Pentair Pool Products MasterTemp 200HD Page 42 Operation And Installation Manual Download

Page: 42 / 52

P/N 474131

Rev. D 27-06-11

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.

Flame is “fluttery .”

Flame is too lean.

See page 14 and verify that the gas

Exhaust may have acrid

regulator setting is 11 ± 5 Pa.

smell or burner may fail
to stay lit.

Combustion appears

Flame current is not

Check for wet or damaged igniter with

normal, but flame does

being sensed.

low resistance to ground. Replace with

not stay lit.

new igniter.

Verify burner flameholder is properly
grounded.

Ignition Control Module.

Heat Exchanger Troubleshooting

SYMPTOM

CAUSE

REMEDY

Boiling in heat exchanger.

Low water flow to heater.

pump and or filter.

May be accompanied by

Heat exchanger plugged.

Service

heat exchanger. Correct water

“bumping” sounds.

chemistry.

Bypass valve stuck open.

Service bypass valve.

Thermal governor stuck

Replace

Contact a qualified technician or service
agency to replace the gas orifice.

thermal governor.

closed.

Sweating.

Thermal governor failed.

thermal governor.

Section 5. Troubleshooting

Summary of Contents for MasterTemp 200HD

Page 1: ...e flammable materials near this appliance Do not spray aerosols in the vicinity of this appliance while it is in operation WHAT TO DO IF YOU SMELL GAS 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 t...

Page 2: ... www onga com au 2011 PentairWater Pool and Spa Inc All rights reserved PentairWater AU NZ Head Office 2 Redwood Drive Notting Hill VIC 3168 AUS 61 3 9574 4000 1620 Hawkins Ave Sanford NC 27330 USA 800 831 7133 or 919 566 8000 10951 West Los Angeles Ave Moorpark CA 93021 USA 800 831 7133 or 805 553 5000 This document is subject to change without notice Trademarks and Disclaimers MasterTemp Intelli...

Page 3: ...s Vent 21 Connecting Single Wall Stainless Steel Vent to the Heater 22 Horizontal or Vertical Venting Flexible Duct Flex Vent 24 Corrosive Vapors and Possible Causes 25 ControlPanelIndexing 25 Final Installation Check 25 Electrical Connections 26 Fireman sSwitchConnection RemoteControlConnections 27 MasterTemp Wiring Diagram Electrical Schematic Ladder Diagram 28 29 Section 4 Operation 30 Basic Sy...

Page 4: ...TE LABEL P N INPUT RATE MAX MJ Hr MODEL NO 50 HZ SEE INSTALLATION MANUAL 240 VAC DESIGNED AND MANUFACTURED BY VOLTS ORIFICE SIZE ELECTRICAL RATING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance HERTZ mm Sanford NC USA 27330 THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE AUSTRALIAN STANDARD AS5601 2004 INSTALLATION CODES AN...

Page 5: ...ON For the installer and operator of the MasterTemp pool and spa heater The manufacturer s warranty may be void if for any reason the heater is improperly installed and or operated Be sure to follow the instructions set forth in this manual 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 o...

Page 6: ...of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant women beware Soaking in water above 37 C can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 37 C maximum rule 4 Before entering...

Page 7: ...carbon monoxide meter and or by consulting with a gas professional Pool heaters must be used in conjunction with carbon monoxide detectors installed near the pool heater The carbon monoxide detectors must be periodically inspected for proper operation so as to insure continued safety Broken or malfunctioning carbon monoxide detectors must be replaced immediately WARNING This heater is equipped wit...

Page 8: ...onnect heater to 240 Volt 50 Hz Single Phase power only Verify proper operation after servicing Do not allow children to play on or around heater or associated equipment Never allow children to use the pool or spa without adult supervision Read and follow other safety information contained in this manual prior to operating this pool heater GENERAL SPECIFICATIONS NOTICE Combustion air contaminated ...

Page 9: ...ture drops below the temperature set on the operating control the burner controller supplies power to the combustion air blower through a series of safety interlocks The interlocks consist of the pressure switch PS which senses that the pump is running the high limit switch HLS which opens if the heat exchanger outlet temperature goes above 53 C 127 F and the air flow switch AFS which senses the p...

