly connected to 240 Volts AC The good your meter will read some voltage between 0 and Ignition Control Module ICM will convert the 240VAC to 240 VAC Exactly what reading you get will depend on the an intermittent pulse to the ignitor Digital meters don t read meter but with a good ICM the reading won t be 0 VAC or this type of signal well An analog meter will
49. 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 To connect a negative pressure metal gas vent to the heater order the appropriate Metal Flue Collar from the chart below Metal Flue Collar Sta Rite Part No 4x6 77707 0076 4x8 77707 0077 1 See Table 3 below to determine allowable vent sizes for your heater NOTICE Table 3 is for installations in which the total later al 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 2 Install the metal Flue Collar in the Vent Body of the heater located under the outside vent cover Fasten the metal Flue Collar to the Vent Body with two 10 sheet metal screws Use UltraCopper silicone RTV to seal the Flue Collar to the Vent Body Before connecting the metal Flue Collar to the Vent Body wet a clean cloth or paper towel with isopropyl alcohol rubbing alcohol and vigorously wipe the socket of the Vent Body Immediately wipe the cleaned surfaces dry with a clean cloth or paper towel R
50. cid 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 aerosol cans containing chlorocarbons or fluorocarbons Beauty parlors Refrigeration plants or various industrial finishing and processing plants Refrigerants acids glues and cements construction adhesives Dry cleaning and laundry areas Bleaches detergents or laundry soaps containing chlorine Waxes and cleaners containing chlorine calcium or sodium chloride COMBUSTION AND VENTILATION AIR SUPPLY For shelter installation the heater requires air supply open ings for ventilation and combustion The minimum require ments are for two 2 openings one 12 inches 30cm from the ceiling for ventilation air and one 12 inches 30cm from the floor for combustion air in accordance with the latest edition of ANSI Z223 1 or the National Fuel Gas code the All Air From All Air From Inside Building Outside Building Model Combustion Vent Combustion Vent 200 200 sq in 200 sq in 50 sq in 50 sq in 1 291 sq cm 1 291 sq cm 323 sq cm 323 sq cm 333 333 sq in 333 sq in 84 sq in 84 sq in 2 149 sq cm 2 149 sq cm 542 sq cm 542 sq cm 400 400 sq in 400 sq in 100 sq in 100 sq in 2 581 sq cm 2 581 sq cm 645 sq cm 645
51. ding hazard If the unit overheats and the burner fails to shut off follow instructions under To Turn Off Gas to the Appliance Page 6 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 ther mostat to 65 F 18 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 COLD WEATHER OPERATION The heater may be operated in the wintertime provided air temperatures remain above freezing and the water temper ature is not permitted to drop below 65 F 18 C Extended heater operation with water temperatures below 65 F 10 C can result in serious damage to the heater and is not covered by warranty NOTICE 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
52. e operating controls SEQUENCE OF OPERATION An electronic temperature sensing thermistor in the mani fold adapter inlet controls the heater operation When the inlet water temperature drops below the temperature set on the operating control the burner controller supplies power to the combustion air blower through a series of safety interlocks The interlocks consist of 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 e the automatic gas shutoff AGS switch which opens if the heat exchanger outlet temperature goes above 140 F 60 C e the stack flue sensor SFS which shuts down the heater if the flue gas temperature reaches 500 F 260 C The air flow switch AFS senses the pressure drop across the air metering orifice As soon as there is sufficient air flow the AFS closes closing the circuit to the hot surface igniter HSI which ignites the fuel mixture On a call for heat the blower and HSI are energized In about 20 seconds the gas valve opens and ignition occurs The HSI then switches to a sensing mode and monitors the flame The heater is equipped with a digital operating control that enables the user to pre set the desired pool and spa water temperatures The control enables the user to select between pool and spa heating and features a digital dis play that indicates the
