Table of Contents
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OPERATION AND INSTALLATION MANUAL
240 VAC NATURAL GAS/LP GAS
MODELS
200HD (200 MJ/h)
300HD (300 MJ/h)
400HD (400 MJ/h)
FOR YOUR SAFETY –
by authorized personnel, qualified in pool/spa heater installation.
Improper installation and/or operation can create carbon monoxide
gas and flue gases which can cause serious injury, property damage,
or death. As an additional measure of safety, Pentair Water Pool and
Spa, Inc. strongly recommends installation of suitable Carbon Monoxide
detectors in the vicinity of this heater. Improper installation and/or
operation will void the warranty.
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.
•
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, personal injury or death. Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
•
Do not place articles or against this appliance.
•
Do not use or store flammable materials near this appliance.
•
Do not spray aerosols in the vicinity of this appliance while it is in operation.
•
Do not try to light any appliance.
•
Do not touch any electrical switch; do not use any phone in your building.
•
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
•
If you cannot reach your gas supplier, call the fire department.
For additional free copies of this manual; call 1800 664 266 – AUS.
Pentair Water AU/NZ – Head Office – 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • +61 3 9574-4000 • 1800 664 266
1620 Hawkins Ave., Sanford, NC 27330, USA • (919) 566-8000 • (800) 831-7133
10951 W. Los Angeles Ave., Moorpark, CA 93021, USA • (805) 553-5000 • (800) 831-7133
Rev. D 27-06-11
MasterTemp
POOL AND SPA HEATER
Natural Propane
460946
460949
460945
460948
460944
460947
This product must be installed and serviced
WHAT TO DO IF YOU SMELL GAS
Pentair Water Pool and Spa, Inc.
™
(Australia)
WARNING
1
1
1
Owner:
Retain For
Future
Reference
P/N 474131
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Table of Contents
Troubleshooting
Related Manuals for Pentair Pool Products MasterTemp 200HD
Summary of Contents for Pentair Pool Products MasterTemp 200HD
- Page 1 For additional free copies of this manual; call 1800 664 266 – AUS. Pentair Water AU/NZ – Head Office – 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • +61 3 9574-4000 • 1800 664 266 Pentair Water Pool and Spa, Inc.
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Page 2: Customer Service
Unless noted, names and brands of others that may be used in this document are not used to indicate an affiliation or endorsement between the proprietors of these names and brands and Pentair Water Pool and Spa, Inc. Those names and brands may be the trademarks or registered trademarks of those parties or others. -
Page 3: Table Of Contents
Contents Section 1. Heater Identification Information (HIN) ............. Heater Data Rating Plate ..................Section 2. Introduction ......................Important Notices ....................................Warranty Information .................................... Code Requirements ....................................Consumer Information and Safety Information ............................6 - 8 General Specifications ..................................Section 3. Installation ......................Heater Description .................................... -
Page 4: Section 1. Heater Identification Information (Hin)
3) Construction : (HD = Heavy Duty Model) 4) Fuel Type : (LP = Propane gas or N = Natural gas) H. I. N. HEATER IDENTIFICATION NUMBER ID DESIGNATOR FOR PENTAIR WATER POOL AND SPA MASTERTEMP HEATERS Example: = NATURAL GAS FUEL TYPE =... -
Page 5: Section 2. Introduction
If you need more information or if you have any questions regarding to this pool heater, please contact Pentair Water AU/NZ, AUS – at 1800 664 266 • +61 3 9574-4000 or Pentair Water Pool and Spa, Inc., USA –... -
Page 6: Code Requirements
Section 2. Introduction CODE REQUIREMENTS Installation must be in accordance with the following: Manufacturer’s Installation Instructions S.A.A. Wiring Code, • • • AS/NZS 5601.1 for Gas Installations • Local Electrical Regulations • Local Gas Fitting Regulations, • Any other statutory regulations •... -
Page 7: Safety Information
Section 2. Introduction 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 “... -
Page 8: General Specifications
Section 2. Introduction SAFETY INFORMATION, (cont’d.) WARNING — Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, varnishes, paints, or other volatile flammable liquids near heater. WARNING — Risk of explosion if unit is installed near propane gas storage. Propane (LP) gas is heavier than air. -
Page 9: Section 3. Installation
Section 3. Installation Installation Instructions THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED IN POOL HEATER INSTALLATION. Pentair strongly recommends that all vents, pipes and exhaust systems be initially and periodically tested for proper operation. This testing can be accomplished by using a hand-held carbon monoxide meter and/or by consulting with a gas professional. -
Page 10: Specifications
