MASTERTEMP ® POOL AND SPA HEATER INSTALLATION AND USER’S GUIDE FOR YOUR SAFETY - READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. For additional free copies of this manual; call (800) 831-7133. FOR YOUR SAFETY - This product must be installed and serviced by authorized personnel, qualified inpool/spa heater installation.
Customer Service and Tecnincal Support If you have questions about ordering Pentair Quality Water Systems replacement parts, and pool products, please call: Phone: (800) 831-7133 Fax: (800) 284-4151 (8 A.M. to 7:00 PM Eastern Time/Pacific Time) Web sites: www.pentairpool.com - www.staritepool.com P/N 472592 Rev. M 1/2015 MASTERTEMP® Pool and Spa Heater Installation and User’s Guide Rev.
Contents Section 1. Heater Identification Information ....................................................................... Section 2. Warning and Safety Information ......................................................................... 4 5 Important Notices ................................................................................................................................................................................. Warranty Information ............................................
Section 1. Heater Identification Information 4 Section 1: Heater Identification Information To identify the heater, see rating plate on the inner front panel of the heater. There are two designators for each heater, one is the Model Number and the other is the Heater Identification Number (HIN). a.
Section 2. Warning and Safety Instructions 5 Section 2: Warning and Safety Instructions IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS MASTERTEMP ® Pool and Spa Heater Congratulations on your purchase of the MasterTemp Pool and Spa Heater. Proper installation and service of your new heating system and correct chemical maintenance of the water will ensure years of enjoyment.
Section 2. 6 Warning and Safety Instructions CODE REQUIREMENTS Installation must be in accordance with all local codes and/or the latest edition of the National Fuel Gas Code, ANSI Z223.1 and the latest edition of the National Electrical Code, NFPA 70 (US). Installation in Canada must be in accordance with the latest CAN/CGA-B149.1 or .2 and CSA C22.1 Canadian Electric Code, part 1.
Section 2. Warning and Safety Instructions 7 SAFETY INFORMATION The MasterTemp® pool heaters are designed and manufactured to provide many years of safe and reliable service when installed, operated and maintained according to the information in this manual. Throughout the manual, safety warnings and cautions are identified by the “ “ symbol. Be sure to read and comply with all of the warnings and cautions.
Section 2. 8 Warning and Safety Instructions SAFETY INFORMATION, (cont’d.) WARNING — Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should attempt to convert heater from one fuel to the other. Do not attempt to alter the rated input or type of gas by changing the orifice. If it is necessary to convert to a different type of gas, consult your Pentair dealer.
Section 2. Warning and Safety Instructions 9 CONSUMER INFORMATION AND SAFETY WARNING The U.S. Consumer Product Safety Commission warns that carbon monoxide is an "invisible killer". Carbon monoxide is a colorless and odorless gas. 1. Carbon monoxide is produced by burning fuel, including natural gas and propane. 2. Proper installation, operation and maintenance of fuel-burning appliances in the home is the most important factor in reducing carbon monoxide poisoning. 3.
Section 3. 10 Installation Instructions Section 3: Installation Instructions HEATER DESCRIPTION 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.
Section 3. Installation Instructions 11 SPECIFICATIONS These installation instructions are designed for use by qualified personnel only, trained especially for installation of this type of heating equipment and related components. Some states require installation and repair by licensed personnel. If this applies in your state, be sure your contractor bears the appropriate license. See Figure 2 for Outdoor and Indoor Installations. DIMENSIONS IN INCHES 23.02" (58.5 cm) 28.15" (71.5 cm) 21.0" (53.
Section 3. Installation Instructions 12 PLUMBING CONNECTIONS The MasterTemp heater has the unique capability of direct schedule 40 PVC plumbing connections. A set of bulkhead fittings is included with the MasterTemp heater to insure conformity with Pentair’s recommended PVC plumbing procedure. Other plumbing connections can be used. See Figure 3 for plumbing connections.
Section 3. Installation Instructions 13 VALVES When any equipment is located below the surface of the pool or spa, valves should be placed in the circulation piping system to isolate the equipment from the pool or spa. Check valves are recommended to prevent back-siphoning. Backsiphoning is most likely to occur when the pump stops, creating a pressure-suction differential. Do NOT sanitize the pool by putting chlorine tablets or sticks into the skimmer(s).
