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MasterTemp Heater Installtion and User`s Guide

1. Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board Verify that there is no block age in Blower intake Heat Exchanger and exhaust and that exhaust 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 Disconnect wires F1 and F2 from Ignition Control Module and short them together Does Blower come on Connect correctly and retry Does Blower start NO z bk Replace Blower Does Blower start on ignition try YES THERMISTOR on Replace Ignition Control Module Verify Thermistor wiring If OK replace Thermistor 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 Coil for leaks liming soot or low flow Heater starts and runs OK but temperature of exhaust climbs to 450 500 in 3 5 YES Check Thermal Regulator Open at minutes NO 120 Heater starts after several tries exhaus
2. 400 40 gal min 151 LPM If water pressure is outside of adjustment range that will open switch with pump off and close switch with pump on replace with flow switch set above minimum flow requirement Minimum Flow Requirements Model Flow 200 20 gal min 76 LPM 250 25 gal min 95 LPM 300 30 gal min 114 LPM 400 40 gal min 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 tempera 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 bet
3. 4 Remove the factory installed jumper between the Fireman s Switch terminals see Figure 23 5 Connect the wires between the Fireman s Switch ter minals 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 knock out on the bottom of the Control Box Use a 90 con duit elbow and conduit run out through the cutout on the Lower Enclosure next to the Junction Box THERMISTOR OPERATING CONTROL MEMB RANE PAD CONNECTION ENABLE TOGGLE DISABLE TOGGLE TERMINAL BOARD al I JUNCTION 2 BOX Time Clock or Remote Purchase Separately Supplies Power to l Circulator Pump Fireman s Switch Completes the heater I 24 Volt AC Control 1 Board Circuit DO NOT connect this circuit to Line Voltage L gt gt I GROUND GND H gt los 4 cts 12 Pin Receptacle FIGURE 23 Fireman s Switch Connections 6 Reinstall the access door panels 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 the Door Panels see Figure 3 Page 5 2 Access the control panel board on the underside of the top cover Locate the red button on the corner of the control board see Figure 24 3 Push the Max Temp Set Point button on the back o
4. 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 day break 4 For pools used only on weekends lower the thermo stat 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 MAINTENANCE MAINTENANCE INSTRUCTIONS WARNING Risk of fire or explosion from flammable vapors Do not store gasoline cleaning fluids varnishes paints or other volatile flammable liquids near heater or in the same room with heater The following maintenance is recommended every six months and at the start of every swimming season 1 Inspect the heater panels and venting system to make sure that there are no obstructions to the flow of ventilating air or burner exhaust Check that room air intakes are open and clear of obstructions 2 Keep the area in and around the heater clear and free from combustible materials gasoline and other flammable vapors and corrosive liquids 3 Test the operation of the pressure relief valve by lift ing the valve lever 4 Test for proper operati
5. Vent Body ollar 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 13 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 Table 5 Page 14 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 speci fied 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 com bustible surfaces according to the vent manufacturer s instructions and code requirements Do not place any insulating materials around the vent or inside the required clear air space surrounding the vent See Table 6 Page 15 for maximum permissible vent lengths See Table 7 Page 15 for Listed vent components CONNECTING SPECIAL GAS VENT TO THE HEATER Metallic 1 Order an Appliance Adapter kit Part No 77707 0086 for Saf T Vent or Saf T Vent CI Part No 77707 0087 fo
6. after it has been off for an extended time perform the following checklist 1 Remove debris or other articles from inside the heater and the area around the heater and its exhaust vent Make sure the ventilation openings are clear of debris or obstruction For installations in an enclosed space make sure openings for combustion and ventilation air are unobstructed 2 Keep heater area clear and free from com bustibles flammable liquids and chemicals 3 Check that all water connections are tight 4 Water must be flowing through the heater during operation Make sure that pool spa is filled with water and have pump operating Check that water flow is unobstructed from the appliance When operating for the first time or after an extended shut down run filter pump for several minutes to clear all air from the system 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 considered safe for a healthy adult Special caution is suggested for young children 2 Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant women beware Soaking in water above 102 F 39 C can cause fetal damage during the fi
7. 120V plug in 240V T I Board circuit Replace trans on Terminal Boar former control board YES Check wiring connections and ignition control between Terminal Board and module see HEATER Check for Line Voltage at NO Transformer primary and WILL NOT FIRE C and Transformer primary pins restore continuity D Pages 26 and 27 White connects to Pin 3 on Check fuse and all Transformer Black to Pin 2 other 24V components Orange to Pin 1 YES for damage 240V check Pin1 to Pin 3 Replace Transformer 120V check Pin 2 to Pin 3 Jumper Fireman s Switch at YES Check Fireman s Switch circuit Terminal Board and depress connections time clock wiring POOL or SPA ON button on external controller relay membrane pad Does SPA or POOL LED come on NO eras Remove jumper Check wiring ke Laem NO y between Transformer and J7 Fi i terminals on Control Board ireman s Switch terminals and between J7 and and ground Fireman s Switch on Terminal Board check fuse and Remove jumper Check ribbon restore continuity cable connection between Membrane Pad and J6 on Control Board Depress YES Heater should fire on NO POOL or SPA On pad c demand for heat again Does POOL or SPA LED come on YES Replace Membrane Pad Jumper pins 6 and 5 on J6 of Control Board Does SPA LED come on NO Jumper pins 6 and 4 on J6 of 7 gt Replace Control Board Control Board D
8. High Side of Differential Pressure Gauge ee Differential Pressure Gauge 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 flowing or dynamic 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 applica ble local codes Install a manual shut off valve and a sed iment trap and union located outside the heater panels Figure 21 Do not use a restrictive gas cock The following minimum 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 31 62M 62 92M 200 3 4 in 1 in 1 in 1 1 4 in 1 1 4 in 250 3 4 in 1 in 1 1 4 in 1 1 4 in 1 1 4 in 300 1 in 1 1
9. 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 0 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 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 NO 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 YES Check gas pressure OK Replace HSI Igniter NO Increase gas flow into heater e Replace gas line with larger line e Replace regulator e Replace meter or All of the above 27 Diagnostic LED s AGS AFS HLS PS THERMISTOR AGS or HLS on Replace High Limit Swit
10. TDS and any other inorganic salt added at start up PRESSURE RELIEF VALVE Canadian code requires and some U S local codes may require installation of a pressure relief valve Purchase separately and install a 3 4 pressure relief valve comply ing with the ANSI ASME Boiler and Pressure Vessel Code having a capacity equal to the Btu hr rating of the heater The relief pressure of the valve MUST NOT EXCEED 50 PSI 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 19 No valve is allowed to be placed between the mani fold adapter and the relief valve To avoid water damage or scalding from operation of the relief valve install a drain pipe in the outlet of the pres sure relief valve that will direct water discharging from the valve to a safe place for disposal Do not install any reducing couplings or valves in the drain pipe The drain pipe must be installed so as to allow complete drainage from the valve and drain line The relief valve should be tested at least once a year by lifting the valve lever Raise Pressure Turn star wheel to raise pressure set point if pressure switch is more than WARNING Explosion hazard Any heater installed with restrictive devices in the piping system downstream from the heater including check valves i