Section 3. Installation SPECIFICATIONS These installation instructions are designed for use by qualified personnel only, trained especially for installation of this type of heating equipment and related components. Some states require installation and repair by licensed personnel. If this applies in your state, be sure your contractor bears the appropriate license. See Figure 2 for Outdoor Installations. -
Page 11: Plumbing Connections
Section 3. Installation 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 to insure conformity with Pentair’s recommended PVC plumbing procedure. Other plumbing connections can be used. See Figure 3 for plumbing connections. -
Page 12: Water Connections
Section 3. Installation WATER CONNECTIONS 3-Way Chlorinator The heater requires proper water flow and pressure for its Valve operation. See Figure 5 for the recommended installation. The filter pump discharges to the filter, the filter discharges to the Check Valve heater, and the heater discharges directly to the pool or spa. -
Page 13: Gas Connections
Section 3. Installation GAS CONNECTIONS GAS LINE INSTALLATIONS The gas supply must be installed in accordance with the Gas Installation Code, AS/NZS 5601.1, as applicable and all applicable local codes. 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. -
Page 14: Testing Gas Leaks And Gas Pressure
Section 3. Installation TESTING GAS LEAKS 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. The gas valve must be completely disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 6.0 kPa (.87 psig). -
Page 15: Outdoor Installation / Heater Clearances
Section 3. Installation OUTDOOR INSTALLATION (Australia) For heaters located outdoors, using the built-in stackless venting system. DANGER CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains carbon monoxide, a dangerous, poisonous gas you cannot see or smell. Symptoms of carbon monoxide exposure or poisoning include dizziness, headache, nausea, weakness, sleepiness, muscular twitching, vomiting and inability to think clearly. - Page 16 Section 3. Installation HEATER CLEARANCES – OUTDOOR IMPORTANT! • In an outdoor installation it is important to ensure water is diverted from overhanging eves with a proper gutter/drainage system. The heater must be set on a level foundation for proper drainage. •...
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Page 17: Indoor Venting-General Requirements Heater Clearances / Outside Vent Removal )
Section 3. Installation INDOOR VENTING — General Requirements NOTE: REMOVE OR COVER “OUTDOOR ONLY” LABEL LOCATED ON HEATER OUTSIDE PANEL WITH “INDOOR INSTALLATION” LABEL (P/N 474275) INCLUDED IN ACCESSORY BAG (P/N 473607). INDOOR INSTALLATION (SEE INSTALLATION GUIDE FOR CORRECT PLACEMENT OF THIS LABEL) P/N 474275 If you are considering connecting this heater to a pre-existing vent system, make sure that the vent system meets the appropriate venting requirements as given in this manual on... -
Page 18: Combustion Air Supply / Corrosive Vapors And Possible Causes
These openings shall directly, or through duct, connect to outdoor air. c i d o l f n i l i Pentair Water Pool and Spa, Inc. does not recommend Table 4. indoor installations that do not provide combustion air from outside the building. CAUTION Chemicals should not be stored near the heater installation. -
Page 19: Vertical Venting
Section 3. Installation VERTICAL VENTING (See Figures 12 and Vent the heater vertically in a system in accordance with AS/NZS 5601.1 and Clean the Interior Surface local codes. Double-wall vent connector is recommended; however single-wall Vent Bod 4" x 8" Metal Flue Collar pipe is allowed in some circumstances. - Page 20 Section 3. Installation 2. Install the metal Flue Collar in the Vent Body of the heater (located under the outside vent cover). Approved Fasten the metal Flue Collar to the Vent Body Termination Min. 3 M with two #10 sheet metal screws. Use high (10 ft) temperature silicone RTV to seal the Flue Collar Storm Collar...
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Page 21: Horizontal Or Vertical Venting - Using Single-Wall Stainless Gas Vent
Section 3. Installation 5. Use approved fire stop for floor and ceiling penetrations. Use approved thimble for wall penetrations. Use a approved roof flashing, roof jack, or roof thimble for all roof penetrations. Do not fill the space around the vent (that is, the clear air space in the thimble or fire stop) with insulation. -
Page 22: Connecting Single-Wall Stainless Steel Vent To The Heater
Section 3. Installation Flue gases may escape into the dwelling with any cracks or loose joints in the vent pipe, or improper vent installation. The vent pipe must be of a sealed-seam construction and for operating temperatures less than 204° C (400°F). Vent pipe construction will be of AS/NZS 5601.1 approved non-corrosive material, such as stainless steel. - Page 23 Section 3. Installation 6. Vent Termination – Vertical (See Figures 14, 15 and 16), for height of vent termination above the roof. Use an “Approved” vent terminal specified by local and national codes and your manufacturer’s instructions. A roof termination must be vertical. 7.
