1 1 STA-RITE® MAX-E-THERM® POOL AND SPA HEATER INSTALLATION AND USER’S GUIDE Warning: 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.
Customer Service and Technical Support If you have questions about ordering Pentair Aquatic Systems replacement parts, and pool products, please call: Phone: (800) 831-7133 Fax: (800) 284-4151 (8 A.M. to 4:30 P.M. Eastern Time/Pacific Time) Web sites www.pentairpool.com - www.staritepool.com P/N S794 REV H 8/14 MAX-E-THERM® Pool and Spa Heater Installation and User’s Guide P/N S794 Rev.
Contents Section 1. Introduction .......................................................................................................... Important Notices ................................................................................................................................................................................. Warranty Information ........................................................................................................................................................
Section 1. 4 Introduction Introduction Max-E-Therm® Pool and Spa Heater Congratulations on your purchase of a Max-E-Therm high performance heating system. Proper installation and service of your new heating system and correct chemical maintenance of the water will ensure years of enjoyment. The Max-E-Therm heater is a lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe, [schedule 80 CPVC for ASME models only].
Section 1. Introduction 5 CODE REQUIREMENTS Installation must be in accordance with all local codes and/or the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54 and the National Electrical Code, ANSI/NFPA70 (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).
Section 1. Introduction 6 IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS SAFETY INFORMATION The Max-E-Therm® pool heaters are designed and manufactured to provide many years of safe and reliable service when installed, operated and maintained according to the information in this manual. Throughout the manual, safety warnings and cautions are identified by the “ “ symbol. Be sure to read and comply with all of the warnings and cautions.
Section 1. Introduction 7 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 1. Introduction 8 GENERAL SPECIFICATIONS NOTICE: • Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warranty. • The Combination Gas Control Valve on this heater differs from most appliance gas controls. If it must be replaced, for safety reasons replace it only with an identical gas control. • The access door panels must be in place to provide proper ventilation.
Section 2. Installation 9 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. The heater operator control panel board assembly is located on top of the heater.
Section 2. Installation 10 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 13.59 30.03 INLET 4.57 9.19 4.62 OUTLET 18.02 19.41 31.69 25.
Section 2. Installation 11 PLUMBING CONNECTIONS TM The Max-E-Therm® heater has the unique capability of direct schedule 40 PVC, [schedule 80 CPVC for ASME models] plumbing connections. A set of bulkhead fittings is included with the Max-E-Therm heater to insure conformity with Pentair’s recommended PVC plumbing procedure. Other plumbing connections can be used. See Figure 3 for plumbing connections.
Section 2. Installation 12 WATER CONNECTIONS 3-Way Valve Figure 5. The heater requires proper water flow and pressure for its operation. See Figure 5 for the recommended installation. The filter pump discharges to the filter, the filter discharges to the heater, and the heater discharges directly to the pool or spa. A manual bypass valve should be installed across the heater when the pump flow exceeds 120 GPM (454 LPM). See “WATER FLOW RATE” on page 11- Table 1 for setting of the manual by-pass valve.
Section 2. Installation 13 GAS CONNECTIONS GAS LINE INSTALLATIONS Before installing the gas line, be sure to check which gas the heater has been designed to burn. This is important because different types of gas require different gas pipe sizes. The rating plate on the heater will indicate which gas the heater is designed to burn. The tables, shown on page 14, show which size pipe is required for the distance from the gas meter to the heater. The table is for natural gas at a specific gravity of .
Section 2. Installation 14 GAS PIPE SIZING Table 2. PIPE SIZING FOR GAS LINE CONNECTIONS MAXIMUM EQUIVALENT PIPE LENGTH (Ft.) Natural Gas at 1000 B.T.U. per Cubic Foot Propane Gas at 2500 B.T.U.
Section 2. Installation 15 TESTING GAS PRESSURE Before operating the heater, the heater and its gas connections must be leak tested. Do NOT use an open flame to test for leaks. Test all gas connections for leaks with soapy water or another non-flammable method (see page 14). The heater and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).
Section 2. Installation 16 OUTDOOR INSTALLATION (U.S. and Canada) For heaters located outdoors, using the built-in stackless venting system. WARNING Risk of explosion if a unit burning propane gas is installed in a pit or other low spot. Propane is heavier than air. Do not install the heater using propane in pits or other locations where gas might collect.