11. barrier A Propane LPG fired heater must not be installed in a garage in Massachusetts by order of the Massachusetts State Fire Marshall For more information call the Fire Marshall s office DESCRIPTION OF THE HEATER sey Air ZN Na Mixer Inlet Cold Water _ gt gt KEJ AAA N pri m LAAS Outlet Mixed Water FIGURE 2 Figure 2 is a diagram of the heater showing how it oper ates 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 dis charging exhaust gases out the flue Two inch PVC water piping connects directly to the manifold header on the heat exchanger using 2 PVC slip unions provided with the heater The outer manifold remains cool no heat sinks are required A thermal regulator and an internal bypass regulate the water flow through the heat exchanger to maintain the correct outlet temperature The heater operator control panel board assembly is located on top of the heater SEQUENCE OF OPERATION An electronic temperature sensing thermistor in the manifold adapter inlet controls the heater operation When the inlet water temperature drops below the temperature set on the operating control the burner control
12. below Metal Flue Collar 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 lat eral 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 Repeat 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 following the vent manufacturer s instruc tions included with kit Do not use a draft hood with this heater 3 Attach the vent pipe to the meta
13. 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 pip ing 4 Remove the Water Pressure Switch Plug the port in the manifold to prevent bugs and dirt from getting into the manifold 5 Drain the plastic inlet outlet manifold through the outlet pipe If the pipe does not drain naturally to the pool install a drain cock in the outlet pipe to drain the manifold 6 Cover air inlet grate with a plastic bag to prevent bugs leaves etc from getting into the heater NOTICE Water trapped in the heater can cause freeze damage Allowing the heater to freeze voids the warranty To return the heater to service after winterizing 1 Close drain cock and fittings 2 Before starting the heater circulate water through the heater for several minutes until all air noises stop See also BEFORE STARTUP Page 4 and CARE AND MAINTENANCE above INSTALLATION INSTRUCTIONS WARNING 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 ser vice technician holds all required licenses or certification for your area Attempts by unqualified persons to service or repair this heater are dangerou
14. flashing roof jack or roof thimble for all roof penetrations Do not fill the space around the vent that is the clear air space in the thimble or firestop with insulation The roof opening must be located so that the vent is vertical 6 Do not run the heater vent into a common vent with any other appliance 7 A WARNING Fire Hazard Do not vent the heater directly into a masonry chimney Installation into a masonry chimney must use a chimney liner and must meet the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Codes requirements and all local code requirements lt Listed Termination Cap t Min 2 Ft TM il Min 10 Ft 3 3 M Storm Collar 6 15 cm Minimum Clearance to Combustible Materials Type B Double Wall etal Vent Pipe Firestop E g Metal Flue Type B Double Wall Collar Metal Vent Tee Support Vertical Vent Pipe so adapter does not take weight of Vent Body Condensate Drain w trap pipe Dispose of condensate according to local codes FIGURE 12A Typical Metal Vent Pipe Installation Canada Vertical Negative Pressure lt Listed Termination Cap lt Min 8 Ft See Table 4 For Min Hght y Storm Collar 6 Minimum Clearance to Combustible Materials Class B Double Wall Metal Vent Pipe E Metal Flue
15. heater to 240V line current will immediately destroy the trans former control board and ignition control module and will void warranty If you install the 240V plug and con nect 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 proceed ing 1 All wiring must be in accordance with all applicable codes The heater when installed must be electrically grounded and bonded in accordance with local codes or in the absence of local codes with the National Electrical Code or the Canadian Electrical Code as applicable A bonding lug is provided on the outside of the panel under the vent for this purpose Electrical power circuits to the pool heater must fol low 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 All line voltage wiring shall be enclosed in approved flexible conduit and shall be securely attached to the field wiring box located inside the access door panel The conduit or cable connector at the field wiring box should contain an insulating bushing or its equivalent to prevent abrasion of the wires as they enter the box The filter pump should run continuously when the heater is on and for at least 15 minutes after the he
16. housing the heater Exhaust venting to the out doors is required for all outdoor shelter installations AX WARNING Risk of explosion if a unit burning propane gas is installed in a pit or other low spot Propane is heav ier than air Do not install the heater using propane in pits or other locations where gas might collect Consult your local building code officials to determine installation require ments of heater relative to propane storage tanks and fill ing equipment Installation must meet the requirements for the Standard for the Storage and Handling of Liquefied Petroleum Gases CAN CSA B149 2 latest edition or ANSI NFPA 58 latest edition Consult local codes and fire 10 protection authorities about specific installation restrictions The heater is design certified by CSA International for installation on combustible flooring in alcoves base ments in closet or utility rooms in the U S INSTALLATION IN A GARAGE OR UTILITY ROOM In Canada the heater must be installed in a room that is not normally occupied and has no openings directly to occupied areas WARNING Risk of fire and explosion if installed at floor level in an automotive garage or near gasoline or flam mable 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 fl
17. service access it is recommended to leave at least 24 in clearance for one of the door panels The heater is design certified by CSA International for installation on combustible flooring For installation on carpeting the heater must be mounted on a metal or wood panel that extends at least three inches 10cm beyond the base of the heater If the heater is installed in a 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 operat ing controls The control panel located on the top panel can be rotated to any of the three sides of the heater for easy access However the control panel must not be located on the side where the vent is located Table 1 Corrosive Vapors and Possible Causes Area Likely Contaminants Chlorinated swimming pools and spas Pool or spa cleaning chemicals Acids such as hydrochloric or muriatic acid New construction and remodeling areas Glues and cements construction adhesives paints varnishes and paint and varnish strippers Waxes and cleaners containing calcium or sodium chloride Beauty parlors Permanent wave solutions bleaches aerosol cans containing chlorocarbons or fluorocarbons Refrigerants acids glues and cements construction adhesives Refrigeration plants or various industrial finishing
18. 04 04 06 SAVE THESE INSTRUCTIONS Fool Products INSTALLATION OPERATION AND SERVICE MANUAL 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 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 FIGURE 1 For instructions on checking the gas pressure through the Combination Gas Control Valve See the sidebar on Page 19 Table of Contents Safety orr eG site Gaon a wee wales 2 General Specifications Requirements 3 Description of the Heater 0 00000eaes 4 Sequence of Operation 0000eceeneeee 4 Owner s Operating Instructions 4 Before Startup n s cee 4 What To Do If You Smell Gas 200 8 4 Spa Temperature Caution nasasa 0000s 5 Operating Instructions 0000 a 5 To Switch Off Gas To the Appliance 6 Operating Control ee es 6 After Start Up s asa ca cie siesta vac LG 7 Care Maintenance Winterizing 0 005 8 Installation Instructions 00000ee eens 8 Pre Existing Vent Systems 0000 8 Outdoor Installation 0 cee eee 9 Outdoor Shelter Indoor Inst