53. eet below or horizontally from or 1 foot above any doors or windows or gravity air inlet to a building e At least 3 feet above any forced air inlet located within 10 feet e At least 4 feet horizontally from electric meters gas meters regulators and relief equipment e At least 7 feet above grade adjacent to walkways or sim ilar traffic areas Table 5 Recommended Special Gas Vents Positive Pressure Brand Manufacturer Material Type Sealant Saf T Vent 4 Heat Fab Inc Metal Consult Manufacturer Special Gas Vent 38 Hayward Street Single Wall Greenfield MA 01301 800 772 0739 Saf T Cl Vent Heat Fab Inc Metal Consult Manufacturer Special Gas Vent 38 Hayward Street Double Wall Greenfield MA 01301 800 772 0739 Z Vent 4 Special Z Flex U S Inc Metal G E RTV 106 Gas Vent Type BH 20 Commerce Park North Model SVE Bedrford NH 03110 6911 800 654 5600 Termination a Mi Mi id ES E Vent Vent Termination ai Termination 4 Min Y 4 Min 1M E Min HH At least 7 above grade adjacent to public walkways FIGURE 13 U S minimum Exhaust Vent clearances Local 1 Minimum above snow or finished grade whichever is higher Gas Meter Forced Air Inlet 3 Minimum clearance if horizontal distance to exhaust opening is less than 10 feet e Vent it horizontally or vertically using a Special Gas Vent see Table 4 Page 14
54. epeat for the exterior of the 4 end of the metal Flue Collar Attach the metal Flue Collar to the Vent Body using the RTV supplied with the kit fol lowing the vent manufacturer s instructions included with kit Do not use a draft hood with this heater 3 Attach the vent pipe to the metal Flue Collar with sheet metal screws AWARNING 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 interchange able Mixing parts from more than one manufacturer may cause leaks or damage to vent When assembling a vent pick one manufacturer and be sure that all vent parts come from that manufacturer and are specified by the manufac turer for your system Follow manufacturer s instructions local code requirements National Fuel Gas Code require ments U S or standards CSA B149 1 and B149 2 Canada carefully during assembly and installation 4 Install vent pipe so that it can expand and contract freely as the temperature changes Support the vent pipe according to applicable codes and the vent manufactur er s instructions Pipe support must allow the vent pipe free movement out and back from side to side or up and down as necessary without putting a strain on the heater or vent body Slope horizontal pipe runs up from the heater at least 1 4 per foot 2cm per meter Install L
55. ff Knob Style Valve Turn the knob on the gas control clockwise to the black line depress slightly and turn to OFF position See Figure 4 Toggle Style Valve Knob Style Valve lt Gas control is shown ON Indexing Point e Pull toggle toward you peg Sl as A to turn OFF You are here y Gas control is shown ON Turn Clockwise and press down to turn gas OFF FIGURE 4 Turning Gas Control OFF 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the Before Startup instructions Page 4 If you don t smell gas go to the next step 8 Toggle Style Valve Push toggle away from you to turn gas on Knob Style Valve Turn the knob on the gas control counter clockwise to the ON position See Figure 5 Toggle Style Valve Knob Style Valve a Gas control is shown OFF F a7 8 Push toggle away from Indexing Point See you to turn ON Sig You are here Pie ZN 4 Ooa WW Gas control is shown OFF Turn Counter clockwise and release to turn gas on FIGURE 5 Turning Gas Control ON 9 Replace jacket cover s All jacket covers must be in place when operating the appliance 10 Set 3 way valves on inlet and outlet to pool or spa as appropriate 11 Turn on all electric power to the appliance 12 Press either the POOL ON or SPA ON button switch on the operating control 13 Set the thermostat to desired setting
56. give a better 240 VAC but somewhere in between reading than a digital meter If the ICM is bad your volt Start Gas flows during igni tion try but burner does not fire YES Check voltage across igniter leads OK NO Replace Ignition Control Module On a 120 V installation check the ignitor for damage if it has seen 240 VAC Go back to chart HEATER WILL NOT FIRE C Page 26 YE Check gas pressure OK MER Replace HSI Igniter NO Increase gas flow into heater e Replace gas line with larger line e Replace regulator e Replace meter or e All of the above 27 Diagnostic LED s AGS AFS HLS PS THERMISTOR AGS or HLS on Replace High Limit Switch HLS or Automatic Gas Shutoff AGS Verify that water flow rate is above minimum required for heater NO A YES Service pump and filter to restore proper flow After ser vicing verify proper operation of Pressure Switch PS YES lt lt Verify that inlet water temper ature is below 104 F NO CONTINUE ie ee If problem persists verify proper operation of Internal Bypass Valve and Thermal Governor and check for Heat Exchanger blockage Replace thermistor or Control Board to correct overheating EIC ee Verify that wiring is OK and pressure tap is not blocked