Page 10: ...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 SPECIFICATIONS Figure 2 53 3 cm 21 0 82 8 cm 32 61 58 5 cm 23 02 71 5 cm 28 15 40 6 cm 16 TOP FRONT EXHAUST SIDE PLUMBING SIDE 25 7 cm 10 13 14 2 cm 5 6 ELECTRICAL CONDUIT PORT 71 6 cm 28 2 57 7 cm 22 7 40 6 cm 16 0 ...

Page 11: ...sanitize the pool by putting chlorine tablets or sticks into the skimmer s When the pump is off this will cause a high concentration of chlorine to enter the heater which could cause corrosion damage to the heat exchanger CAUTION Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater filters or pump When chemical feeders are installed in the ci...

Page 12: ...l mass of the heater will prevent overheating of the piping connected to the pump even if the heater shuts down unexpectedly Occasionally a two speed pump will not develop enough pressure on the low speed to operate the heater In this case run the pump at high speed only to operate the heater If this does not solve the problem do not try to run the heater Instead correct the installation Do not op...

Page 13: ... heater will be over gassed and cause serious damage within minutes This damage is not covered under the heater warranty Install a manual shut off valve that conforms with Type 1 or Type 2 as per AG201 and or AS4617 standards and a sediment trap drip leg and union located outside the heater panels see Figure 6 Do not use a restrictive gas cock The heater and any other gas appliances must be discon...

Page 14: ... the gas supply to the heater 5 Turn on the heater 6 Take the gas pressure reading 7 Turn off the heater 8 Shut off the gas supply to the heater 9 Disconnect the manometer hose 10 Tighten the small screw inside the pressure tap 11 Open the gas supply to the heater 12 Verify that the seal connection in the pressure tap is closed by testing for leaks with soapy water Note If the pressure reading is ...

Page 15: ...ling of Liquid Petroleum Gases Consult local codes and fire protection authorities about specific installation restrictions Locate the heater in an open unroofed area and on a level surface that is protected from drainage or run off Install the heater in an area where leaves or other debris will not collect on or around the heater It is recommended that a non combustible base be a platform under t...

Page 16: ...PORTANT 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 This unit shall not be operated outdoors at temperatures below 7o C If the heater is located under a roof or deck overhang there must be at least 1 meter 3 ft of clearance between the bottom of the...

Page 17: ...inches 10cm beyond the base of the heater If the heater is installed in a closet or alcove the entire floor shall be covered by the panel 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...

Page 18: ...s 0 0 4 m c q s 0 8 5 2 n i q s 0 0 4 m c q s 0 8 5 2 n i q s 0 0 1 m c q s 5 4 6 n i q s 0 0 1 m c q s 5 4 6 g n i l i e c e h t t a e n o d n a l e v e l r o o l f t a e n o s g n i n e p o o w t f o e n o r o f s i d e t a c i d n i a e r A a e r A s t n a n i m a t n o C y l e k i L g n i m m i w s d e t a n i r o l h C s a p s d n a s l o o p d i c a c i t a i r u m r o c i r o l h c o r d y ...

Page 19: ...D e z i S t n e V 0 0 2 l e d o M x a m n i m t h g i e H 0 0 3 l e d o M x a m n i m t h g i e H 0 0 4 l e d o M x a m n i m t h g i e H n i 6 m m 0 5 1 t f 2 7 m 2 2 t f 6 m 8 1 t f 2 7 m 2 2 t f 0 3 m 9 e l b a t i u S t o N n i 8 m m 0 0 2 t f 2 7 m 2 2 t f 6 m 8 1 t f 2 7 m 2 2 t f 6 m 8 1 t f 2 7 m 2 2 t f 8 m 4 2 t e e F s r e t e M n i r o t c e n n o C l l a W e l g n i S h t i w t n e V ...

