Pentair 175K BTU/HR Installation And User Manual

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Installation and user manual (56 pages)

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Page 1 Improper installation and/or operation can create carbon monoxide gas and flue gases which can cause serious injury, property damage, or death. For indoor installations, as an additional measure of safety, Pentair Aquatic Systems strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
Page 2 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.
Page 3: Table Of Contents
Contents Section 1. Heater Identification Information ............... Section 2. Warning and Safety Information ................. Important Notices ....................................Warranty Information .................................... Code Requirements ....................................Consumer Information and Safety Information ............................6 - 9 General Specifications ..................................Section 3. Installation ......................Heater Description ....................................Putting the Heater into Service ................................
Page 4: Section 1. Heater Identification Information
(ASME = ASME Certified Model) (HD ASME = Heavy Duty ASME Model) HEATER IDENTIFICATION INFORMATION — (HIN) H. I. N. HEATER IDENTIFICATION NUMBER ® ID DESIGNATOR FOR PENTAIR AQUATIC SYSTEMS MASTERTEMP HEATERS Example: ASME = STANDARD MODEL = HEAVY DUTY MODEL CONSTRUCTION =...
Page 5: Section 2. Warning And Safety Information
Be sure to follow the instructions set forth in this manual. If you need any more information, or if you have any questions regarding to this pool heater, please contact Pentair Aquatic Systems at (800) 831-7133.
Page 6: Code Requirements
Section 2. 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.
Page 7: Safety Information
If used outdoors, install far from open windows, doors, vents and other openings. 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 8 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.
Page 9: General Specifications
Section 2. Warning and Safety Instructions 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.
Page 10: Section 3. Installation
Section 3. Installation Instructions Section 3: Installation Instructions HEATER DESCRIPTION Figure 1 is a diagram of the heater showing how it operates. Precisely matched orifice plates meter the air and gas into the mixer. The blower draws the air and gas through the mixer and forces it into the burner’s flame holder.
Page 11: Specifications
Section 3. Installation Instructions 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.
Page 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.
Page 13: Valves
Section 3. Installation Instructions 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. Back- siphoning is most likely to occur when the pump stops, creating a pressure-suction differential.
Page 14: Gas Connections
Section 3. Installation Instructions 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.
Page 15: Gas Pipe Sizing
Section 3. Installation GAS PIPE SIZING STAGE TWO “LOW PRESSURE” GAS PIPE SIZING ) . t l a r c i b c i b ” 2 ” 4 ” 1 / 1 - ” 4 / 1 - ” 2 ”...
Page 16: Testing Gas Pressure/Gas Pressure Requirements
Section 3. Installation Instructions 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 l a r . C . t e l t e l o f i ±...
Page 17: Outdoor Installation Venting Guidelines
Section 3. Installation Instructions 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.
Page 18: Indoor Venting - General Requirements (Category I And Category Iii Requirements)
Section 3. Installation Instructions 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.
Page 19: Combustion Air Supply /Direct Air Intake Duct With 3-Inch Pvc Pipe (Indoor Installation)
Section 3. Installation Instructions COMBUSTION AIR SUPPLY For indoor installation, the heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area. The minimum requirements for the air supply specify that the room in which a heater is installed should be provided with two permanent air supply openings;...
Page 20: Corrosive Vapors And Possible Causes
Section 3. Installation Instructions 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) 70 ft. (21.3 M) 58 ft. (17.7 M) 46 ft.
Page 21: Vent Installation (Indoor Installation For U.s. Or Outdoor Shelter For Canada)
Section 3. Installation Instructions VENT INSTALLATION – INDOOR INSTALLATION (U.S.) OR OUTDOOR SHELTER (CANADA) (Category I) NOTE *: Vent must be at least eight (8) feet away from nearest vertical surface. Vents extending five (5) feet or Always vent the heater to the outdoors, see Note*. more above the roof must be braced or guyed.
Page 22 Section 3. Installation Instructions 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.
Page 23 Section 3. Installation Instructions 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.
Page 24: Horizontal Or Vertical Venting - Positive Pressure
CONNECTING SPECIAL METALIC GAS VENT TO THE HEATER 1. Order an optional appliance adapter kit, (800) (Pentair offers optional appliance adapter kits, call Customer Service at 831-7133 : Part No. 77707-0086 for Saf-T Vent® or Saf-T Vent® CI. Part No. 77707-0087 for more information) for Z-Vent.
Page 25 Section 3. Installation Instructions 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.
Page 26 Section 3. Installation Instructions Max. 12" 4' Min. 4' Min. Min. 3" Vent Vent Termination Termination Vent 4' Min. Termination 1' Min. 4' Min. At least 7' above grade adjacent 1' Minimum Gas Meter to public above snow or Forced Air walkways finished grade Inlet...