57. haust is not too long see Indoor Vent Installation Page 15 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 A CAUTION remedy a failed switch Do not jumper a safety switch to NOTE ES1 is a spare and should be jumpered 28 YES Diagnostic LED s SFS Check Heat Exchanger NO Coil for leaks liming soot or low flow NO Heater starts and runs OK but temperature of exhaust climbs to 450 500 in 3 5 HD YES Check Thermal Regulator Open at minutes NO 120 No Heater starts after several tries exhaust temperature stays below 250 OR Heater doesn t start at all exhaust stays cold Correct problem Heater should fire No YES gt Check Thermal Regulator Seats correctly Check pressure and volume of fuel supply NOT OK ok Correct Fuel Supply reset Disconnect the sensor and check continuity across its terminals Resistance should be 3 5 4 0 mega ohms co open circuit 0 shorted Does sensor check OK YES Heater and retry Heater should fire correctly NO gt Replace Stack Flue Sensor DONE Reset
58. heater s minimum setting of 65 F 18 C DO NOT operate this unit outdoors at temperatures below 40 F 4 C During cold weather if there is no danger of freezing operate the filter pump continuously even if the heater is not operating If air temperatures are expected to drop below freezing 32 F 0 C shut down the heater and win terize it See WINTERIZING Page 8 Allowing the heater to freeze will void the warranty MAINTAINING POOL TEMPERATURE To maintain pool temperature make sure that the heater switch and valving are reset to pool settings after using the spa ENERGY SAVING TIPS 1 Keep the pool or spa covered when not in use This will reduce heating costs reduce water evaporation con serve 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 3 Use a time clock to start the filter pump at 6 a m or later The swimming pool loses less heat after daybreak 4 For pools used only on weekends lower the thermostat setting by 10 F to 15 F 5 C to 8 C during the week to reduce heat loss A properly sized heater will restore normal temperature within one day 5 Turn the heater off when the pool will not be used for an extended period 6 Follow a regular program of preventive maintenance for the heater each new swimming season Check operation of the heater and its controls CARE AND MAINTENANC
59. imates shut the heater down and drain it for winter as follows 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater Turn switch on heater gas valve to OFF 3 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 Assist the draining by blowing out the heat exchanger through the pressure switch fitting with low pressure compressed air less than 5 PSI or 35 kPa AWARNING 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 out let 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 Manual Gas Valve OFF Combination Gas Con
60. ired in order for the appliance to satisfactorily meet the application needs must be made by a Sta Rite 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 Models with NA or HD suffix burn nat ural gas models with LP suffix burn LP gas propane e Use heater only with the fuel for which it is designed e If a fuel conversion is necessary refer this work to a qualified service technician or gas supplier before putting the heater into operation Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or other volatile flammable liquids near heater or in the same room with heater AWARNING Risk of fire carbon monoxide poisoning or asphyxiation if exhaust venting system leaks Only quali fied service technicians should attempt to service the heater as leakage of exhaust products or flammable gas may result from incorrect servicing 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 equip ment as specified by the Standard fo
