Pentair 400K BTU/HR manual

POOL AND SP A HEA TER 120/240 V AC NA TURAL GAS/LP GAS INSTALLATION and USER’S GUIDE MODELS Natural Propane 200K B TU/HR 460730 460731 250K B TU/HR 460732 460733 300K B TU/HR 460734 460735 400K B TU/HR 460736 460737 IMPOR T ANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SA VE THESE INSTRUCTIONS If the information in these instructions i[...]

INST ALLA TION, OPERA TION AND SERVICE MANUAL TO INSTALLER: Affix these instructions adjacent to the heater. T O CONSUMER: Retain these instructions f or 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 [...]

SAFET Y INSTRUCTIONS ( Continued ) 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 quali[...]

The heater may not be installed within five feet of the inside surface of a pool or spa unless it is separ ated by a solid fence, wall or other permanent barrier . A Propane (LPG) fired heater must not be installed in a garage in Massachusetts, by order of the Massachuset ts State Fire Marshall. For more inf ormation, call the Fire Marshall’ s of[...]

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 at tempted 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 techn[...]

8. Push the toggle switch away from you to switch the gas on. 9. Replace the Door Access P anels. All panels must be in place when operating the heater . 10. Set 3-way v alves on inlet and outlet to pool or spa, as appropriate. 11. T urn on all electric power to the appliance. 12. Press either the POOL ON or SPA ON button switch on the operating co[...]

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 qualified se[...]

CARE AND MAINTENANCE MAINTENANCE INSTRUCTIONS Risk of fire or explosion from flammable vapors. Do not store gasoline, cleaning fluids, v arnishes, 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 t[...]

OUTDOOR INST ALL A TION INSTRUCTIONS For heaters located outdoors, using the built -in stackless venting system. 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 build[...]

CONTROL P ANEL 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 f ollows: 1. Remove the bolts from the door panels. R emove both door panels. 2. Remove the f our corner screws that secure [...]

NOTICE: Combustion air contaminated by corrosive chemical fumes can damage the heater and will void the warr anty (See T able 1 below). HEA TER CLEARANCES – OUTDOOR SHEL TER (Canada) or INDOOR (U.S. ) The following clear ances must be maintained from com- bustible surfaces: TOP ......................................3 ft. (1 m) EXHAUST SIDE ......[...]

OUTSIDE VENT COVER REMOV AL The heater is supplied from the factory with a built -in stackless outside vent for outdoor installation. R emove the outside vent cover f or outdoor shelter installation. VER TICAL VENTING - NEGA TIVE PRESSURE (See Figures 11 and 12) V ent the heater vertically in a negative pressure (positive dr aft) system in accordan[...]

5. Use Listed firestop for floor and ceiling penetrations. Use Listed thimble for wall penetr ations. 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 [...]

Risk of fire or asphyxiation if vent is not assembled according to manufacturer’ s instructions or if vent parts from different manuf acturers are mixed. V ent parts from different manuf acturers 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[...]

The terminal must be located (Canada): • at least 10 feet (3.3M) from any opening into a build- ing. • at least 12" (.3M) abov e finished grade or the normally expected snow accumulation level, whichever is higher • At least 4 feet (1.2M) horizontally from electric meters, gas meters, regulators and relief equipment • At least 7 feet ([...]

Install a check valv e to prevent back -siphoning through the heater when the pump is off . NOTICE: Improper operation of chemical f eeders can cause severe damage to the heater which is not covered by the warr anty . Install the chemical feeder downstream of the heater (see “W ater Chemistry , ” below). Install a chemical resistant one-way che[...]

17 V erify proper operation of the w ater 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 of f , and then turn off the filter pump. 3. T urn up the thermostat as though to fire the burner . 4.[...]

18 PRESSURE RELIEF V AL VE Canadian code requires and some U.S. local codes may require installation of a pressure relief valv e. Purchase separately and install a 3/4" pressure relief valve comply- ing with the ANSI/ASME Boiler and Pressure V essel Code, having a capacity equal to the Btu/hr r ating of the heater . The relief pressure of the [...]

19 Risk of fire and explosion. Improper inst allation, adjustment, alteration, service, or main- tenance of the Combination Gas Control V alve 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[...]

20 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[...]

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 [...]