Section 3. Installation Instructions 14 GAS CONNECTIONS GAS LINE INSTALLATIONS Before installing the gas line, be sure to check which gas the heater has been designed to burn. This is important because different types of gas require different gas pipe sizes. The rating plate on the heater will indicate which gas the heater is designed to burn. The Table 2, shown on page 15, show which size pipe is required for the distance from the gas meter to the heater.
Section 3. Installation 15 GAS PIPE SIZING STAGE TWO “LOW PRESSURE” GAS PIPE SIZING PIPE SIZING FOR GAS LINE CONNECTIONS MAXIMUM EQUIVALENT PIPE LENGTH (Ft.) Natural Gas at 1000 B.T.U. per Cubic Foot Propane Gas at 2500 B.T.U. per Cubic Foot 1/2” MODEL Table 2.
Section 3. Installation Instructions 16 CAUTION The use of Flexible Connectors (FLEX) is NOT recommended unless they are properly sized according to the supplier recommendations for the heater rating. GAS PRESSURE REQUIREMENTS Natural Gas Pressure Propane Model Inches W.C. Maximum Inlet MT 14 14 Minimum Inlet MT 4 4 Manifold MT -0.2 ± 0.1 -0.2 ± 0.1 NOTE: All readings must be taken while heater is operating.
Section 3. Installation Instructions 17 For minimum exhaust vent clearances for all building openings, including but not limited to vented eaves, doors, windows, gravity air inlet, see Figure 9, show below. In Canada, the heater must be installed with the top of the vent at least 10 feet (3m) below, or to either side of, any opening into a building. Orient the heater for convenient access to the water connections and the gas and electrical connections.
Section 3. Installation Instructions 18 INDOOR VENTING — General Requirements The heater may be installed as a Category I or Category III appliance. Vented Appliance (Category I) – Vertical only An appliance that operates with a nonpositive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent, see pages 20-23.
Section 3. Installation Instructions 19 COMBUSTION AIR SUPPLY For indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area.
Section 3. Installation Instructions 20 Combustion 3 in. PVC Pipe Inlet Air Intake Duct Requirements* Combustion Air Intake 3 in. Pipe (Vertical or Horizontal) No. of 90° Elbows Maximum Length in Feet (M) 0 70 ft. (21.3 M) 1 58 ft. (17.7 M) 2 46 ft. (14.0 M) 3 34 ft. (10.4 M) 4 22 ft. ( 6.7 M) Table 5. WARNING! DO NOT USE PVC PIPE FOR FLUE EXHAUST VENT. FLUE EXHAUST VENT TEMPERATURES CAN BE IN EXCESS OF 400° F. FLUE EXHAUST VENT MUST BE CATEGORY I or CATEGORY III METAL VENT.
Section 3. Installation Instructions VENT INSTALLATION – 21 INDOOR INSTALLATION (U.S.) OR OUTDOOR SHELTER (CANADA) (Category I) Always vent the heater to the outdoors, see Note*. • Vent it vertically using Type “B” double wall vent connector pipe. NOTE *: Vent must be at least eight (8) feet away from nearest vertical surface. Vents extending five (5) feet or more above the roof must be braced or guyed. Consult your local code officials for detailed information.
Section 3. Installation Instructions 22 NOTE The allowable vent runs for each vent pipe diameter are different and can not be exceeded. Each 90-degree elbow reduces the maximum horizontal vent run by 12 feet and each 45-degree elbow in the vent run reduces the maximum vent run by 6 feet. See Table 7 on page 21 for the maximum vent lengths using 90-degree and 45-degree elbows. 2. Install the metal Flue Collar in the Vent Body of the heater (located under the outside vent cover).
Section 3. Installation Instructions 23 4. Install vent pipe so that it can expand and contract freely as the temperature changes. Support the vent pipe according to applicable codes and the vent manufacturer’s instructions. Pipe support must allow the vent pipe free movement out and back, from side to side, or up and down as necessary, without putting a strain on the heater or vent body. Slope horizontal pipe runs up from the heater at least 1/4" per foot (2cm per meter).