Page 20: ...local code requirements and AS NZS 5601 1 standards carefully during assembly and installation 150 mm 6 in minimum clearance to combustible materials Approved Termination Cap Storm Collar Flashing Firestop Vent Body Metal Flue Collar Double Wall Metal Vent Pipe Support Vertical Vent Pipe so adapter does not take weight of pipe Min 3 M 10 ft 6 15 cm Minimum Clearance to Combustible Materials Approv...

Page 21: ...d combustible surfaces Follow the vent manufacturer s instructions and code requirements Do not place any insulating materials around the vent or inside the required clear air space surrounding the vent SeeTable 7 for maximum permissible vent lengths 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 ve...

Page 22: ...rior of the heater end of the Appliance Adapter Attach the appliance adapter to the vent body using the adhesive specified by the vent manufacturer following the vent manufacturer s 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...

Page 23: ...7 in above grade adjacent to public walkways Vent Termination Vent Termination Gas Meter Max 304 mm 12 in Min 76 mm 3 in 1 2 M 4 in Min Figure 15 Figure 16 Chimney or Gas Vent Vent Cap and Riser Furnished by Installer Side Wall Vent Heater Outlet Air Opening Inlet Air Opening Figure 17 8 Vent Termination Horizontal The terminal must be located See Figure 17 at least 76 mm 3 in and at most 304 mm 1...

Page 24: ...ation related problems and or the use of a condensate trap in the vent run close to the heater may be necessary in certain installations such as cold climates Horizontal vents 1 m 3 feet or less in length do not require a condensate tee The MasterTemp heater is suitable for through the wall venting See Table 8 for maximum permissible Flexible Vent lengths CAUTION Do NOT combine exhaust vent pipes ...

Page 25: ...460738 a e r A s t n a n i m a t n o C y l e k i L g n i m m i w s d e t a n i r o l h C s a p s d n a s l o o p d i c a c i t a i r u m r o c i r o l h c o r d y h s a h c u s s d i c A s l a c i m e h c g n i n a e l c a p s r o l o o P d n a n o i t c u r t s n o c w e N s a e r a g n i l e d o m e r d n a t n i a p d n a s e h s i n r a v s t n i a p s e v i s e h d a n o i t c u r t s n o c s...

Page 26: ... in the absence of local codes with the National Electrical Standards A bonding lug is provided on the outside of the panel under the vent for this purpose 3 Electrical power circuits to the pool heater must follow local codes and National Electrical Standards 4 All wiring between the heater and devices not attached to it or between separate devices which are installed in the field must be Type T ...

Page 27: ... terminals on the heater and the external relays as shown in Figure 25 on page 28 Use at least 2 relays per heater to allow for an OFF setting on each heater mode Select relays that can handle logic level switching DO NOT apply line voltage to control board terminals Move jumper as shown in Figure 25 on page 28 to enable external control and to disable the heater membrane pad s Pool ON and Spa ON ...

Page 28: ...IGNITION CONTROL MODULE DIAGNOSTIC INDICATOR F1 F2 24 VAC S1 240 S1 120 L1 L1 L2 BM FL F1 L2 S2 TH IND VALGND GND GND BLOWER Line 2 120 VAC IGNITER TRANS Line 1 Ground JUNCTION BOX F I R E M A N S S W I T C H Replace jumper with leads to Fireman s Switch field installed 24VAC SEC Y W Y W Y R Y O Y BL O W W BK BK O GY GY BK BK R Y BK W BL Y BK W BL GY GY GY GY BK BK W R R W G Y Y R R Y Y Y W BK Y W...

Page 29: ...L 24 VAC LOGIC TH IND AIR FLOW SWITCH HI LIMIT SWITCH WATER PRESSURE SWITCH COM NO AGS SWITCH VAL GAS VALVE THERMISTOR SENSOR STACK FLUE SENSOR NOTES 1 AND TH L1 L2 F1 F2 S1 24 VAC S2 GND IND VAL ARE CONNECTED ON THE IGNITION MODULE 2 3 PIN AND SOCKET CONNECTOR IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED THEY MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT LADDE...

Page 30: ...s supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the Fire Department 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 Forced or attempted repair may result in a fire or explosion D Do not use this heater...