22 6. Reinstall the access door panels. The fuse for the Fireman’ s Switch is a 1.25 amp 1-1/4x1/4" f ast blow fuse, av ailable locally . MAXIMUM TEMPERA TURE 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 [...]

23 Hazardous voltage. Can shock, burn or kill. Disconnect power before servicing any components. Fire and Explosion hazard. Do not jumper switch terminals to remedy a failed safety switch. W ARNIN G W ARNIN G Initial T roubleshooting Only qualified, trained service technicians with appropriate test equipment should service the heater . Remember tha[...]

24 Heater Will Not Fire - A S tart GO TO “HEA TER WILL NOT FIRE - B” Page 25 Heater should fire on demand for heat. Check Fireman’s Switch circuit connections (time clock, wiring, external controller relay). Remove jumper . Check wiring between T ransformer and J7 terminals on Control Board and between J7 and Fireman’s Switch on T erminal B[...]

25 Heater Will Not Fire - B S tart Increase POOL/SP A 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 flo[...]

26 Heater Will Not Fire - C S tart 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 a[...]

27 Heater Will Not Fire - D S tart IMPORT ANT! READ ME FIRST!! If your heater is correctly connected to 240 V olts AC, The Ignition Control Module (ICM) will convert the 240V AC 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 IC[...]

28 Diagnostic LED’ s: AGS, AFS, HLS, PS, THERMIST OR Do not jumper a safety switch to remedy a failed switch. NOTE: ES1 is a spare and should be jumpered. CAUTIO N Service pump and filter to restore proper flow . After ser- vicing, verify proper operation of Pressure Switch (PS). Replace thermistor or Control Board to correct overheating. Replace[...]

29 Diagnostic LED’ s: SFS NO (HD ) NO (Basic) NO Reset power to Heater and retry . Heater should fire. Does the Digital T emperature Display show Error Code “E05” or “E06”? Heater start s and runs OK, but temperature of exhaust climbs to 450º–500º in 3–5 minutes. Heater start s after several tries, exhaust temperature stays below 25[...]

30 Burner T roubleshooting SYMPT OM CAUSE REMEDY Loud, high-pitched whine Flame is too rich. V erify pressure tap between gas valve and blower inlet. T urn to Page 19 and verif y 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[...]

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33 REP AIR P AR TS – BURNER SYSTEM Model Key Part 200NA 250NA 300NA 400NA No. Description Qty . 200LP 250LP 300LP 400LP 1 Combination Gas Control V alve 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)† 77[...]

34 REP AIR P AR TS – W A TER SYSTEM 1 3 20 21 22 4 5 8 9 12 11 10 2 7 6 19 14 15 13 18 17 16 * Not available separately . • Not illustrated. Model Key Part 200NA 250NA 300NA 400NA No. Description Qty . 200LP 250LP 300LP 400LP 1 T ube Sheet Coil Assembly Kit (NA, LP Series) (Includes Key No.3) 1 77707-0232 460747 77707-0233 77707-0234 2 Manifold[...]

35 REP AIR P AR TS – ELECTRICAL SYSTEM 3 8 9 1 0 11 12 4 5 19 1 3 18 15 4 2[...]

36 Pool Heater Wiring Connection Diagram Plug –12 pin 120V – Black 240V – Red JMP 9 1 J6 JMP 1 JMP 1 External Control Interface Circuit Disabled, Heater Membrane P ad Enabled External Control Interface Circuit Enabled, "P ool On" and "Spa On" K eys Disabled. "OFF" K ey on Membrane P ad Remains Functional . CONNEC[...]

37 Pool Heater Electrical Schematic Ladder Diagram L1 L2 120/240 VA C 120/240 VA C IGNITER L1 S1 S2 L2 F1 F2 BLOWER GND GND CLASS II TRANSFORMER 24 V AC 24 V AC 24V OPERA TING CONTROL 24 V AC LOGIC TH IND AIR FLOW SWITCH HI LIMIT SWITCH WA T E R PRESSURE SWITCH COM NO AGS SWITCH VA L GAS V AL VE THERMIST OR SENSOR ST A CK FLUE SENSOR NO TES: 1.) AN[...]

© 2006 Pent air W ater Pool and Sp a, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles A ve., Moorpark, CA 93021 • (805) 553-5000 T rademarks and disclaimers: MasterT emp and the Pentair Pool Product s and Pentair W ater Pool and S pa logos a[...]