Section 3. Installation Instructions HORIZONTAL OR VERTICAL VENTING - POSITIVE PRESSURE (See Figures 14, 15, and 16) (Category III) Vent the heater either horizontally or vertically using an optional vent adapter of the 4-inch special gas approved Category III vent pipes. Install the vent pipe in accordance with local codes and the provisions of the National Fuel Gas Code, ANSI Z223.1 (U.S.), or the standards CSA B149.
Section 3. Installation Instructions 25 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. 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.
Section 3. Installation Instructions 26 4' Min. Vent Termination Vent Termination 4' Min. Vent Termination 1' Min. 4' Min. 1' Minimum above snow or finished grade (whichever is higher) Max. 12" Min. 3" 4' Min. At least 7' above grade adjacent to public walkways Gas Meter Forced Air Inlet 3' Minimum clearance if horizontal distance to exhaust opening is less than 10 feet. Figure 16. 8. Vent Termination – Horizontal The terminal must be located (U.S.
Section 3. Installation Instructions 27 OUTDOOR SHELTER INSTALLATION In Canada, this pool heater can only be installed outdoors or in an enclosure that is not normally occupied and has no direct openings into occupied areas. WARNING Risk of asphyxiation if exhaust is not correctly vented. Follow venting instructions exactly when installing heater.
Section 3. Installation Instructions CONTROL PANEL INDEXING On an outdoor shelter installation, the exhaust discharges into a vent pipe. Orient the heater so that the vent pipe does not interfere with adjustment of the operating controls. The control panel located on the top panel can be rotated to any of the three sides of the heater for easy access, see Figure 19. Top Panel Door Access Panel 1. Remove the bolts from the door panels. Remove both door access panels. 2.
Section 3. Installation Instructions 29 ELECTRICAL CONNECTIONS Electrical Rating: 60 Hz 120 / 240 Volts AC, single phase Enclose the incoming AC power line to the heater, in an approved flexible conduit connected directly to the junction box on the inside of the access door panel. Line voltage field wiring should be 14 gauge, with a circuit capacity of 15 Amps. CAUTION This heater is designed to operate at 120 or 240 VAC. It is not recommended to be connected to OR operate on a 208 VAC.
Section 3. Installation Instructions 30 CONNECTION OF FIREMAN’S SWITCH OR REMOTE CONTACT CAUTION If, while there is line voltage connected to the heater, you touch either line voltage terminal with any 24VAC wire that is connected to the control board (including the Fireman’s Switch jumper), you will immediately destroy the control board and void the warranty. REMOTE CONTROL CONNECTIONS 1. Switch off power to heater at main circuit breaker panel. 2. Unbolt and remove the access door panels. 3.
Section 3.
Section 3. Installation Instructions 32 MASTERTEMP HEATER ELECTRICAL SCHEMATIC LADDER DIAGRAM LADDER DIAGRAM 240 VAC L1 L2 IGNITER L1 S1 F1 F2 S2 L2 BLOWER GND 240 VAC CLASS II TRANSFORMER 24 VAC OPERATING CONTROL 24 VAC 24 VAC GND AIR FLOW SWITCH LOGIC 24V TH WATER PRESSURE SWITCH HI LIMIT SWITCH IND COM NO AGS SWITCH INLET TEMPERATURE CONTROL SWITCH VAL GAS VALVE STACK FLUE SENSOR THERMISTOR SENSOR NOTES: 1.
Section 4. Operation Instructions 33 Operation Instructions BASIC SYSTEM OPERATION Start pump, make sure the pump is running and is primed, to close the water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. Follow the Lighting/Operating instructions below.
Section 4. Operation Instructions OPERATING INSTRUCTIONS 1. STOP! Read the safety information on (page 33). Water Pressure Switch 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. 5.
Section 4. Operation Instructions 35 SAFETY CONTROLS Figure 27. AIR FLOW SWITCH (AFS) The air flow switch, (see Figure 27), is a safety device used to insure that the combustion air blower (fan) is operating and has been designed to monitor the vacuum (negative) pressure within the blower housing. The air flow switch is factory set and is connected upstream of the ignition module. The ignition module does not operate unless the air pressure switch and all safety switches are closed.