Page 31: ...e first time the burner may not fire on the first try because of air in the gas line If it does not fire at first push the OFF switch wait five minutes and again push the POOL or SPA ON switch The burner should fire after about 20 seconds You may have to repeat this until all of the air has cleared the gas line 13 The burner should fire until the pool spa temperature reaches the desired temperatur...

Page 32: ... it is open when the pump is off and closed when the pump is running Turn the star wheel on the switch clockwise to raise setting heater below the pool and counterclockwise to lower the setting heater above the pool see Figure 30 Test the switch after resetting NOTICE When the heater is mounted more than 1 5M 5 ft above or 1 2M 4 ft below the deck level a Pressure Switch is no longer adequate A Fl...

Page 33: ...ion to the digital temperature display there are five indicator lights The POOL ON light indicates that the pool water temperature is governing operation of the heater The SPA ON light indicates that the spa water temperature is governing operation of the heater The HEATING light comes on and stays on when the burner is firing This light should be on whenever the burner is on It blinks when the he...

Page 34: ...anel board on the underside of the top cover Locate the yellow button on the corner of the control board 3 Push the Max Temp Set Point button on the back of the control board see Figure 34 The following sequence should happen A The unit turns on and the POOL ON light will turn on B Press the TEMP or TEMP pad on TOP of the panel to set maximum pool temperature C Wait up to 30 seconds the POOL ON li...

Page 35: ... or THERMISTOR on NO NO NO NO NO YES YES YES NO YES YES Does red SERVICE HEATER LED come on Verify that water temperature setting is above water temperature reading If it is and heater either will not fire or no red LED s come on replace Control Board YES Is green POOL or SPA LED on Is red SERVICE SYSTEM LED on Is red SERVICE HEATER LED on Turn off power to heater for about 5 seconds and turn back...

Page 36: ...k for line voltage to heater Check for 24 VAC at sec ondary of Transformer Check for Line Voltage at Transformer primary pins White connects to Pin 3 on Transformer Black to Pin 2 Orange to Pin 1 240V check Pin1 to Pin 3 Jumper Fireman s Switch at Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on Leaving jumper in place check for 24 VAC between Fireman s...

Page 37: ...red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above the minimum requirement Check that water pressure is within the adjustment range of the Pressure Switch 0 35 kPa Verify that switch wiring is OK and Pressure Switch port is not blocked and replace water Pressure Switch Check whether any of the red diagnostic LED s on back of board AGS AFS SFS HLS or ...

Page 38: ...for heat SEE NOTE 2 Turn off power to heater for 5 seconds and turn back on Make sure tempera ture setting is above water temperature Wait one minute Does heater fire and stay on Did Blower come on Verify that gas is flow ing to burner during ignition try Observe gas meter for move ment during ignition try wait for about 30 seconds after calling for heat Check for 24 VAC between TH and GND termina...

Page 39: ... If your ICM is good your meter will read some voltage between 0 and 240 VAC Exactly what reading you get will depend on the meter but with a good ICM the reading won t be 0 VAC or 240 VAC but somewhere in between IMPORTANT READ ME FIRST Gas flows during igni tion try but burner does not fire NO NO YES Go back to chart HEATER WILL NOT FIRE C Page 38 Check voltage across igniter leads OK Replace Ig...

Page 40: ...replace Blower Replace Blower Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board YES YES NO NO NO YES YES NO AFS on Does Blower operate THERMISTOR on Verify Thermistor wiring If OK replace Thermistor Disconnect Blower and check for line voltage between pins 1 and 3 of Blower Connector on ignition try Connect c...

Page 41: ... Does sensor check OK Clean tighten pins as needed Reset power to Heater and retry Heater should fire NOT OK NO NO NO NO NO SFS on Replace Stack Flue Sensor Correct Fuel Supply reset Heater and retry Heater should fire correctly Repeat checks on fuel supply Thermal Regulator check for correct orifices etc DONE DONE YES YES YES YES NO NO YES NO OK YES Replace Heater Control Board Replace Heater Mem...