19. 105S 17 Heater Top 1 42002 0034Z 42002 0034Z 42002 0034Z 42002 0034Z 18 Membrane Pad NA LP Series 1 472610Z 472610Z 4726102Z 4726102Z 19 Stack Flue Sensor 1 42002 0024S 42002 00248 42002 00248 42002 00248 Not available separately Kit parts not available separately 35 Pool Heater Wiring Connection Diagram CONNECTION DIAGRAM AGS Switch Air Flow Switch Stack Flue Sensor Gas Valve Extra Switch 1 YR Hi Limit Switch Pressure Switch e 7 YW Y Y Q Y BL 0 y ie Ww BL 5 k w R R R EHNE Ean it Tt vu PR px eve l l y n DE e s 8 aF222 gt 8 NA LP m HLS YS amp 2 J6 Models Only T gt zas Y BL H Fa _ Jo a 1 ERRER CrS arsyg OPERATING CONTROL B Sl m MEMB RANE PAD eo m aGs CONNECTION sim e e Daa C p o SSES Ti a4 To oAs NA LP Models J6 incl pins 1 6 External Control Interface Circuit Disabled connect TTO Heater Membrane Pad Enabled Spa Line Common Line Pool Line J M P External Control Interface w Y IGNITION CONTROL MODULE External Control Interface Circuit Enabled Pool On and Spa On Keys Disabled OFF Key on Membrane Pad Remains Functional x T 24VAC SEC GY GY BK 120 VAC IGNITER o o aa z __ 0 Plug 12 pin 120V Black 899 i ee piman 12 Position Receptacle J
20. 2 Pressure Relief Valve Recommended Purchase Separately 1 38674 0719 38674 0719 38674 0719 38674 0719 Not available separately Not illustrated 34 REPAIR PARTS ELECTRICAL SYSTEM o Model Key Part 200NA 250NA 300NA 400NA No Description Qty 200LP 250LP 300LP 400LP 2 Heater Display Cover 1 42002 0035 42002 0035 42002 0035 42002 0035 3 Igniter Bracket 1 42001 0030S 42001 0030S 42001 0030S 42001 0030S 4 Igniter Igniter Gasket Kit Incl Key Nos 4 and 5 1 77707 0054 77707 0054 77707 0054 77707 0054 5 Igniter Gasket 1 42001 0066S 42001 0066S 42001 0066S 42001 0066S 7 Automatic Gas Shutoff Switch AGS 1 42002 0025S 42002 0025S 42002 0025S 42002 0025S 8 High Limit Switch 1 42001 0063S 42001 0063S 42001 0063S 42001 0063S 9 Thermistor 1 42001 0053S 42001 0053S 42001 0053S 42001 0053S 10 Terminal Board 1 42001 0056S 42001 0056S 42001 0056S 42001 0056S 11 Fireman s Switch Fuse 1 25A 1 1 4 1 32850 0099 32850 0099 32850 0099 32850 0099 12 Ignition Control Module 1 42001 0052S 42001 0052S 42001 0052S 42001 0052S 13 Transformer 115 230V 1 42001 0107S 42001 0107S 42001 0107S 42001 0107S 14 Air Flow Switch 1 42001 0061S 42001 0061S 42001 0061S 42001 0061S 15 Control Board Kit NA LP Series 1 42002 0007S 42002 0007S 42002 0007S 42002 0007S Heater Wiring Harness 115 230V 1 42001 0104S 42001 0104S 42001 0104S 42001 0104S 120 240 Volt Plug Kit 1 42001 0105S 42001 0105S 42001 0105S 42001 0
21. 2M horizontally from electric meters gas meters regulators and relief equipment e At least 7 feet 2 1M above grade adjacent to walk ways or similar traffic areas Allow at least three feet 1M vertical clearance over vent termination when terminating under an overhang or deck Avoid corners or alcoves where snow or wind could have an effect Exhaust may affect shrubbery and some build ing materials Keep shrubbery away from termination To prevent staining or deterioration sealing or shielding exposed surfaces may be required Metal Special Gas Vent Supron requires weight of pipe Appliance X Listed Adapter Terminal Condensate Tee Metal Vent f Body l E l F Slope at least Cond i 1 4 per foot ondensate 2 cm per Meter i drain w Trap down towards 3 7 6 cm Min condensate drain Clearance FIGURE 14 Typical Special Gas Vent Pipe Installation Horizontal Positive Pressure 12 30 5 cm Max 8 WARNING Fire Hazard Do not run the heater vent into a common vent with any other appliance Do not run the Special Gas Vent into through or within any active vent such as a factory built or masonry chimney 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 1
22. 4 in 1 1 4 in 1 1 2 in 1 1 2 in 400 1 in 1 1 4 in 1 1 4 in 1 1 2 in 2 in Manual shut off valve 18 24 of 3 4 GAS LINE Sediment trap FIGURE 21 Gas line and Trap PRESSURE TESTING Before operating the heater the heater and its gas con nections must be leak tested Test all gas connections for leaks with soapy water WARNING Risk of fire or explosion Do not use an open flame to test for leaks The heater and its individual shut off valve must be disconnected from the gas supply pip 20 ing system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa The heater must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure 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 120V or 240V 60Hz 1Ph power supply Enclose the line to the heater in an approved flexible conduit connected directly to the junction box on the inside of the access door panel Line voltage field wiring should be 14 gauge with a cir cuit capacity of 15 amps ELECTRICAL WIRING NOTICE Before making any electrical connections to the power supply remove the access door panels open the control box remove the 12 pin plugs from their bag and plug in the correct plug 120 volt or 240 volt Note that installing the 120V plug and then connecting the
23. 7 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 local 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 Final Installation Check Check that horizontal vent pipe runs slope uniformly at least 1 4 per foot 2cm per meter to condensate drain s No sags no dips no high or low spots Check that vent is supported at elbows tees and hori zontal and vertical runs according to manufacturer s instructions and code requirements Check that vent supports and wall and ceiling penetra tions allow free movements up down and sideways without putting any strains on the heater or vent body Check for at least six inch 15cm free air clearance between the heater vent pipe and combustible materials Check that all joints are completely together and sealed WATER CONNECTIONS The heater requires proper water flow and pressure for its operation See Figures 15 for the recommended instal lation The filter pump discharges to the filter the filter discharges to the heater and the heater discharges directly to the pool or spa A manual bypass valve should be installed across the heater when the pump flow exceeds 120 GPM 454 LPM See WATER FLOW RATE on page 16 for setting of the manua
24. FE START UP AND OPERATION START UP AND SHUTDOWN INSTRUCTIONS ARE ON THE LABEL ATTACHED TO THE COVER OF THE APPLIANCE CONTROL BOX BEFORE START UP A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the 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 C Use only your hand to turn the gas control on or off Never use tools If you cannot change the ON OFF setting by hand don t try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion D Do not use this heater if any part has been under water Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water E Do not operate the pool heater unless the pool or spa is properly filled with water F Before operating the appliance for the first time or
25. 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 restric tions 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 installation However to avoid damage to the electronic components in the heater take care to prevent prolonged exposure to dri ving 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 discon nect 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 460738 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 clearance between the bottom of the overhang and the top of the heater exhaust vent If the heater is under a roof or deck overhang the space around the heater must be open on three sides See Figure 8 for minimum clear ances For minimum exhaust vent clearances for building open ings see Figure 13 Page 15 In Canada If the heater is located under a roof or de
26. Master Temp POOL AND SPA HEATER 120 240 VAC NATURAL GAS LP GAS INSTALLATION and USER S GUIDE MODELS Natural Propane 200K BTU HR 460730 460731 250K BTU HR 460732 460733 300K BTU HR 460734 460735 400K BTU HR 460736 460737 SPECIAL INSTRUCTIONS TO OWNER Retain this manual for future reference This manual supplies information for the installation operation and servicing of the appliance READ AND REVIEW THIS MANUAL COMPLETELY before proceeding with an installation Its use will reduce service calls and chance of injury and will lengthen product life WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Call 800 831 7133 for additional free copies of these instructions FOR YOUR SAFETY 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 IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS Pentai 472592 Rev A