Section 2. Installation 17 OUTDOOR INSTALLATION VENTING GUIDELINES From window or door 4' 3' SIDE VIEW 4' Property Line 6 in. From building wall 4' Exhaust Grill (Vent) Force Air Inlet es od g c nts. n i e ild m bu uire al oc k req l k ec bac Ch set for Building Exhaust Grill (Vent) Vent Termination: Must be at least 3 ft. above any forced air inlet located within a 10 ft. radius. Must be located 6 in.
Section 2. Installation 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 20-22.
Section 2. Installation 19 COMBUSTION AIR SUPPLY Air Supply Requirements Guide for Max-E-Therm Heaters For indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area.
Section 2. Installation 20 VENT INSTALLATION – 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 2. Installation 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 high temperature silicone RTV to seal the Flue Collar to the Vent Body. Before connecting the metal Flue Collar to the Vent Body, wet a clean cloth or paper towel with isopropyl alcohol (rubbing alcohol) and vigorously wipe the socket of the Vent Body.
Section 2. Installation 22 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 2. Installation 23 HORIZONTAL OR VERTICAL VENTING - POSITIVE PRESSURE (See Figures 16, 17, and 18) (Category III) Vent the heater either horizontally or vertically using an optional vent adapter of the 4-inch special gas approved Category III vent pipes. Install the vent pipe in accordance with local codes and the provisions of the National Fuel Gas Code, ANSI Z223.1 (U.S.), or the standards CSA B149.
Section 2. Installation 24 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 2. Installation 25 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 18. 8. Vent Termination – Horizontal The terminal must be located (U.S.
Section 2. Installation 26 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 2. Installation 27 CONTROL PANEL INDEXING On an outdoor shelter installation, the exhaust discharges into a vent pipe. The heater control panel assembly, on top of the jacket, can be turned to any of six positions for convenient access to the panel, see Figure 21. 1. Unbolt and separate the jacket halves. 2. Pull hair pin clips. 3. Depress plastic clips on the control panel assembly. 4. Lift panel off of support plate. 5. Turn the assembly to the desired position and snap in place. 6.
Section 2. Installation 28 ELECTRICAL CONNECTIONS Electrical Rating: 60 Hz - 120 / 240 Volts AC, single phase Enclose the line to the heater in an approved flexible conduit connected directly to the junction box on the inside of the access door panel. Line voltage field wiring should be 14 gauge, with a circuit capacity of 15 amps. 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 2. Installation 29 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 upper jacket halves (see Figure 24). 3.
Section 2.
Section 2. Installation 31 MAX-E-THERM® HEATERS ELECTRICAL SCHEMATIC LADDER DIAGRAM LADDER DIAGRAM 120/240 VAC L1 L2 IGNITER L1 S1 F1 F2 S2 L2 BLOWER GND 120/240 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 VAL GAS VALVE STACK FLUE SENSOR THERMISTOR SENSOR NOTES: 1.) L1 S2 L2 F1 GND F2 IND S1 24 VAC VAL AND TH ARE CONNECTED ON THE IGNITION MODULE. P/N S794 Rev.
Section 3. Operation 32 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 3. Operation 33 OPERATING INSTRUCTIONS 1. STOP! Read the safety information on (page 32). 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. Remove the jacket cover(s) by unfastening the screws connecting both halves of the top jacket, see Figure 28. 6.
Section 3. Operation 34 SAFETY CONTROLS Figure 30. AIR FLOW SWITCH (AFS) The air flow switch, (see Figure 30), is a safety device used to insure that the combustion air blower (fan) is operating and has been designed to monitor the vacuum (negative) pressure within the blower housing. The air flow switch is factory set and is connected upstream of the ignition module. The ignition module does not operate unless the air pressure switch and all safety switches are closed.
Section 3. Operation 35 SAFETY CONTROLS, (cont’d.) Diagnostic LED 1 Flash - Air Flow Fault 2 Flashes - Flame No Call for Heat 3 Flashes - Ignition Lockout Flame Current Check Point OPERATION OF IGNITION MODULE The Ignition Module, (see Figure 33), is microprocessor based and operates on 24VAC supplied by the transformer. The control utilizes a microprocessor to continually and safely monitor, analyze, and control the proper operation of the gas flame holder.
Section 3. Operation 36 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 4. Troubleshooting 37 Troubleshooting Instructions Initial Troubleshooting Only qualified, trained service technicians with appropriate test equipment should service the heater. Remember that all parts of the system affect heater operation. 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 4. Troubleshooting 38 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) NO 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 If plug is not installed: Install correct plug. 240V plug in 120V circuit: Replace with correct plug.