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Page 24: Horizontal Or Vertical Venting Flexible Duct (Flex-Vent)
Section 3. Installation 8. Vent Termination – Horizontal (Continued) The terminal must be located (See Figure 17): • at least 3.3M (10 ft) from any opening into a building Metal Special Support • at least 0.3 M (12 in) above finished grade or the Gas Vent weight requires... -
Page 25: Corrosive Vapors And Possible Causes
Section 3. Installation NOTE: KEEP A 150 CM (6 IN) MINIMUM CLEARANCE BETWEEN THE VENT PIPE AND COMBUSTIBLE SURFACES. FOLLOW THE VENT MANUFACTURER’S INSTRUCTIONS AND CODE REQUIREMENTS. Each 90° bend reduces the maximum horizontal vent run by 3.6 m (12 feet) and each 45° bend in the vent run reduces the maximum vent run by 1.8 m (6 feet). -
Page 26: Electrical Connections
Section 3. Installation ELECTRICAL CONNECTIONS Electrical Rating 50 Hz 240 Volts AC, single phase The heater is supplied with a 250 VAC, 10 AMP, 50 Hz power cord (AS/NZS 3112) approved for outdoor use. The power cord wire is 3 x 16 AWG (3 x 10 mm CAUTION This heater is designed to operate at 240 VAC. -
Page 27: Fireman's Switch Connection/Remote Control Connections
Section 3. Installation 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. -
Page 28: Mastertemp Wiring Diagram / Electrical Schematic Ladder Diagram
Section 3. Installation MASTERTEMP WIRING DIAGRAM (3-WIRE SYSTEM) CONNECTION DIAGRAM AGS Switch Air Flow Switch Stack Flue Sensor Extra Switch 1 Y/BL Gas Valve Hi-Limit Switch Pressure Switch NA/LP Models Only Y/BL OPERATING CONTROL MEMBRANE PAD CONNECTION JMP3 External Control Interface Circuit Disabled, Heater Membrane Pad Enabled Spa Line Common Line... - Page 29 Section 3. Installation MASTERTEMP ELECTRICAL SCHEMATIC LADDER DIAGRAM LADDER DIAGRAM IGNITER BLOWER CLASS II TRANSFORMER 24 VAC OPERATING CONTROL 24 VAC 24 VAC FLOW LOGIC SWITCH WATER PRESSURE LIMIT SWITCH SWITCH COM NO SWITCH GAS VALVE STACK FLUE THERMISTOR SENSOR SENSOR NOTES: 24 VAC...
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Page 30: Section 4. Operation
Section 4. Operation Operation Instructions BASIC SYSTEM OPERATION Start pump, make sure the pump is running and is primed, to close the water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. Follow the Lighting/Operating instructions below. -
Page 31: Operating Instructions
Section 4. Operation OPERATING INSTRUCTIONS 1. STOP! Read the safety information on (page 30). 2. Set both pool and spa thermostats to the lowest settings. External Manual Shut-off Valve 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. -
Page 32: Safety Controls (Air Flow Switch / Water Pressure Switch / Hight Limits / Operation Of Ignitiion Module)
Section 4. Operation SAFETY CONTROLS AIR FLOW SWITCH (AFS) The air flow switch, (see Figure 28), 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. -
Page 33: Operating The Control Panel / Temperature Setting / Maximum Temperature Set Point
Section 4. Operation SAFETY CONTROLS, (cont’d.) Diagnostic LED Flame Current 1 Flash - Lockout Check Point 2 Flashes - Air Flow Fault OPERATION OF IGNITION MODULE 4 Flashes - Erroneous Flame , (see Figure 31), The Ignition Module is microprocessor based and operates on 24VAC supplied by the transformer. - Page 34 Section 4. Operation TEMPERATURE SETTING The heater comes factory set at 25.6° C (78° F). for the pool mode and 37.8° C (100° F). for the spa mode. Using the up and down arrows, you can set the pool/spa thermostats to a minimum temperature of 18.3° C (65° F.), or a maximum of 40°...
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Page 35: Section 5. Troubleshooting
Section 5. Troubleshooting 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. -
Page 36: Heater Will Not Fire Troubleshooting (A, B, C, D)
Section 5. Troubleshooting Heater Will Not Fire - A Start Depress “POOL” or “SPA” ON Heater should fire on demand Is green “SPA” or button on Membrane Pad. for heat. “POOL” LED “on” Does “POOL” or “SPA” LED come on? Check that the 12-pin Check for line voltage to Restore power to heater. - Page 37 Section 5. Troubleshooting Heater Will Not Fire - B Start Increase POOL/SPA tempera- Is red “SERVICE Is red “SERVICE SYSTEM” ture setting on Membrane HEATER” LED “on” LED on? Pad above actual water tem- perature. Heater should fire on demand for heat. If not, Verify that pump is on, filter is and no other red LED’s light, not blocked, and the water...
- Page 38 Section 5. Troubleshooting Heater Will Not Fire - C Start Is “SERVICE HEATER” LED Go to “INITIAL “on”? TROUBLESHOOTING” Turn off power to heater for 5 seconds, Continue to observe heater and turn back on. for several minutes. Cycle Make sure tempera- heater on and off several ture setting is above times.