27. UNCTION BOX imeta gt 4 s Line 2 gt gt R eer Ground gt 2 L cnb NOTICE Touching any 24VAC wire including the Fireman s Switch wire to any 120 240V terminal while the heater is connected to line power will immediately destroy the control board and void the warranty 36 G L GND Repla ce jum per with leads to Firenan s Swi tch field installed 3661 0200 Pool Heater Electrical Schematic Ladder Diagram LADDER DIAGRAM bo ee _ 120280 __ gt gt L2 IGNITER BLOWER 120 240 VAC CLASS II TRANSFORMER OPERATING CONTROL 24 VAC eeececocece AIR s 24V LOGIC FLOW SWITCH PRESSURE LIMIT e e e e i WATER HI e e SWITCH O SWITCH COM NO D lt GAS VALVE STACK FLUE SENSOR THERMISTOR SENSOR NOTES 9 nea an S ARE CONNECTED ON THE IGNITION MODULE 2 a 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 105C OR ITS EQUIVALENT 37 Customer Support Sanford North Carolina 8 A M to 5 P M Eastern Standard Time Phone 800 831 7133 Fax 919 566 8920 Moorpark California 8 A M to 5 P M Pacific Standard Time Phone 800 831 7133 Pentair Pool Products SAVE THESE INSTRUCTIONS 2006 Pentair Water Pool and Spa Inc All rights reserved This document is subject to change with
28. a tube with a tee running to the high side of a differential pressure gauge and to the blower s air orifice grille See Figure 20 Turn on the heater and verify the gas supply pres sure 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 WARNING Risk of fire or explosion if Combination Gas Control Valve is incorrectly adjusted If it is nec essary 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 mixer Remove the barbed fitting 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 access door panels and cycle the heater to check for proper operation NOTE The gas piping and unions have been omitted for clarity make this test with all gas piping connected as for normal service To Air Flow Switch To Air Flow To Gas Valve Vent Connection for Service FIGURE 20 Connect Gas Valve to End Cap Air Orifice Connection for Test To Low Side of To Gas Valve Vent To
29. all of the diag on Page 26 nostic LED s may come on momentarily when you turn on the power to the heater 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 kill Disconnect power before servicing any components WARNING Fire and Explosion hazard Do not jumper switch terminals to remedy a failed safety switch 23 Heater Will Not Fire Start A Heater should fire on demand Is green SPA or NO Depress POOL or SPA ON YES POOL LED on gt button on Membrane Pad e for heat Does POOL or SPA LED YES come on NO Check that correct 12 pin YES Check for line voltage to NO plug is installed red is heater Restore power to heater 240V black is 120V NO 7 a for 24 VAC at sec eee peas ondary of Transformer Check wiring connections between power supply and 240V plug in 120V V NO Junction Box and between circuit Replace with Check for Line Voltage NO Junction Box and Terminal Gorey plug between L1 and L2 terminals Board restore continuity
30. allation 10 15 Water Connections 000 2 eae 15 18 Pressure Relief Valve 2 cee ees 18 Checking Combination Gas Control Valve 19 Gas Connections 0c eee eee es 20 Pressure Testing 2 00 cece eee ee eee 20 Electrical Wiring 00 000 20 22 Troubleshooting 000eeee ee ee eee 23 30 Repair Parts cia eh ee eee 31 35 Wiring Diagrams External Control Interface 36 37 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 CODES AND STANDARDS Installation must be in accordance with all local codes and or the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA54 and the National Electrical Code ANSI NFPA7O U S or standards CSA B149 INSTALLATION CODES FOR GAS BURNING APPLIANCES AND EQUIPMENT and or local codes and Standard CSA C22 1 Canadian Electrical Code Part 1 Canada The heater when installed must be electrically grounded and bonded in accordance with local codes or in absence of local codes with the Canadian Electrical Co
31. and processing plants 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 2223 1 or the National Fuel Gas code the CSA B149 1 Natural Gas and Propane Installation Codes as applicable and any local codes that may apply The minimum net free area in square inches are as follows Table 2 Combustion and Ventilation Air Requirements All Air From All Air From Inside Building Outside Building Model Combustion Vent Combustion Vent 100 sq in 100 sq in 50 sq in 50 sq in 645 sq cm 645 sq cm 323 sq cm 323 sq cm 125 sq in 125 sq in 63 sq in 63 sq in 807 sq cm 807 sq cm 403 sq cm 403 sq cm 150 sq in 150 sq in 75 sq in 75 sq in 969 sq cm 969 sq cm 485 sq cm 485 sq cm 200 sq in 200 sq in 100 sq in 100 sq in 1290 sq cm 1290 sq cm 645 sq cm 645 sq cm OUTDOOR SHELTER VENT INSTALLATION Canada or INDOOR INSTALLATION U S Always vent the heater to the outd
32. ater turns off Any switches in the pump circuit including circuit breakers that can disconnect the pump must also disconnect the heater Do not wire single pole switches including protective devices into a grounded line The heater is not sen sitive to polarity 2 Connect the L1 of the power supply to the black wire the L2 or neutral lead to the red wire and the ground wire to the green wire A time clock controlling the filter pump should have a low voltage Fireman s Switch that switches off the heater at least 15 minutes before shutting off the pump 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 including the Fireman s Switch jumper you will immedi ately destroy the control board and void the warranty Pull down to open cover FIGURE 22 Open Control Box Cover 21 NOTICE When using 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 It DOES NOT get any line voltage power from the power supply Connect the Fireman s switch to the heater as follows 1 Switch off power to heater at main circuit breaker panel 2 Unbolt and remove the access door panels see Figure 3 Page 5 3 Open control box cover see Figure 22
33. cated 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 similar traffic areas Table 5 Recommended Special Gas Vents Positive Pressure 20 Commerce Park North Bedrford NH 03110 6911 800 654 5600 Gas Vent Type BH Model SVE 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 GE RTV 106 Max 12 Min 3 lt lt Vent ee Vent Termination rea a Vent y 4 Termination At least 7 above grade adjacent to public walkways 1 Minimum above snow or Forced Air finished grade Intas is Inlet 3 Minimum clearance if higher horizontal distance to exhaust opening is less than 10 feet Gas Meter FIGURE 13 U S minimum Exhaust Vent clearances Local codes may differ consult local code officials The terminal must be located Canada e at least 10 feet 3 3M from any opening into a build ing e at least 12 3M above finished grade or the normally expected snow accumulation level whichever is higher e At least 4 feet 1
34. ch HLS or Verify that water flow rate is above minimum required for heater NO gt YES Service pump and filter to restore proper flow After ser vicing verify proper operation of Pressure Switch PS Automatic Gas YES Shutoff AGS lt CONTINUE Verify that inlet water temper ature is below 104 F NO T 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 l Verify that wiring is OK and pressure tap is not blocked Re place Pressure Switch Verify that water flow rate is above minimum required for heater NO r Service pump and filter to restore proper flow e YES CONTINUE CONTINUE l Adjust Water Pressure Switch to close with pump running and open with pump off Does Blower operate YES No Replace Blower 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
35. ck 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 If the heater is under a roof or deck overhang the space around the heater must be open on three sides See Figure 8 for minimum clear ances The heater must be installed with the top of the vent at least 10 feet 3M below or to either side of any open ing into a building In the U S and Canada The heater is certified for instal lation on combustible flooring The following clearances must be maintained from combustible surfaces TOP isasi 3 ft 1 m EXHAUST SIDE 6 in 15 cm HEADER SIDE 18 in 5 m DOOR PANELS 12 in 30 cm Note For service access it is recommended to leave at least 24 in clearance for one of the door panels Orient the heater for convenient access to the water connections and the gas and electrical connections Install the heater at least 18 in 45 cm from any property line Space around the heater must open on three sides when under Outdoor installation must roof or have at leave 3 ft or more overhang of clearance above heater 3 ft 1 M or more Recommended 24 clearance or more on one or both door panels tor servicing 12 in 1 in O00 Leave at least 6 in 15 cm of clearance or more between the heater an