Section 4. Troubleshooting 39 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 4. Troubleshooting 40 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 42 and 43. 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 4. Troubleshooting 41 Heater Will Not Fire - D IMPORTANT! READ ME FIRST! IMPORTANT! READ ME FIRST!! If your heater is correctly connected to 240 Volts AC, the Ignition Control Module (ICM) will convert the 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 4. Troubleshooting 42 Diagnostic LED's: AGS, AFS, HLS, PS, THERMISTOR AGS Verify that water flow rate is above minimum required for heater. HLS 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 4. Troubleshooting 43 Diagnostic LED's: SFS S S 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).
Section 4. Troubleshooting 44 Burner Troubleshooting SYMPTOM CAUSE REMEDY Loud, high-pitched whine Flame is too rich. Verify pressure tap between gas valve and blower inlet. See page 16 and verify that the gas regulator setting is –0.2" (–0.5cm) wc. Contact a qualified technician or service agency to replace the gas orifice. Flame is “fluttery .” 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 5. Maintenance 45 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 5. Maintenance 46 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 33, and call a qualified service technician to repair unit. After start-up, the outlet water pipe should feel slightly warmer than the inlet pipe. If it feels hot, or if you hear the water in the heater boiling, there may not be enough water flow to the appliance.
Section 5. Maintenance 47 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 5. Maintenance 48 CHEMICAL BALANCE, (cont’d.) It is wise to test pool water regularly. Never allow chlorine residual to drop below 0.6 ppm (parts per million). The minimum level for effective chlorine or bromine residual is 1.4 ppm. pH - The term pH refers to the acid/alkaline balance of water expressed on a numerical scale from 0 to 14. A test kit for measuring pH balance of your pool water is available from your local pool supply store; see Table 12. Muriatic Acid has a pH of about 0.
MAX-E-THERM® HEATER REPLACEMENT PARTS 1 S794_revC 11-19-10 For complete Electrical System parts breakdown (Key Nos. 1 through 4), See Page 53 2 5 3 6 9 4 For complete Burner System parts breakdown (Key Nos. 5 through 9), See Pages 51 and 52 7 12 8 1 4 10 For complete Water System parts breakdown (Key Nos. 10 through 12), 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. P/N S794 Rev.
MAX-E-THERM® HEATERS REPLACEMENT PARTS For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No. 42001-0085S. Operating Control Assy. Lead Anchor Combustion Chamber Cover Assy. w/Vent Cover & Vent Elbow CLAMP LID TUB DESIGN Lid, nut/washer (9x) Combustion Chamber Gasket Electrical Control Box w/Index Plate 22 24 Tube Sheet Coil Assy.
MAX-E-THERM® HEATERS REPLACEMENT PARTS REPAIR PARTS – BURNER SYSTEM Model Key Part No. Description Qty. SR200NA SR200LP SR200HD SR333NA SR333LP SR333HD SR400NA SR400LP SR400HD 460763 - NA 460764 - LP 1 Combination Gas Control Valve Kit 1 42001-0051S 42001-0051S 42001-0051S 2 3/4" Union 2 38404-4097S 38404-4097S 38404-4097S 3 Gas Orifice 1 4 Gas Orifice O-Ring 1 • Gas Orifice Kit – NG (Incl. Key Nos.
MAX-E-THERM® HEATERS 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 Qty. SR200NA SR200LP SR200HD SR333NA SR333LP SR333HD SR400NA SR400LP SR400HD (ASME) 460763 - NA400 460767 - NA250 460764 - LP400 460768 - LP250 Tube Sheet Coil Assembly Kit (NA, LP Series) (Includes Key No.
MAX-E-THERM® HEATERS REPLACEMENT PARTS 1 2 18 3 4 17 19 16 5 15 12 14 6 7 10 11 9 6 8 REPAIR PARTS – ELECTRICAL SYSTEM Model SR400NA SR400LP SR400HD 460763 - NA 460764 - LP Part Description 1 Display Cover Retainer Cap Kit, 1 77707-0009 77707-0009 77707-0009 2 Heater Display Cover 1 42001-0008S 42001-0008S 42001-0008S 42001-0030S Cap and CPSC Warning Label Qty. SR200NA SR200LP SR200HD SR333NA SR333LP SR333HD Key No.
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40 40 56 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 one of its global affiliates. Pentair Aquatic Systems™, Sta-Rite®, Max-ETherm®, 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.