- Page 39 Section 5. Troubleshooting Heater Will Not Fire - D IMPORTANT! READ ME FIRST! IMPORTANT! READ ME FIRST!! If your heater is correctly connected to 240 Volts AC, the meter will read either 0 VAC or 240 VAC. If your ICM is good, your meter will read some voltage between 0 and Ignition Control Module (ICM) will convert the 240VAC to an intermittent pulse to the ignitor.
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Page 40: Led Diagnostics (Ags, Afs, Hls, Ps Thermistor)
Section 5. Troubleshooting Diagnostic LED's: AGS, AFS, HLS, PS, THERMISTOR Verify that water flow rate is Service pump and filter to AGS or HLS "on" above minimum required for restore proper flow. After ser- heater. vicing, verify proper operation Replace High Limit of Pressure Switch (PS). - Page 41 Section 5. Troubleshooting 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 204˚–260˚C in Check Thermal 3-5 minutes. Regulator: Open at 48.9˚C? Replace Heater (HD ) Membrane Pad.
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Page 42: Burner / Heat Exchanger Troubleshooting
Section 5. Troubleshooting Burner Troubleshooting SYMPTOM CAUSE REMEDY Loud, high-pitched whine Flame is too rich. Verify pressure tap between gas valve and blower inlet. See page 14 and verify that the gas regulator setting is 11 ± 5 Pa. Contact a qualified technician or service agency to replace the gas orifice. -
Page 43: Section 6. Maintenance
Section 6. Maintenance 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. -
Page 44: After Start-Up
Section 6. Maintenance 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 31, and call a qualified service technician to repair unit. After start-up, the outlet water pipe should feel slightly warmer than the inlet pipe. -
Page 45: Maintaining Pool Temperature / Energy Saving Tips
Section 6. Maintenance 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. -
Page 46: Chemical Balance
Section 6. Maintenance CHEMICAL BALANCE, (cont’d.) It is wise to test pool water regularly. Never allow chlorine residual to drop below 0.6 ppm (parts per million). The minimum level for effective chlorine or bromine residual is 1.4 ppm. pH - The term pH refers to the acid/alkaline balance of water expressed on a numerical scale from 0 to 14. A test kit for measuring pH balance of your pool water is available from your local pool supply store;... -
Page 47: Replacement Parts
MASTERTEMP REPLACEMENT PARTS For complete Electrical System parts breakdown (Key Nos. 1 through 4), see Page 51. For complete Burner System parts breakdown (Key Nos. 5 through 7), see Page 49. Combustion Chamber Clamp Assy. For complete Water System parts breakdown (Key Nos. - Page 48 MASTERTEMP REPLACEMENT PARTS For Heater mounting bolts and clamps, purchase separately Bolt Down Bracket Kit, Part No. 460738. Lead Anchor P/N 474131 Rev. D 27-06-11...
- Page 49 MASTERTEMP REPLACEMENT PARTS REPAIR PARTS – BURNER SYSTEM Model Part 200NA 300NA 400NA Qty. Description 200LP 300LP 400LP Gas Valve Assembly [Australia] 474133Z 474133Z 474133Z Gas Train Assembly [Australia] Gas Orifice Gas Orifice O-Ring • Gas Orifice Kit – NG (Incl. Key Nos. 3 and 4)† 474136 474135 474134...
- Page 50 MASTERTEMP REPLACEMENT PARTS REPAIR PARTS – WATER SYSTEM Model Part 200NA 300NA 400NA Description Qty. 200LP 300LP 400LP Tube Sheet Coil Assembly Kit (NA, LP Series) (Includes Key No.3) 77707-0232 77707-0233 77707-0234 Tube Sheet Coil Assembly Kit (NA – HD Series) (Includes Key No.3) –...
- Page 51 MASTERTEMP REPLACEMENT PARTS REPAIR PARTS – ELECTRICAL SYSTEM Model Part 200NA 300NA 400NA Description Qty. 200LP 300LP 400LP Heater Display Cover 42002-0035 42002-0035 42002-0035 Igniter Bracket 42001-0030S 42001-0030S 42001-0030S Igniter/Igniter Gasket Kit Incl. Key Nos. 3 and 4) 77707-0054 77707-0054 77707-0054 Igniter Gasket 42001-0066S...
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Page 52: Save These Instructions
Technical Support at 1800 664 266 – AUS, +61 3 9574-4000 – Victoria, AUS or (800) 831-7133 – USA or visit www.pentairpool.com/safety. SAVE THESE INSTRUCTIONS Pentair Water AU/NZ – Head Office 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • +61 3 9574-4000 • 1800 664 266 Pentair Water Pool and Spa, Inc.