36. d combustible surfaces FIGURE 8 Combustible clearances CONTROL PANEL INDEXING The exhaust discharges vertically from outside the vent cover The heater control panel assembly located on the top panel can be rotated to any of three positions for convenient access to the panel as follows 1 Remove the bolts from the door panels Remove both door panels 2 Remove the four corner screws that secure the top panel 3 Lift the top panel upward to remove the top panel 4 Rotate the top panel to the desired position located at 90 degree angles Note that the control board can not be located on the same side as the exhaust 5 Replace the top panel down onto the side panels Be sure that there are no wires caught under the panel 6 Secure the top panel using the four corner screws 7 Reattach the door access panels OUTDOOR SHELTER Top panel Door access panel vn fl TRHA Oa Door access EN panel eo 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 WARNING Risk of asphyxiation if exhaust is not cor rectly 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
37. de or the National Electrical Code ANSI NFPA70 as applicable SAFETY INSTRUCTIONS Continued WARNING This appliance is equipped with an unconventional gas control valve that is factory set with a manifold pressure of 2 inches wc Improper installation adjustment alteration ser vice or maintenance can cause property damage personal injury or loss of life Installation or service must be performed by a qualified installer service agency or the gas supplier If this control is replaced it must be replaced with an identical control Do not attempt to adjust the gas flow by adjusting the regulator setting WARNING Risk of fire or explosion from incorrect fuel use or faulty fuel conversion Do not try to runa heater set up for natural gas on propane gas or vice versa Only qualified service technicians should attempt to convert heater from one fuel to the other Do not attempt to alter the rated input or type of gas by changing the orifice If it is necessary to convert to a differ ent type of gas consult your Pentair dealer Serious mal function of the burner can occur which may result in loss of life Any additions changes or conversions required in order for the appliance to satisfactorily meet the application needs must be made by a Pentair dealer or other qualified agency using factory specified and approved parts The heater is available for use with natural gas or LP propane gas only It is no
38. ect water chemistry Service bypass valve Replace thermal governor Sweating Thermal governor failed 30 Replace thermal governor For complete Electrical System parts breakdown Key Nos 1 through 4 See Page 35 Li VN OATS x ys Loi SfN oes For complete Water System parts breakdown Key Nos 10 through 13 see Page 34 For complete Burner System parts breakdown Key Nos 5 through 9 See Pages 32 and 33 Repair Parts are available from your Pentair dealer If your dealer cannot supply you call Customer Support at 1 800 831 7133 31 For Heater mounting bolts and clamps purchase separately Bolt Down Bracket Kit Part No 460738 32 REPAIR PARTS BURNER SYSTEM Model Key Part 200NA 250NA 300NA 400NA No Description Qty 200LP 250LP 300LP 400LP 1 Combination Gas Control Valve Kit 1 42001 0051S 42001 0051S 42001 0051S 42001 0051S 2 3 4 Union 2 38404 4097S 38404 4097S 38404 4097S 38404 4097S 3 Gas Orifice 1 Gas Orifice Kit NG Incl Key Nos 3 and 4 t 77707 0431 460739 460753 77707 0411 Gas Orifice Kit Propane Incl Key Nos 3 and 4 t 77707 0461 460740 460754 77707 0441 NG to Propane Conversion Kit Incl Key Nos 3 and 4 t 77707 1461 460741 460755 77707 1441 Propane to NG Conversion Kit Incl Key Nos 3 and 4 t 77707 1431 460742 460756 77707 1411 5 Air Blower Kit Natural Gas Un
39. emistry 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 concentrated chemicals from back siphoning into the heater Back siphoning is 16 3 Way Chlorinator Valve lt a lt lt l 4 4 Check valve t I I t E Heater t Main ilter Drain 8 Q Pool Spa x SIS E ae 6 i 4 lt y Pm ANYS 3 Way t y lt Valve From Pool 3 Way Valve FIGURE 15 Typical pool piping layout 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 corro sion damage to the heat exchanger WATER PRESSURE SWITCH WARNING Hazardous pressure Do not bypass the Water Pressure Switch or render it inoperable Switch Settings The water pressure switch turns off the burner if the water flow is interrupted If the water flow is restricted the water pressure switch may prevent the burner from firing and cause the Service System light to go on If the light remains on after the filter has been serviced have a qualified service technician check the syste
40. emperature set on the thermo stat 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 opera tion 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 SWITCH OFF GAS TO THE APPLIANCE and call your service technician or gas supplier TO SWITCH OFF GAS TO THE APPLIANCE 1 Press the OFF button on operating control 2 Switch off all electric power to the unit 3 Remove the access door panels See Figure 3 page 5 A WARNING HEATER PARTS MAY BE HOT 4 Toggle Style Valve Pull toggle toward you to turn gas off 5 Replace the Access Door Panels OPERATING CONTROL The five operating switches are POOL ON Press this button to govern heater operation by the pool temperature setting SPA ON Press this button to govern heater operation by the spa temperature setting HEATER OFF Press this button to switch off the heater A TEMP Press this button to raise the temperature setting v TEMP Press this button to lower the temperature setting To toggle the display between degrees Centigrade C and degrees Fahrenheit F 1 Turn the Operating Control OFF 2 Press A TEMP or W TEMP for 5 seconds The dis
41. f the control board see Figure 24 The following sequence should happen A The unit will come on and the POOL ON light will come on B Press the A TEMP or W TEMP pad on TOP of the panel to set maximum pool temperature C Wait up to 30 seconds the POOL ON light will go FIGURE 24 Max Temperature Set Point Controls off and the SPA ON light will come on To override the time delay push the Max Temp Set Point button again D Press the A TEMP or W TEMP button on the control panel and set maximum spa temperature to 104 F 40 C or less E Wait up to 30 seconds the SPA ON light will go off and the unit will shut down To override the time delay push the Max Temp Set Point button again 4 Reinstall the access door panels 22 Initial Troubleshooting Only qualified trained service technicians with appropriate test equipment should service the heater Remember that all parts of the system affect heater operation Before starting this troubleshooting procedure make sure that the pump is running correctly that there are no blockages in the system that the valves are correctly set and that the time clock is correctly set and is running IMPORTANT READ ME FIRST NOTICE Installing the black 120 volt plug in the control box and then connecting the heater to a 240 volt line will destroy the trans former control board and ignition control module and will void the warranty If you install the red 240 vol
42. five 5 feet or more above the roof must be braced or guyed Consult your local code officials for detailed information WARNING Risk of fire or asphyxiation if vent is not assembled according to manufacturer s instructions or if vent parts from different manufacturers are mixed Vent parts from different manufacturers ARE NOT 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 manufacturer for your system Follow manufacturer s instructions and local and National Fuel Gas Code U S or CSA B149 1 Natural Gas and Propane Installation Codes Canada requirements carefully during assembly and installation 4 Install vent pipe so that it can expand and contract freely as the temperature changes Support the vent pipe according to applicable codes and vent 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 condensate might collect Plumb con densate drains to a drain through hard piping or high temperature tubing such as silicone rubber or EPDM rubber do not use vinyl or othe
43. 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 NS S Gas control is shown i AY ON Pull toggle switch le toward you to switch L OE g s lt re You a here FIGURE 4 Turning Gas Control OFF 8 Push the toggle switch away from you to switch the gas on 9 Replace the Door Access Panels All panels must be in place when operating the heater 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 Gas control is shown OFF Push toggle switch away from you to switch ON FIGURE 5 Turning Gas Control ON 13 Set the thermostat to desired setting NOTICE Set point must be above actual water temperature or burner will not fire See OPERATING CONTROL 14 The blower should come on immediately and after about 20 seconds the burner should fire When operating for the first time the burner may not fire on the first try because of air in the gas line If it does not fire at first push the OFF switch wait five minutes and again push the POOL or SPA ON switch The burner should fire after about 20 seconds You may have to repeat this until all of the air has cleared the gas line 15 The burner should fire until the pool spa temperature reaches the desired t