Page 27: Outdoor Shelter Vent Installation
Section 3. Installation Instructions 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. Do not use a draft hood with this heater, as the exhaust is under pressure from the burner blower and a draft hood will allow exhaust fumes to blow into the room housing the heater.
Page 28: Control Panel Indexing
Section 3. Installation Instructions CONTROL PANEL INDEXING On an outdoor shelter installation, the exhaust discharges into a vent pipe. Top Panel Orient the heater so that the vent pipe does not interfere with adjustment of the Door operating controls. The control panel located on the top panel can be rotated to Access Panel any of the three sides of the heater for easy access, see...
Page 29: Electrical Connections
Section 3. Installation Instructions 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.
Page 30: Fireman's Switch Connection/Remote Control Connections
3. Open control box cover (see Figure 21). ® ® 4a. To connect a 2-Wire Control (such as Pentair’s IntelliTouch or EasyTouch Control Systems) or a timer: - Remove the factory installed jumper from the Fireman’s Switch terminals. - Connect wires between the Fireman’s Switch terminals on the heater and the relay.
Page 31: Mastertemp Heater Wiring Diagram
Section 3. Installation Instructions MASTERTEMP HEATER 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...
Page 32: Electrical Schematic Ladder Diagram
Section 3. Installation Instructions MASTERTEMP HEATER ELECTRICAL SCHEMATIC LADDER DIAGRAM LADDER DIAGRAM IGNITER BLOWER CLASS II TRANSFORMER 24 VAC OPERATING CONTROL 24 VAC 24 VAC FLOW LOGIC SWITCH WATER LIMIT PRESSURE SWITCH SWITCH COM NO INLET TEMPERATURE SWITCH CONTROL SWITCH GAS VALVE STACK FLUE THERMISTOR...
Page 33: Section 4. Operation
Section 4. Operation Instructions 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 34: Operating
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.
Page 35: Safety Controls
Section 4. Operation Instructions 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.
Page 36 Section 4. Operation Instructions SAFETY CONTROLS, (cont’d.) Diagnostic LED Flame Current 1 Flash - Air Flow Fault Check Point 2 Flashes - Flame No Call for Heat OPERATION OF IGNITION MODULE 3 Flashes - Ignition Lockout , (see Figure 30), The Ignition Module is microprocessor based and operates on 24VAC supplied by the transformer.
Page 37: Temperature Setting
Section 4. Operation Instructions 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.
Page 38: 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 39: Heater Will Not Fire Troubleshooting
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 correct 12-pin Check for line voltage to Restore power to heater.
Page 40 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 41 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 42 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.
Page 43: Led Diagnostics
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 44 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 450˚–500˚ in 3–5 Check Thermal minutes. Regulator: Open at 120˚? Replace Heater (HD ) Membrane Pad.
Page 45: 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 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.
Page 46: 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 47: 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 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.
Page 48: Maintaining Pool Temperature
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 49: 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 50: Replacement Parts
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. ® MASTERTEMP Pool and Spa Heater Installation and User’s Guide...
Page 51 Section 6. Maintenance/Replacement Parts 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) ®...
Page 52 Section 6. Maintenance/Replacement Parts MASTERTEMP HEATER REPLACEMENT PARTS REPAIR PARTS – BURNER SYSTEM Model Part 175NA 200NA 250NA 300NA 400NA Qty. Description 175LP 200LP 250LP 300LP 400LP Combination Gas Control Valve Kit 42001-0051S 42001-0051S 42001-0051S 42001-0051S 42001-0051S 3/4" Union 38404-4097S 38404-4097S 38404-4097S 38404-4097S...
Page 53 Section 6. Maintenance/Replacement Parts MASTERTEMP HEATER REPLACEMENT PARTS REPAIR PARTS – WATER SYSTEM Model Part 175NA - 200NA 250NA 300NA 400NA Description Qty. 175LP - 200LP 250LP 300LP 400LP Tube Sheet Coil Assembly Kit (NA, LP Series) (Includes Key No.3) 77707-0232 460747 77707-0233...
Page 54 Section 6. Maintenance/Replacement Parts MASTERTEMP HEATER REPLACEMENT PARTS REPAIR PARTS – ELECTRICAL SYSTEM Model Part 175NA - 200NA 250NA 300NA 400NA Description Qty. 175LP - 200LP 250LP 300LP 400LP Heater Display Cover 42002-0035 42002-0035 42002-0035 42002-0035 Igniter Bracket 42001-0030S 42001-0030S 42001-0030S 42001-0030S Igniter/Igniter Gasket Kit Incl.
Page 55 United States and/ or other countries. Unless expressly noted, names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa, Inc.

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Pentair 175K BTU/HR Installation And User Manual

Contents

Section 1. Heater Identification Information

Section 2. Warning and Safety Information

Section 3. Installation

Section 4. Operation

Section 5. Troubleshooting

Section 6. Maintenance

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Troubleshooting

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