STA-RITE Max-E-Therm Operation & Installation Manual Download

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This document is subject to change without notice.

1620 Hawkins Ave., Sanford, NC 27330 • (800) 831-7133 • (919) 566-8000

10951 West Los Angeles Ave., Moorpark, CA 93021 • (800) 831-7133 • (805) 553-5000

Attention Installer

Please give this manual to the owner and/or
operator once installation is complete.

Attention User

Please retain this manual for future reference, it
contains important information that will help you in
operating and maintaining this heater.

Call (800) 831-7133 for additional free copies of these instructions.

Summary of Contents for Max-E-Therm

Page 1: ...s AngelesAve Moorpark CA 93021 800 831 7133 805 553 5000 Attention Installer Please give this manual to the owner and or operator once installation is complete Attention User Please retain this manual for future reference it contains important information that will help you in operating and maintaining this heater Call 800 831 7133 for additional free copies of these instructions ...

Page 2: ...med by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this heater or other appliances 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 ...

Page 3: ...rk CA 93021 800 831 7133 or 805 553 5000 293 Wright Street Delavan WI 53115 262 728 5551 This document is subject to change without notice Trademarks and Disclaimers Sta Rite Max E Therm IntelliTouch and 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 counties Saf T Vent is a registered tradem...

Page 4: ... S or Outdoor Shelter for Canada 20 Vertical Venting Negative Pressure 20 22 Horizontal or Vertical Venting Positive Pressure 23 Connecting Special Gas Venting 23 25 Outdoor Shelter Installation 26 Garage or Utility Room Installation 26 ControlPanelIndexing 27 Final Installation Check 27 Electrical Connections 28 Fireman sSwitchConnection RemoteControlConnections 29 Max E Therm WiringDiagram 30 El...

Page 5: ...P N S794 Rev B 6 23 08 4 Max E Therm Pool and Spa Heater ...

Page 6: ...staller and operator of the Max E Therm 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 any more information or if you have any questions regarding to this pool heater please contact Pentair Water Pool and Spa Inc at 800 831 7133 WARRANTY INFORMAT...

Page 7: ...ersons with a medical history of heart disease circulatory problems diabetes or blood pressure problems should obtain their physician s advice before using spas or hot tubs 6 Persons taking medication which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs WARNING Should overheating occur or the gas supply fail to shut off turn off the manual ...

Page 8: ...ld 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 Serious malfunction of the burner can occur which may result in loss of life Any additions changes or conversions required in order for the appliance to satisfactorily meet the app...

Page 9: ... heater 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 Do not op...

Page 10: ...e heat exchanger outlet temperature goes above 135 F 57 C and the air flow switch AFS which senses the pressure drop across the air metering orifice the automatic gas shut off AGS switch which opens if the heat exchanger outlet temperature goes above 140 F 60 C the stack flue sensor SFS which shuts down the heater if the flue gas temperature reaches 500 F 260 C The air flow switch AFS senses the p...

Page 11: ...tion 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 SPECIFICATIONS DIMENSIONS IN INCHES Figu...

Page 12: ... 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 damage to the heat exchanger CAUTION Exercise care when installing chemical feeders so as to not allow back siphoning of c...

Page 13: ... unions provided Heat sinks are not required The low thermal 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 t...

Page 14: ... dynamic inlet pressure while the heater is running of 4 10 2cm wc is required to maintain input rating with no more than a 2 pressure drop between static and dynamic The gas supply must be installed in accordance with the National Fuel Gas Code ANSIZ223 1 or standard CSA B149 1 Natural Gas and Propane Installation Codes as applicable and all applicable local codes Install a manual shut off valve ...

Page 15: ... R O F G N I Z I S E P I P H T G N E L E P I P T N E L A V I U Q E M U M I X A M t F t o o F c i b u C r e p U T B 0 0 0 1 t a s a G l a r u t a N t o o F c i b u C r e p U T B 0 0 5 2 t a s a G e n a p o r P L E D O M 2 1 4 3 1 4 1 1 2 1 1 2 2 1 2 T A N O R P T A N O R P T A N O R P T A N O R P T A N O R P T A N O R P T A N O R P 0 0 2 0 2 0 3 0 8 5 2 1 0 5 2 0 5 4 0 0 6 3 3 3 0 1 0 3 0 5 0 0 1 0...

Page 16: ...vice agency These instructions are for the use of qualified service technicians only This appliance is equipped with an unconventional gas control valve that is factory set with a manifold pressure of 2 0 5cm wc Installation or service must be performed by a qualified installer service agency or the gas supplier If this control valve is replaced it must be replaced with an identical control The co...