44. iance gas controls If it must be replaced for safety reasons replace it only with an identical gas control NOTICE The access door panels must be in place to provide proper ventilation Do not operate the heater for more than five 5 minutes with the access door panels removed This heater is design certified by CSA International as complying with the Standard for Gas Fired Pool Heaters ANSI Z21 56 CSA 4 7 and is intended for use in heating fresh water swimming pools or spas 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 8 and 9 The heater should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the heater or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the heater The pan must not restrict air flow The heater may not be installed within five feet of the inside surface of a pool or spa unless it is separated by a solid fence wall or other permanent
45. its 1 77707 0251 460743 460757 77707 0253 Propane Units 1 77707 0254 460744 460758 77707 0256 Air Orifice Kit Includes Key Nos 6 and 7 1 77707 0111 460745 460759 77707 0113 6 Air Orifice 1 7 Air Orifice Grill 1 42001 0114S 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 77707 0011 Flameholder Kit Includes Key Nos 10 11 12 13 and on 300 amp 400 models only Flameholder Insert 77707 0202 460746 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 Flameholder Insert 1 15 Condensate Evaporator Plate 1 16 One Piece Metal Chamber Combustion Chamber Assembly 1 42001 0200S 42001 0200S 42001 0200S 42001 0200S Insulation Kit Includes Key Nos 13 15 23 24 25 and 26 1 77707 0008 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 42001 0074S 42001 0074S 27 One Piece Metal Elbow Combustion Chamber Cover Assembly 1 42001 0214S 42001 0214S 42001 0214S 42001 0214S 28 Metal Vent Cover 1 42002 0005S 42002 0005S 42002 0005S 42002 0005S Not available separately t Not included with heater Order separa
46. l Flue Collar with sheet metal screws WARNING Risk of fire or asphyxiation if vent is not assembled according to manufacturer s instructions or if vent parts from different manufacturers are mixed Vent parts from different manufacturers ARE NOT 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 manufacturer for your system Follow manufacturer s instructions local code requirements National Fuel Gas Code requirements U S or standards CSA B149 1 and B1i49 2 Canada carefully during assembly and installa tion 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 manu facturer s instructions Pipe support must allow the vent pipe free movement out and back from side to side or up and down as necessary without putting a strain on the heater or vent body Slope horizontal pipe runs up from the heater at least 1 4 per foot 2cm per meter Install Listed condensate drains at low points where condensate might collect Plumb con densate drains to a drain through hard piping or high temperature tubing such as silicone rubber or EPDM rubber do not use vinyl or other low temperature tubing Follow drain manufacturer s installation instruc
47. l bypass valve 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 Table 7 Listed Thimbles and Vent Terminals for 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 5490ClI Horizontal Term 5400 Cap Z Vent 2SVSWTFO04 2SVSTTF04 Tee 2SVSRCF04 Cap 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 below 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 NOTICE 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 di
48. ler 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 suffi cient air flow the AFS closes closing the circuit to the hot surface igniter HSI which ignites the fuel mixture On a call for heat the blower and HSI are energized In about 20 seconds the gas valve opens and ignition occurs The HSI then switches to a sensing mode and monitors the flame The heater is equipped with a digital operating control that enables the user to pre set the desired pool and spa water temperatures The control enables the user to select between pool and spa heating and features a digital display that indicates the water temperature OWNER S OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LI
49. m 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 open when the pump is off and closed when the pump is running Turn the star wheel on the switch clock wise to raise setting heater below the pool and counterclockwise to lower the setting heater above the pool see Figures 17 and 18 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 Cool water Warm water out 1 Set Manual Bypass Valve 2 Remove handle Outlet to pool Inlet from pool FIGURE 16 Manual bypass valve 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 4 Wait one minute The Service Syste
50. m light should go Table 9 Water Chemistry Parameters 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 pressure switch malfunction Immediately press the OFF button on the operating control to turn the burner off and call a qualified service technician to check the system 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 Water pressure switch FIGURE 17 Remove side panel for access to Water Pressure Switch Disinfectant levels Minimum Free Chlorine ppm 1 0 Combined Chlorine ppm None Bromine ppm 2 0 Other Sanitizers Chemical Values pH 7 2 Total Alklinity Buffering ppm 60 as CaCO3 Total Dissolved Solids ppm N A Calcium Hardness ppm as CaCO3 150 Heavy Metals None Biological Values Algae None Bacteria None Ideal Maximum 2 0 4 0 10 0 None 0 2 4 6 10 0 Levels not established Consult local health department before use 7 4 7 6 7 8 80 100 180 N A 1 500 ppm gt TDS at startup 200 400 500 1 000 None None None 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 and will void the warranty Start up TDS includes source water
51. oes POOL LED come on GO TO HEATER WILL NOT FIRE B Page 25 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 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 within the adjustment range of the Pressure Switch 0 5 psig 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 NO GO TO HEATER WILL NOT FIRE C Page 26 25 NO NO YES Increase POOL SPA tempera ture setting on Membrane Pad above actual water tem perature Heater should fire on demand for heat If not and no other red LED s light replace Control Board Service pump filter and elimi nate other flow obstructions Heater should fire on call for heat Re verify that water flow is above minimum require ment Minimum Flow Requirements Model Flow 200 20 gal min 76 LPM 250 25 gal min 95 LPM 300 30 gal min 114 LPM
52. on 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 For outdoor heaters in freezing climates shut the heater down and drain it for winter as follows 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater 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 A WARNING Explosion hazard Purging the system with
53. oor 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 A PROPANE LPG fired heater must not be installed in a garage in Massachusetts by order of the Massachusetts State Fire Marshall For more information call the State Fire Marshall s office HEATER INSTALLATION IN A GARAGE OR UTILITY ROOM Leave 3 ft 1 M or more of clearance above heater Leave 6 in 15cm of clear space between heater and combustible surface RAISE AT LEAST 18 in 5M above floor to avoid flammable vapors FIGURE 10 Minimum outdoor shelter clearances Canada or minimum garage or utility room clearances U S NOTICE Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty See Table 1 below HEATER CLEARANCES OUTDOOR SHELTER Canada or INDOOR U S The following clearances must be maintained from com bustible surfaces TOP sscclecchescaanthciieeetescteseea 3 ft 1 m EXHAUST SIDE sssseeees 6 in 15 cm HEADER SIDE sseseeseees 18 in 5 m DOOR PANELS 00000 12 in 30 cm Note For
54. oors 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 hori zontal 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 4 x 8 Metal Flue Collar Vent Body Chamber Flue Collar 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 Natural Gas and Propane Installation Codes and local codes Type B Double wall vent connector is rec ommended however single 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