61. isted condensate drains at low points where conden sate 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 manufactur er s installation instructions Table 3 Permitted Minimum and Maximum Vent Heights By Size and Heater Model Read VERTICAL VENTING NEGATIVE PRESSURE above before using this table 12 Type B Double Wall Vent With Type B Double Wall Connector In Feet Meters Model 200 Model 333 Model 400 Vent Size Min Height Max Height Min Height Max Height Min Height Max Height 6 in 6 Ft 1 8 100 Ft 30 5 30 Ft 9 100 Ft 30 5 Not Rec Not Rec 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 30 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 Model 200 Model 333 Model 400 Vent Size Min Height Max Height Min Height Max Height Min Height Max Height 6 in 6 Ft 1 8 15 Ft 4 6 Not Rec Not Rec Not Rec Not Rec 7 in 6 Ft 1 8 8 Ft 2 4 10 Ft 3 20 Ft 6 15 Ft 4 6 50 Ft 15 3 8 in Not Rec Not Rec 6 Ft 1 8 20 Ft 6 8 Ft 2 4 20 Ft 6 9 in Not Rec Not Rec Not Rec Not Rec 6 Ft 1 8 6 Ft 1 8
62. more than two feet above pool level the pressure switch setting should be adjusted See PRESSURE SWITCH in the MAINTENANCE section Before putting the heater into service for the first time fol low the instructions under BEFORE STARTUP in the front of this manual Check for proper operation of the heater by following the steps under OPERATING INSTRUCTIONS Damage to equipment caused by improper installation or repair will void the warranty OUTDOOR INSTALLATION INSTRUCTIONS 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 build ing code officials to determine installation requirements of heater relative to propane storage tanks and filling equip ment Installation must meet the requirements of the Standard for the Storage and Handling of Liquid Petroleum Gases ANSI NFPA 58 latest edition in the U S or CAN CSA B149 2 latest edition in Canada Consult local codes and fire protection authorities about specific installation restrictions Locate the heater on a level surface in an open area that is protected from drainage or run off Install the heater in an area where leaves or other debris will not collect on or around the heater This heater is designed for outdoor installa
63. n adjustment alteration service or main tenance of the Combination Gas Control Valve can lead to fire or explosion causing loss of life per sonal injury or property damage These instructions are for the use of qualified service technicians only Do not attempt this procedure unless you have been trained and certified in the care and repair of gas fired appliances Do not attempt this procedure if the following instructions are confusing 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 per formed by a qualified installer service agency or the gas supplier If this control valve is replaced it must be replaced with an identical control The combination gas valve incorporates dual shut off valves and a negative pressure regulator For proper operation the regulated pressure at the outlet manifold of the valve must be 0 2 0 5cm wc below the refer ence pressure at the blower mixer inlet and the gas valve VENT tap must be connected to the endcap air orifice as shown in Figure 21 above Do not attempt to adjust the gas input by adjusting the regulator setting The correct gas regulator setting is required to maintain proper combustion and must not be altered To check that the gas pressure setting is correct use the following procedure 1 Turn off the heater and remove the top covers for access to
64. n the Vent Body of the heater located under the outside vent cover Fasten the Special Gas Vents Vent Brand Wall Thimble Horizontal Terminal Vertical Terminal Saf T Vent Part of Vent term 5490CI Horizontal Term 5400 Cap Saf T Cl Vent Part of Vent term 5490CI Horizontal Term 5400 Cap Z Vent 2SVSWTF04 2SVSTTF04 Tee 2SVSRCF04 Cap A manual bypass valve should be installed across the heater when the pump flow exceeds 120 GPM 454 LPM See instructions below for setting of the manual bypass Make sure that the outlet plumbing from the heater con tains no shut off valves or other flow restrictions that could prevent flow through the heater except as noted below To switch flow between the pool and spa use a diverter valve Do not use any valve that can shut off the flow Do not use a shut off valve to isolate the heater unless it is below the level of the pool or spa Install a check valve to prevent back siphoning through the heater when the pump is off NOTICE Improper operation of chemical feeders can cause severe damage to the heater which is not covered by the warranty Install the chemical feeder downstream of the heater see Water Chemistry Page 17 Install a chemical resistant one way check valve between the heater and the chemical feeder NOTICE If you install a chemical feeder and check valve you must install a relief valve on the heater See Pressure Relief Valve Page 18 and 19 N