Page 17: ...nments In extreme weather shut down the heater and disconnect the power to it until the weather has moderated In areas subject to hurricanes or very high winds purchase the Bolt Down Bracket Kit P N 42001 0085S see Figure 8 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...

Page 18: ...operty Line 4 4 6 3 SIDE VIEW Building Window Exhaust Grill Vent Exhaust Grill Vent 6 in 4 ft Figure 11 Must be at least 3 ft 9M above any forced air inlet located within a 10 ft 3M radius Vent Termination Must be located 6 in 15 24cm away from the building wall and at the following distances away from any door window or gravity air inlet 10 ft 3M below 10 ft 3M horizontally Check local building c...

Page 19: ... length of the horizontal run must not exceed the length that is listed in table 11 on page 23 HEATER CLEARANCES General Requirements INDOOR INSTALLATION U S OR OUTDOOR SHELTER CANADA The following clearances must be maintained from combustible surfaces TOP 6 in 15 cm ALL SIDES 6 in 15 cm VENT 6 in 15 cm Note The heater is design certified by CSA International for installation on combustible floor...

Page 20: ...9 2 1 n i q s 0 5 m c q s 3 2 3 n i q s 0 5 m c q s 3 2 3 3 3 3 n i q s 3 3 3 m c q s 9 4 1 2 n i q s 3 3 3 m c q s 9 4 1 2 n i q s 4 8 m c q s 2 4 5 n i q s 4 8 m c q s 2 4 5 0 0 4 n i q s 0 0 4 m c q s 1 8 5 2 n i q s 0 0 4 m c q s 1 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 ...

Page 21: ...eight the vertical distance from the flue collar to the vent termination and which have three or less elbows in the system For venting systems which do not meet these conditions consult the National Fuel Gas Code ANSI Z223 1 U S or the standards CSAB149 1 and B149 2 Canada Read VERTICAL VENTING NEGATIVE PRESSURE before using this table Table 10 Permitted Minimum and Maximum Vent Heights By Size an...

Page 22: ...rchangeable Mixing parts from more than one manufacturer may cause leaks or damage to vent When assembling a vent pick one manufacturer and be sure that all vent parts come from that manufacturer and are specified by the manufacturer for your system Follow manufacturer s instructions local code requirements National Fuel Gas Code requirements U S or standards CSA B149 1 and B149 2 Canada carefully...

Page 23: ... drain manufacturer s installation instructions 5 Use Listed fire stop for floor and ceiling penetrations Use Listed thimble for wall penetrations 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 fire stop with insulation The roof opening must be located so that the vent is vertical 6 ...

Page 24: ... the absence of a clearance recommendation by the vent pipe manufacturer the requirements of the Uniform Mechanical Code should be met The ventilation air requirements for the Max E Therm heater can be found on page 19 It is recommended that vent runs over 18 feet may need to be insulated to reduce condensation related problems and or the useofacondensatetrapintheventrunclosetotheheatermaybenecess...

Page 25: ...on the heater or vent body It is recommended to slope the horizontal pipe runs up from the heater at least 1 4 per foot 2cm M Install Approved condensate drains at low points where condensate might collect Plumb condensate drains to a drain through hard piping or high temperature tubing such as silicone rubber or EPDM rubber do not use vinyl or other low temperature tubing Follow drain manufacture...

Page 26: ...a See Figure 18 at least 10 feet 3 3M from any opening into a building at least 12 3M above 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 2 1M above grade adjacent to walkways or similar traffic areas Allow at least three feet 1M vertical clearance...

Page 27: ... local codes and fire protection authorities about specific installation restrictions The heater is design certified by CSA International for installation on combustible flooring in alcoves basements in closet or utility rooms in the U S GARAGE OR UTILITY ROOM INSTALLATION In Canada the heater must be installed in a room that is not normally occupied and has no openings directly to occupied areas ...

Page 28: ... or low spots Check that vent is supported at elbows tees and horizontal and vertical runs according to manufacturer s instructions and code requirements Check that vent supports and wall and ceiling penetrations allow free movements up down and sideways without putting any strains on the heater or vent body Check for at least six inch 15cm free air clearance between the heater vent pipe and combu...

Page 29: ...n Electrical Code as applicable Abonding 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 Code or Canadian Electrical Code as applicable 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 wi...

Page 30: ...the control board terminals on the heater and the external relays as shown in Figure 26 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 on Figure 26 to enable external control and to disable the heater membrane pad s Pool ON and Spa ON butto...

Page 31: ...ine 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 R R Y Y Y W BK Y...

Page 32: ...TROL 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 LA...

Page 33: ... 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 34: ...OL PANEL 14 The blower should come on immediately and after about 20 seconds the burner should fire When operating for the 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...