55. out notice 1620 Hawkins Ave Sanford NC 27330 919 566 8000 10951 West Los Angeles Ave Moorpark CA 93021 805 553 5000 Trademarks and disclaimers MasterTemp and the Pentair Pool Products and Pentair Water Pool and Spa logos are trade marks 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 proprietary interest in marks and names of others P N 472592 Rev A 04 04 06
56. 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 20 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 access door pan els for access to 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 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 liquid out of the gauge when the blower starts Disconnect the tube from the Gas Valve VENT port Connect it to
57. play will flash once and change modes C to F or vice versa Temperature Up and Down Digital Temperature Display P Pentair Pool Products SERVICE HEATER SERVICE HEATING SYSTEM Dual Temperature Heater OFF System Operation Controls Switch Indicator Lights FIGURE 6 Operating Control for all models When either the A TEMP or Y TEMP buttons are depressed the digital display will indicate the tempera ture 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 tem perature is governing operation of the heater The SPA ON light indicates that the spa water tempera ture is governing operation of the heater The HEATING light comes on and stays on when the burner is firing This light should be on whenever the burner is on It blinks when the heater is calling for heat but not firing If this light is on but the burner fails to come on one of the service lights should come on indicating a fault in the system The SERVICE SYSTEM light indicates that there is insufficient water flow to the heater If the pump is oper ating this usually indicates that the filter and or skim mers should be cleaned some filters may require back washing If the light remains on after the filter skimmers have been serviced the system should be checked by a
58. qualified service technician The SERVICE HEATER light indicates a fault in the heater or its controls If this light comes on shut down the heater See TO SWITCH OFF GAS TO THE APPLIANCE on page 6 and have a qualified service technician check the system WARNING 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 instruc tions under To Switch Off Gas to the Appliance and call a qualified service technician to repair unit AFTER START UP CHECKING WATER FLOW WARNING Fire or flooding hazard If the unit overheats and the burner fails to shut off follow instructions under To Switch 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 sho
59. r Z Vent 2 Remove the outside vent cover 3 Install the Appliance Adapter in the Vent Body of the heater located under the outside Vent Cover Before connecting the Appliance Adapter to the Vent Body wet a clean cloth or paper towel with isopropyl 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 manu facturer following the vent manufacturer s instruc tions WARNING Risk of carbon monoxide poisoning if adapter is improperly attached Mechanical connections such as screws can cause cracking and leaks in the adapter Do not drill holes or use screws to connect the appliance adapter to the heater vent body Attach with manufacturer s specified adhesive 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 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
60. r low temper ature tubing Follow drain manufacturer s installation instructions 5 Use Listed firestop for floor and ceiling penetrations Use Listed thimble for wall penetrations Use a Listed roof flashing roof jack or roof thimble for all roof penetrations Do not fill the space around the vent that is the clear air space in the thimble or 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 termina tions Use a Listed vent terminal specified by local and national codes and your manufacturer s instruc tions A roof termination must be vertical In Canada the Vent Cap location shall have a minimum clear ance of 4 feet 1 2M horizontally from electric meters gas meters regulators and relief openings 7 Vent Termination Horizontal See Table 7 Use a listed 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 instruc tions e at least 12 above finished grade or the normally expected snow accumulation level whichever is higher e at least 4 feet 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 lo
61. rectly to 2 PVC pipe using the integral unions provided Heat sinks are not required The low thermal mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down unexpectedly 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 Model Minimum Flow Maximum Flow 200 20 76 120 454 250 25 95 120 454 300 30 114 120 454 400 40 152 120 454 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 16 After installing the valve adjust the valve to bring the flow rate within the acceptable range Then remove the valve handle or lock it in place to prevent tam pering 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 clean er is also operating If the circulation pump suction is plugged for example by leaves there may not be ade quate 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 page 17 for water ch
62. rom 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 installations in enclosures Canada or indoors U S Use the specified venting and only the specified venting when heater is installed in an enclosure or indoors In Canada this pool heater can only be installed outdoors or in an enclosure that is not normally occupied and has no openings directly into occupied areas See Page 11 for enclosure venting requirements A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Wiring errors can also destroy the control board Connect heater to 120 or 240 Volt 60 Hz 1 Phase power only Verify proper operation after servicing Do not allow children to play on or around heater or associated equipment Never allow children to use the pool or spa without adult supervision Read and follow other safety information contained in this manual prior to operating this pool heater GENERAL SPECIFICATIONS REQUIREMENTS NOTICE Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty NOTICE The Combination Gas Control Valve on this appliance differs from most appl
63. rst 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 4 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 5 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 6 Persons taking medications which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set both pool and spa thermostats to the lowest settings 3 Turn off all electric power to the appliance 4 This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand N T J l f j Sep ars i iN SY if Ni 5 Remove the access door panels by unfastening the four 1 4 20 phillips head screws located on each door then lift up and out from the bottom of the panel to remove If necessary the screws may be used as handles See Figure 3 6 Toggle Style Valve Pull toggle toward you to turn gas off 7 Wait five 5 minutes to clear out any
64. s and could be fatal PRE EXISTING VENT SYSTEMS If you are considering connecting this heater to a pre exist ing vent system make sure that the vent system meets the appropriate 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 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 follow the instructions under BEFORE START UP page 4 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 AX WARNING Risk of explosion if a unit burning propane gas is installed in a pit or other low spot Propane is heav ier than air Do not install the heater using propane in pits or other locations where gas might collect Consult your local building code officials to determine installation require ments of heater relative to propane storage tanks and fill ing equipment Installation must meet the requirements of the Standard for the Storage and
65. solation valves flow nozzles or therapeutic pool valving must have a relief valve installed as described above 2681 1096 Pipe relief valve discharge to a drain or other safe disposal site FIGURE 19 Relief Valve 2 feet 0 6M below water level A reference scale is on the back of pressure switch Lower Pressure o o o ojo o ool Turn star wheel to lower pressure set point if pressure switch is more than 5 feet 1 5M above water level FIGURE 18 Water Pressure Switch Adjustment Instructions For Checking the Gas Pressure Through the Combination Gas Control Valve WARNING Risk of fire and explosion Improper installation 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 we Installation or service must be