Section 4. Operation Instructions 36 SAFETY CONTROLS, (cont’d.) Flame Current Check Point OPERATION OF IGNITION MODULE Diagnostic LED 1 Flash - Air Flow Fault 2 Flashes - Flame No Call for Heat 3 Flashes - Ignition Lockout The Ignition Module, (see Figure 30), is microprocessor based and operates on 24VAC supplied by the transformer. The control utilizes a microprocessor to continually and safely monitor, analyze, and control the proper operation of the gas flame holder.
Section 4. Operation Instructions 37 TEMPERATURE SETTING The heater comes factory set at 78° F. for the pool mode and 100° F. for the spa mode. Using the up and down arrows, you can set the thermostats to a minimum temperature of 65° F., or a maximum of 104° F. If you desire to heat only one body of water, the thermostat is capable of an off mode.
Section 5. Troubleshooting 38 Troubleshooting Instruction 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.
Section 5. Troubleshooting 39 Heater Will Not Fire - A Start NO Is green “SPA” or “POOL” LED “on” YES Check that correct 12-pin plug is installed (red is 240V, black is 120V) YES Depress “POOL” or “SPA” ON button on Membrane Pad. Does “POOL” or “SPA” LED come on? NO YES Check for line voltage to heater. NO Heater should fire on demand for heat. Restore power to heater. YES NO If plug is not installed: Install correct plug. 240V plug in 120V circuit: Replace with correct plug.
Section 5. Troubleshooting 40 Heater Will Not Fire - B Start Is red “SERVICE HEATER” LED “on” NO Is red “SERVICE SYSTEM” LED on? NO YES YES Verify that pump is on, filter is not blocked, and the water flow is above the minimum requirement. NO YES With pump running, adjust Water Pressure Switch to lower pressure until ‘SERVICE SYSTEM” LED goes out. Then verify that “SERVICE SYSTEM” LED goes on with pump off. Increase POOL/SPA temperature setting on Membrane Pad above actual water temperature.
Section 5. Troubleshooting 41 Heater Will Not Fire - C Start NO Is “SERVICE HEATER” LED “on”? YES If any red diagnostic LED’s (AGS, AFS, SFS, HLS, PS, or THERMISTOR) come “on”, go to to Pages 43 and 44. NO Go to “INITIAL TROUBLESHOOTING” Turn off power to heater for 5 seconds, and turn back on. Make sure temperature setting is above water temperature. Wait one minute.
Section 5. Troubleshooting 42 Heater Will Not Fire - D IMPORTANT! READ ME FIRST! IMPORTANT! READ ME FIRST!! If your heater is correctly connected to 240 Volts AC, the Ignition Control Module (ICM) will convert the 240VAC to an intermittent pulse to the ignitor. Digital meters don’t read this type of signal well. (An analog meter will give a better reading than a digital meter). If the ICM is bad, your volt- meter will read either 0 VAC or 240 VAC.
Section 5. Troubleshooting 43 Diagnostic LED's: AGS, AFS, HLS, PS, THERMISTOR Verify that water flow rate is above minimum required for heater. AGS or HLS "on" Replace High Limit Switch (HLS) or Automatic Gas Shutoff (AGS) NO YES YES Verify that inlet water temperature is below 104° F. Service pump and filter to restore proper flow. After servicing, verify proper operation of Pressure Switch (PS). NO Replace thermistor or Control Board to correct overheating.
Section 5. Troubleshooting 44 Diagnostic LED's: SFS SFS "on" 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 minutes. YES YES Check Thermal Regulator: Open at 120˚? NO Heater starts after several tries, exhaust temperature stays below 250˚. OR Heater doesn’t start at all (exhaust stays cold). Check pressure and volume of fuel supply NO YES Replace Heater Membrane Pad.
Section 5. Troubleshooting 45 Burner Troubleshooting SYMPTOM CAUSE REMEDY Loud, high-pitched whine Flame is too rich. Verify pressure tap between gas valve and blower inlet. See page 15 and verify that the gas regulator setting is –0.2" (–0.5cm) wc. Contact a qualified technician or service agency to replace the gas orifice. Flame is “fluttery .” Exhaust may have acrid smell or burner may fail to stay lit. Flame is too lean. See page 16 and verify that the gas regulator setting is –0.2" (–0.
Section 6. Maintenance 46 Maintenance Instructions CARE AND MAINTENANCE 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.