65. ntair Water Pool and Spa Inc The S a Afe ogois a registered trademark of Pentair Water Pool and Spa Inc Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products Pentair Water Pool and Spa Inc disclaims any proprietary interest in trademarks and trade names other than its own
66. odels only HD Models NA LP Models i CONTROL CENTER SPA CONTROL J6 incl pins 1 9 J6 incl pins 1 6 i H ooo leeeeeeeo Connect 6 Wire Connect 9 Wire External Control Interface Circuit Disabled Se Cable s shown Cable as shown Spa Line Common Line Pool Line External Control Interface BK FA IGNITION CONTROL MODULE Y Y Air Flow Switch Extra Switch 1 Hi Limit Switch Pressure Switch Yo 7 YW Y Y 9 Y 0 Y Y 0 lo ml E a N de 3 gF2zg gt g HD Models NA LP m HLS 3 a a 2 J6_ Only Models Only 09 esi 5 J6 pr YW YBL E I YRY Y Y Y EERE a 4 Oe l se 1 lI 24VAC SEC GY GY BK 120VAC IGNITER NOTICE Touching any 24VAC wire including G the Fireman s Switch wire to any 120 240V L terminal while the heater is connected to line N power will immediately destroy the control board and void the warranty Replace jumper with leads to Fireman s Switch field installed 36 Pool Heater Electrical Schematic Ladder Diagram LADDER DIAGRAM u e A __s L2 IGNITER BLOWER 120 240 VAC CLASS II TRANSFORMER OPERATING CONTROL 24 VAC eccccccce AIR 24V LOGIC FLOW SWITCH WATER HI PRESSURE LIMIT SWITCH SWITCH O O rE X e COMNO 4 e eeeceecest rad GAS VALVE STACK
67. ontinuously when the heater is on and for at least 15 minutes after the heater turns off Any switches in the pump circuit including circuit breakers that can disconnect the pump must also disconnect the heater 7 Do not wire single pole switches including protective devices into a grounded line The heater is not sensi tive to polarity Connect the L1 of the power supply to the black wire the L2 or neutral lead to the red wire and the ground wire to the green wire See Figure 23 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 120V White to Red L2 or 240V Red to Red L2 9 Green Ground to Green Ground 120 240V Black to Black L1 in Control Box to match incoming voltage 120 or 240V Cutout for Conduit from Fireman s Switch Wiring Harness to Control Box View From Above S Interior Wire into bottom of Junction box in Flexible Conduit View From Below Exterior FIGURE 23 Field Wiring FIREMAN S SWITCH CONNECTION NOTICE 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 includ ing the Fireman s Switch jumper you will immediately destroy the control board and void the warranty FIGURE 24 Open Control Box Cover NOTICE When u
68. p ade di 7 Care Maintenance Winterizing 8 Installation Instructions 0 9 Pre Existing Vent Systems ooo oooomoo ooo 9 Outdoor Installation 2 2 0 0 0000 9 Outdoor Shelter Indoor Installation 10 15 Water Connections 0004 15 18 Pressure Relief Valve 2 0 e eee eee 18 Checking Combination Gas Control Valve 19 Gas CONNECHONS oid ands bee he ee 20 Pressure Testing setie ici nese ee ewe oe eee ees 20 Electrical Wiring 4 000 00 ta Ae A es 20 22 Troubleshooting 2000 23 30 Repair Parts aus ccs speed nag sew tales 31 35 Wiring Diagrams External Control Interface 36 37 Warranty 4 0 a araia eda aa 38 SAFETY INSTRUCTIONS 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 Installation must be in accordance with all local codes and or the latest edition of the National Fuel Gas Code Z223 1 and the National Electrical Code ANSI NFPA7O U S or standards CSA B149 INSTALLATION CODES FOR GAS BURNING APPLI
69. pe in the outlet of the pressure relief valve that will direct water discharging from the valve to a safe place for disposal Do not install any reduc ing couplings or valves in the drain pipe The drain pipe must be installed so as to allow complete drainage from the valve and drain line The relief valve should be tested at least once a year by lifting the valve lever AWARNING Explosion hazard Any heater installed with restrictive devices in the piping system downstream from the heater including check valves isolation valves flow nozzles or therapeutic pool valving must have a relief valve installed as described above User supplied pipe fittings 2681 1096 Pipe relief valve discharge to a drain or other safe disposal site FIGURE 20 Relief Valve ane To Air Flow Switch To Air Flow C Switch To Gas Valve Vent Connection for Test FIGURE 21 Connect Gas Valve to End Cap Air Orifice NOTE The gas piping and unions have been omitted for clarity make this test with all gas piping connected as for normal service To High Side of Differential Pressure Gauge NOTE Your model may be equipped with a Gas Control Knob instead of an ON OFF To Low Side of toggle switch Differential Pressure Gauge Instructions For Checking the Gas Pressure Through the Combination Gas Control Valve AWARNING Risk of fire and explosion Improper installatio