66. t designed to operate with any other fuels Refer to the nameplate for the type of gas the heater is equipped to use e Use heater only with the fuel for which it is designed e Ifa fuel conversion is necessary refer this work to a qualified service technician or gas supplier before putting the heater into operation WARNING Risk of fire or explosion from flamma ble vapors Do not store gasoline cleaning fluids var nishes paints or other volatile flammable liquids near heater or in the same room with heater A WARNING Risk of fire carbon monoxide poison ing or asphyxiation if exhaust venting system leaks Only qualified service technicians should attempt to service the heater as leakage of exhaust products or flammable gas may result from incorrect servicing WARNING Risk of explosion if unit is installed near propane gas storage Propane LP gas is heavier than air Consult local codes and fire protection authorities about specific installation requirements and restrictions Locate the heater away from propane gas storage and fill ing equipment as specified by the Standard for the Storage and Handling of Liquefied Petroleum Gases CAN CSA B149 2 latest edition or ANSI NFPA 58 latest edition A WARNING Risk of asphyxiation if exhaust is not correctly vented Follow venting instructions exactly when installing heater Do not use a draft hood with this heater as the exhaust is under pressure f
67. t plug and then connect the heater to a 120 volt line the heater will not operate READ THE FOLLOWING CAREFULLY 1 Check the line voltage to your heater This heater will operate on either 120 Volts AC or 240 Volts AC 2 Remove the covers and check the 12 pin plug in the back of the control box The plug must match the voltage in the heater circuit 3 If the 12 pin plug is not plugged into the back of the control box select the correct plug from the bag in the control box and plug it in The BLACK plug is for 120 volts the RED plug is for 240 volts Start here for directions to specific Troubleshooting Chart Y Is green POOL or SPA NO Go to chart HEATER WILL LED on l NOT FIRE A i Page 24 YES Is red SERVICE SYSTEM YES ng LED on a NOT FIRE B i Page 25 no Are any red diagnos Fe r j YES tic LED s on back of YES Go to specific safety switch oe nen gt board AGS AFS troubleshooting chart SFS HLS PS or Pages 28 and 29 io THERMISTOR on NO 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 YES back of board AGS AFS SFS HLS PS or ee NO Does red SERVICE YES Go to chart HEATER WILL yon HEATER LED come NOT FIRE C NOTICE Any or
68. t temperature stays below 250 OR Heater doesn t start at all exhaust stays cold Check pressure and volume of fuel supply ok Disconnect the sensor and check continuity across its terminals Resistance should be 3 5 4 0 mega ohms open circuit 0 shorted Does sensor check OK YES Check continuity in wiring harness between Control Board and Probe Continuity OK no Check the J3 and J6 connectors for corrosion looseness on the male pins ves Clean tighten pins as needed Done Reset power to Heater and retry Heater should fire 29 NO NO Replace Heater ooo po HD Membrane Pad Correct problem Heater should fire BONE No YES gt Check Thermal Regulator Seats correctly Replace Heater Control Board NOT OK DONE Correct Fuel Supply reset Heater and retry Heater should fire correctly NO Reset power to Heater and gt Replace Stack Flue Sensor retry Heater should fire DONE No Reset power to Heater and retry Heater should fire Check Heat Exchanger Coil for NO leaks liming soot or low flow Repeat checks on fuel Replace Heater Control Board supply Thermal Regulator check for correct orifices DONE etc Reset power to Heater and YES retry Heater should fire INO Does
69. tely 33 REPAIR PARTS WATER SYSTEM Model Key Part 200NA 250NA 300NA 400NA No Description Qty 200LP 250LP 300LP 400LP 1 Tube Sheet Coil Assembly Kit NA LP Series Includes Key No 3 1 77707 0232 460747 77707 0233 77707 0234 2 Manifold Kit Includes Key Nos 3 14 21 and Key Nos 7 9 in Electrical System Page 35 1 77707 0014 460748 77707 0015 77707 0016 3 Coil Tubesheet Sealing O Ring Kit 77707 0117 6 460749 8 77707 0118 10 77707 0119 12 4 Manifold Bottom Plate 1 5 Manifold O Ring 1 O Ring Kit Incl Key Nos 3 5 1 77707 0120 77707 0120 77707 0120 77707 0120 6 Manifold Insert 1 7 Manifold Baffle Plate 1 8 Manifold Bypass Valve 1 9 Water Pressure Switch 1 42001 0060S 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16x18x2 3 4 Hex Cap screw 10 13 Connector Tube O Ring 2 14 Connector Tube Kit Includes 1 Connector Tube and 1 O Ring 2 77707 0017 77707 0017 77707 0017 77707 0017 15 Thermal Regulator Kit Incl Key Nos 16 17 18 19 and Spring Clip 1 77707 0010 77707 0010 77707 0010 77707 0010 16 Thermal Regulator Includes Spring Clip 1 38000 0007S 38000 0007S 38000 0007S 38000 0007S 17 Thermal Regulator Spring 1 18 Thermal Regulator Cap O Ring 1 35505 1313 35505 1313 35505 1313 35505 1313 Thermal Regulator Spring Clip 1 19 Thermal Regulator Cap 1 20 Drain Plug 1 U178 920P U178 920P U178 920P U178 920P 21 3 4 Pipe Plug 1 472618 472618 472618 472618 2
70. the Digital NO Temperature Display show Error Code E05 or E06 Replace Heater Membrane Pad Basic DONE Reset power to Heater and retry Heater should fire NO Burner Troubleshooting 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 Flame is too lean Turn to Page 19 and verify that the gas Exhaust may have acrid smell or burner may fail regulator setting is 0 2 0 5cm wc below the blower inlet pressure to stay lit Replace gas orifice with larger size Burner pulsates or Exhaust vent is too long Reduce length of exhaust vent and or surges especially on number of elbows ignition Combustion appears Flame current is not Check for wet or damaged igniter with normal but flame does being sensed low resistance to ground Replace with not stay lit new igniter Verify burner flameholder is properly grounded Heat Exchanger Troubleshooting SYMPTOM CAUSE Boiling in heat exchanger Low water flow to heater May be accompanied by bumping sounds Heat exchanger plugged Bypass valve stuck open Thermal governor stuck closed Replace Ignition Control Module REMEDY Service pump and or filter Service heat exchanger Corr
71. tions Table 3 Permitted Minimum and Maximum Vent Heights By Size and Heater Model Read VERTICAL VENTING NEGATIVE PRESSURE above before using this table Type B Double Wall Vent With Type B Double Wall Connector In Feet Meters Model 200 Model 250 Model 300 Model 400 Vent Size Height min max Height min max Height min max Height min max 6 in 6 ft 1 8 100 ft 30 5 18 ft 5 5 100 ft 30 5 30 ft 9 100 ft 30 5 Not Rec 7 in 6 ft 1 8 100 ft 30 5 8 ft 2 4 100 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 6ft 1 8 100 ft 30 5 6ft 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 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 250 Model 300 Model 400 Vent Size Height min max Height min max Height min max Height min max 6 in 6 ft 1 8 15 ft 4 6 6 ft 1 8 15 ft 4 6 Not Rec Not Rec 7 in 6 ft 1 8 8 ft 2 4 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 6 ft 1 8 6 ft 1 8 10 in Not Rec Not Rec Not Rec Not Rec 12 5 Use Listed firestop for floor and ceiling penetrations Use Listed thimble for wall penetrations Use a Listed roof
72. uld 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 temperature 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 sea son with a water temperature below 50 F 10 C the heater may be used to heat the water however make sure that the heater operates continuously until the water temperature reaches the heater s minimum setting of 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 winterize 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 conserve chemicals and reduce load on the filtering system 2
73. ween 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 AES SFS HLS PS NO water temperature YES F gt Or Wait one minute Lo THERMISTOR come on go to to Pages 28 and 29 Does heater fire and stay on CONTINUE NO NO Did burner fire at all H Did Blower come on YES YES NO Go to BURNER Verify that gas is flow TROUBLESHOOTING ing to burner during i Page 30 ignition try Observe gas meter for move ment during ignition Go to HEATER WILL NOT YES try wait for about 30 NO FIRE D Page 27 seconds after calling 9 for heat iti Check for 24 VAC Repl Ignit trol ee ee YES between TH and GND i terminals on Ignition A NO Control Module Check for 24 VAC between PEE NOTEN VAL and GND terminals on NO YES Ignition Control Module e SEE NOTE 2 Check for 24 VAC between TH and GND j YES terminals on Control NO Check for 24 VAC between yEs poate SEB NOTE 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 oo 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

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