Page 42: ...ow resistance to ground Replacewith not stay lit new igniter Verify burner flameholder is properly grounded Ignition Control Module Heat Exchanger Troubleshooting SYMPTOM CAUSE REMEDY Boiling in heat exchanger Low water flow to heater pump and or filter May be accompanied by Heat exchanger plugged Service Service heat exchanger Correct water bumping sounds chemistry Bypassvalve stuck open Service ...

Page 43: ...erson of sufficient skill The heater MUST be disconnected from the pool plumbing gas plumbing and electric The heater may be placed on its side with the water manifold up The diluted muriatic acid may be recirculated until visible bubbles are no longer produced Before being restored to service the heater water ways should be completely rinsed with regular tap water PRESSURE RELIEFVALVE Local codes...

Page 44: ...f air temperatures are expected to drop below freezing 0 C 32 F shut down the heater and winterize it For outdoor heaters in freezing climates shut the heater down and drain it for winter as follows 1 Turn off electrical supply to the heater and pump 2 Close the external manual shut off gas valve located outside the heater 3 In colder climates where they may be required open drain cock located on ...

Page 45: ...e heater and the chlorinator to prevent concentrated chemicals from back siphoning into the heater Back siphoning 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 When the pump is off this will cause a high concentration of chlorine to enter the heater which could cause corrosion d...

Page 46: ...higher or bromine residual is 6 0 ppm or higher See your local pool supply store for help in properly balancing your water chemistry RULE Chemicals that are acid lower pH Chemicals that are alkaline raise pH ALKALINITY High or Low Total alkalinity is a measurement of the total amount of alkaline chemicals in the water and control pH to a great degree It is not the same as pH which refers merely to...

Page 47: ...u call Customer Support AU NZ at 1800 664 266 USA at 1 800 831 7133 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 For complete Water System parts breakdown Key Nos 8 through 9 see Page 50 1 2 3 5 6 4 8 9 7 Combustion Chamber Clamp Assy ...

Page 48: ...P N 474131 Rev D 27 06 11 48 MASTERTEMP REPLACEMENT PARTS Lead Anchor For Heater mounting bolts and clamps purchase separately Bolt Down Bracket Kit Part No 460738 ...

Page 49: ... Plate Gasket 9 Blower Adapter Plate 10 Flameholder Adapter Plate Gasket 11 Flameholder Assembly 12 Flameholder Combustion Chamber Gasket 13 Flameholder Insulation Cap Flameholder Insert 14 Condensate Evaporator Plate 15 One Piece Metal Chamber Combustion Chamber Assembly 474095 474095 474095 Insulation Kit Includes Key Nos 13 14 16 17 18 and 19 77707 0008 77707 0008 77707 0008 16 Bottom Outer Ins...

Page 50: ...os 3 5 1 77707 0120 77707 0120 77707 0120 6 Manifold Insert 1 7 Manifold Baffle Plate 8 Manifold Bypass Valve 1 1 9 Water Pressure Switch 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16 18 x 2 3 4 Hex Cap Screw 10 13 Connector Tube O Ring 2 14 Connector Tube Kit Includes 1 Connector Tube and 1 O Ring 2 77707 0017 77707 0017 77707 0017 15 Thermal Regulator Kit Incl K...

Page 51: ...a 1 474171Z 474171Z 474171Z 7 Thermistor 1 42001 0053S 42001 0053S 42001 0053S 8 Terminal Board 1 1 1 1 1 42001 0056S 42001 0056S 42001 0056S 9 Fireman s Switch Fuse 31 75 mm X 6 35 mm 32850 0099 32850 0099 32850 0099 10 Ignition Control Module Australia 1 474103Z 474103Z 474103Z 11 Transformer 120 240V 1 42001 0107S 42001 0107S 42001 0107S 12 Air Flow Switch 42001 0061S 42001 0061S 42001 0061S 13...

Page 52: ...Spa Inc 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 If you have any questions about use of this product or safety precautions contact Pentair s Customer Service and Technical Support at 1800 664 266 AUS 61 3 9574 4000 Victoria AUS or 800 831 7133 USA orvisitwww pentairpool com safety 353850 ...

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