70. pera ture setting is above 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 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 YES Replace Gas Valve with identical part 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 AGS AFS SFS HLS PS NO water temperature YES y gD OF Wait one minute A THERMISTOR come on go i to to Pages 28 and 29 Does heater fire and stay on CONTINUE NO NO Did burner fire at all m Did Blower come on gt YES y YES Go to BURNER Verify that gas is flow TROUBLESHOOTING ing to burner during f Page 30 ignition try Observe gas meter for move ment during ignition Go to HEATER WILL NOT YES try wait for a
71. r the Storage and Handling of Liquified Petroleum Gases CAN CSA B149 2 latest edition or ANSI NFPA 58 latest edition 44 WARNING Risk of asphyxiation if exhaust is not correct ly 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 The heater is supplied with an integral venting system for outdoor installation A vent conversion kit See Page 14 for Part Numbers for Conversion Kits is available for installa tions in enclosures Canada or indoors U S Use the specified venting and only the specified venting when heater is installed in an enclosure or indoors In Canada this pool heater can only be installed outdoors or in an enclosure that is not normally occupied and has no open ings directly into occupied areas See Page 11 for enclo sure venting requirements 4 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 1 Phase power only Verify proper operation after servicing Do not allow children to play on or around heater or asso ciated equipment Never allow children to use the pool or spa without adult supervision Read and follow
72. s time clock wiring external controller relay y No Leaving jumper in place check for 24 VAC between Fireman s Switch terminals and ground NO Remove jumper Check ribbon cable connection between Membrane Pad and J6 on Control Board Depress POOL or SPA On pad again Does POOL or SPA LED come on 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 YES Heater should fire on demand for heat E 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 Jumper pins 9 and 8 on HD models Jumper pins 9 and 7 on HD models YES r Replace Membrane Pad NO Replace Control Board 24 Heater Will Not Fire B Start Is red SERVICE HEATER LED on NO CONTINUE Is red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above the minimum requirement NO 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 No Check that water pressure is NO within the
73. sing a timer and Fireman s Switch the heater s power supply should come from the load side of the timer The Fireman s Switch completes the circuit for the low voltage safety switches lt DOES NOT get any line voltage power from the power supply Connect the Fireman s switch to the heater as follows 1 Turn off power to heater at main circuit breaker panel 2 Unbolt and remove the upper jacket halves see Figure 3 Page 5 3 Open control box cover see Figure 24 4 Remove the factory installed jumper between the Fireman s Switch terminals see Figure 25 5 Connect the wires between the Fireman s Switch termi nals on the heater and those on the time clock using 18 gauge wire with a minimum 3 64 1 2mm thick insulation rated for a temperature rise of at least 105 C Route the wires out through the knockout on the bottom of the Control Box Use a 90 conduit el and conduit run out through the cutout on the Lower Enclosure next to the Junction Box see Figure 23 THERMISTOR OPERATING CONTROL MEMBRANE PAD CONNECTION ENABLE TOGGLE e DISABLE TOGGLE HD CONTROL CENTER SPA CONTROL Only 00000000 000000 HA TERMINAL BOARD I I rol ji al Time Clock or Remote l Purchase Separately A A Supplies Power to por l Circulator Pump l l l Fireman s Switch l l l l JUNCTION BOX Completes the heater 16 24 Volt AC Control