Section 6. Maintenance 47 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 Turn Off Gas to the Appliance”, page 34, 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.
Section 6. Maintenance 48 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. Reduce pool thermostat to 78° F (25° C) or lower; reduce spa temperature to 100° F (38° C).
Section 6. Maintenance 49 CHEMICAL BALANCE, (cont’d.) It is wise to test pool water regularly. Never allow chlorine residual to drop below 0.6 ppm (parts per million). The minimum level for effective chlorine or bromine residual is 1.4 ppm. pH - The term pH refers to the acid/alkaline balance of water expressed on a numerical scale from 0 to 14. A test kit for measuring pH balance of your pool water is available from your local pool supply store; see Table 9. Muriatic Acid has a pH of about 0.
Section 6. Maintenance/Replacement Parts 50 MASTERTEMP HEATER REPLACEMENT PARTS 1 For complete Electrical System parts breakdown (Key Nos. 1 through 4), See Page 53 3 For complete Burner System parts breakdown (Key Nos. 5 through 7), See Page 51 2 5 6 7 9 4 8 For complete Water System parts breakdown (Key Nos. 8 through 9), see Page 52 Repair Parts are available from your Pentair dealer. If your dealer cannot supply you, call Customer Support at 1-800-831-7133.
Section 6. Maintenance/Replacement Parts 51 MASTERTEMP HEATER REPLACEMENT PARTS CLAMP LID TUB DESIGN Lid Nut/Washer (9x) Combustion Chamber Gasket For heaters manufactured between 1/12/2009 and 10/31/2013 (clamp lid tub design) Note: Kits also include Clamp Assembly, O-Ring and Silicon Tube (see page 52) Rev.
Section 6. Maintenance/Replacement Parts 52 MASTERTEMP HEATER REPLACEMENT PARTS REPAIR PARTS – BURNER SYSTEM Model Key Part No. Description 175NA 200NA 250NA 300NA 400NA Qty. 175LP 200LP 250LP 300LP 400LP 1 Combination Gas Control Valve Kit 1 42001-0051S 42001-0051S 42001-0051S 42001-0051S 42001-0051S 2 3/4" Union 2 38404-4097S 38404-4097S 38404-4097S 38404-4097S 38404-4097S 3 Gas Orifice 1 4 Gas Orifice O-Ring 1 • Gas Orifice Kit – NG (Incl. Key Nos.
Section 6. Maintenance/Replacement Parts 53 MASTERTEMP HEATER REPLACEMENT PARTS 1 3 4 2 5 7 6 8 9 10 11 12 13 14 15 16 17 18 22 19 21 20 REPAIR PARTS – WATER SYSTEM Model Key Part No. Description 1 1 1 175NA - 200NA 250NA 300NA 400NA Qty. 175LP - 200LP 250LP 300LP 400LP Tube Sheet Coil Assembly Kit (NA, LP Series) (Includes Key No.3) 1 Tube Sheet Coil Assembly Kit (NA - HD Series) (Includes Key No.
Section 6. Maintenance/Replacement Parts 54 MASTERTEMP HEATER REPLACEMENT PARTS 1 15 2 14 3 16 13 4 10 11 12 5 8 9 7 6 REPAIR PARTS – ELECTRICAL SYSTEM Model Key No. Part Description Qty. 175NA - 200NA 175LP - 200LP 250NA 250LP 300NA 300LP 400NA 400LP 1 Heater Display Cover 1 42002-0035 42002-0035 42002-0035 42002-0035 2 Igniter Bracket 1 42001-0030S 42001-0030S 42001-0030S 42001-0030S 3 Igniter/Igniter Gasket Kit Incl. Key Nos.
56 40 1620 HAWKINS AVE., SANFORD, NC 27330 • (919) 566-8000 10951 WEST LOS ANGELES AVE., MOORPARK, CA 93021 • (805) 553-5000 www.pentairpool.com All Pentair trademarks and logos are owned by Pentair or by one of its global affiliates. Pentair Aquatic Systems™, MasterTemp®, IntelliTouch®, EasyTouch®, are trademarks and/or registered trademarks of Pentair Water Pool and Spa, Inc. and/or its affiliated companies in the United States and/ or other countries.