Page 35: ...o that 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 32 Test the switch after resetting NOTICE When the heater is mounted more than five feet 1 5M above or four feet 1 2M below the deck level a Pressure Switch is no long...

Page 36: ...s 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 heater is calling for heat but not firing If this light is on but the burner fails to come on one of the service lights should come on...

Page 37: ...yellow button on the corner of the control board 4 Push the Max Temp Set Point button on the back of the control board see Figure 36 The following sequence should happen A The unit will come on and the POOL ON light will come 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 light will go off and the SPA ON light will come on To...

Page 38: ...me 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 on Make sure tempera ture setting is above water temperature Wait one minute Do any diagnostic LED s on back of board AGS AFS SFS HLS PS or THERMISTOR come on and stay on NOTICE Any or all of the diag nostic LED s may come ...

Page 39: ...dary 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 120V check Pin 2 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 Switch terminals and ground ...

Page 40: ...ement Model Flow 200 20 gal min 76 LPM 333 30 gal min 114 LPM 400 40 gal min 151 LPM Is red SERVICE HEATER LED on YES YES NO YES NO NO Is 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 5 psig Verify that switch wiring is OK and Pressure Switc...

Page 41: ...r 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 terminals...

Page 42: ...d 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 40 Check voltage across igniter leads OK Replace Ignition Control Module On a 120 V install...

Page 43: ...Switch AFS If problem persists 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 Conn...

Page 44: ...es 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 Membra...

Page 45: ...for wet or damaged igniter with normal but flame does being sensed low 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 Co...

Page 46: ...ce technician if you suspect that the burner may require maintenance PRESSURE RELIEFVALVE Some U S local codes may require installation of a pressure relief valve PRV Purchase separately and install a 3 4 pressure relief valve complying with the ANSI ASME Boiler and Pressure Vessel Code having a capacity equal to the Btu hr rating of the heater The relief pressure of the valve MUST NOTEXCEED 50 PS...

Page 47: ...n it for winter as follows see Figure 38 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater Turn switch on heater gas valve to OFF 3 In northern climates where they may be required open drain cock located on the bottom of the manifold adapter and drain the heat exchanger and manifold adapter completely If heater is bel...

Page 48: ...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 dam...

Page 49: ...gher 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 t...

Page 50: ... cannot supply you call Customer Support at 1 800 831 7133 4 1 3 4 5 6 8 10 9 2 7 12 1 For complete Electrical System parts breakdown Key Nos 1 through 4 See Page 53 For complete Burner System parts breakdown Key Nos 5 through 9 See Pages 51 and 52 For complete Water System parts breakdown Key Nos 10 through 12 See Page 52 ...

Page 51: ...8 50 MAX E THERM REPLACEMENT PARTS 1 2 3 4 5 6 7 2 8 9 10 11 12 13 14 15 16 17 19 18 20 21 22 23 24 25 26 27 28 For Heater mounting bolts and clamps purchase separately Bolt Down Bracket Kit Part No 42001 0085S Lead Anchor ...

Page 52: ... Nos 10 11 12 13 and on 333 400 models only Flameholder Insert 77707 0202 77707 0203 77707 0204 8 Blower Adapter 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 15 Condensate Evaporator Plate 16 One Piece Metal Chamber Combustion Chamber Assembly 42001 0200S 420...

Page 53: ... 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16x18x2 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 Key Nos 16 17 18 19 and Spring Clip 77707 0010 77707 0010 77707 0010 16 Thermal Regulator Includes Spring Clip 38000 0007S 38000 0007S 38000...

Page 54: ...2001 0061S 42001 0096S 42002 0007S 15 Control Board Kit NA LP Series 1 42001 0104S 1 1 1 1 42001 0105S 16 Junction Box Cover Kit 1 77707 0022 Control Board Enclosure Membrane Panel Kit 1 77707 0004 HD Series Includes Key Nos 17 and 18 Control Board Enclosure Membrane Panel Kit 1 77707 0013 NA LP Series Includes Key Nos 17 and 18 Control Board Enclosure 18 17 Membrane Pad HD Series 18 Membrane Pad ...

Page 55: ...P N S794 Rev B 6 23 08 54 NOTES ...

Page 56: ...Rev B 6 23 08 P N S794 55 NOTES ...

Page 57: ...rights reserved This document is subject to change without notice 1620 Hawkins Ave Sanford NC 27330 800 831 7133 or 919 566 8000 10951 W Los Angeles Ave Moorpark CA 93021 800 831 7133 or 805 553 5000 293 Wright Street Delavan WI 53115 262 728 5551 SAVE THESE INSTRUCTIONS ...

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