74. such locations cannot be avoided it is recommended that a suit able drain pan adequately drained be installed under the heater The pan must not restrict air flow The heater may not be installed within five feet of the inside surface of a pool or spa unless it is separated by a solid fence wall or other permanent barrier Propane LPG fired heaters must not be installed in Massachusetts by order of the Massachusetts State Fire Marshall For more information call the Fire Marshall s office DESCRIPTION OF THE HEATER Inlet Cold Water Outlet Mixed Water Burner Heating Coils FIGURE 2 Figure 2 is a diagram of the heater showing how it operates Precisely matched orifice plates meter the air and gas into the mixer The blower draws the air and gas through the mixer and forces it into the burner s flameholder A sealed heat exchanger surrounds the flameholder discharging exhaust gases out the flue Two inch PVC water piping connects directly to the mani fold header on the heat exchanger using 2 PVC slip unions provided with the heater The outer manifold remains cool no heat sinks are required A thermal regulator and an inter nal bypass regulate the water flow through the heat exchanger to maintain the correct outlet temperature A plastic jacket with the top half split for access surrounds the assembly The heater control board assembly set into the top of the jacket contains th
75. tion However to avoid damage to the electronic components in the heater take care to prevent prolonged exposure to driving sources of water such as lawn sprinklers heavy roof runoff hoses etc Avoid operation in persistent extreme moist or salty environments In extreme weather shut down the heater and disconnect the power to it until the weather has moderated In areas subject to hurricanes or very high winds purchase the Bolt Down Bracket Kit Part No 42001 0085S HEATER CLEARANCES OUTDOOR In the U S If the heater is located under a roof or deck overhang there must be at least three feet 1M of clear ance between the bottom of the overhang and the top of the heater exhaust vent The heater must be at least six inches 15cm from the nearest wall clearance for service access will depend on the installation If the heater is under a roof or deck overhang the space around the heater must be open on three sides For minimum exhaust vent clearances to building open ings see Figure 13 Page 15 In Canada If the heater is located under a roof or deck overhang there must be at least three feet 1M of clear ance between the bottom of the overhang and the top of the heater exhaust vent The heater must be at least six inches 15cm from the nearest wall clearance for service access will depend on the installation If the heater is under a roof or deck overhang the space around the heater must be open on three sides
76. trol Valve OFF Knob Style Turn Clockwise and press down to turn off gas Toggle Style Throw switch Q to OFF gt Drain Inlet Outlet Manifold Drain Cock s and Plugs OPEN Close Isolation Valves 5030 0505 FIGURE 7 Winterizing 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 STARTUP Page 4 and CARE AND MAINTENANCE above INSTALLATION INSTRUCTIONS Risk of fire explosion or asphyxiation if heater is improperly installed adjusted serviced or maintained These instructions are for licensed certified trained and experienced installers only Be sure your installer or service technician holds all required licenses or certification for your area Attempts by unqualified persons to service or repair this heater are dangerous and could be fatal PRE EXISTING VENT SYSTEMS If you are considering connecting this heater to a pre existing vent system make sure that the vent system meets the appro priate venting requirements as given in this manual Pages 9 15 If not replace the vent system DO NOT use a draft hood with this heater PUTTING THE HEATER INTO SERVICE If the heater is installed below the level of the pool or
77. water temperature OWNER S OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING AWARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE START UP AND OPERATION START UP AND SHUTDOWN INSTRUCTIONS ARE ON THE LABEL ATTACHED TO THE COVER OF THE APPLI ANCE CONTROL BOX BEFORE START UP A 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 B BEFORE OPERATING check for odor Sniff all around the appliance area for gas Be sure to sniff next to the floor because some gas such as propane is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control on or off Never use tools If you cannot change the ON OFF set ting by hand don t try to repair it call a qualified ser vice technician Force or attempted repair may result in fire or explosion Do not use this heater if any part has been under water Immediately call a qualified service technician to

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