Pentair Pool Products MasterTemp 200HD User manual

Rev. B 2-26-10 P/N 474131
1
1
MasterTemp (Australia)
Pool & Spa Heater (Indoor & Outdoor use)
OPERATION & INSTALLATION MANUAL
WARNING
Pentair Water AU/NZ – Head Office – 2 Redwood Drive, Notting Hill, VIC 3168 – AUS • [phone] • 1800 664 266
Pentair Water Pool and Spa, Inc.
1620 Hawkins Ave., Sanford, NC 27330, USA • [phone] • [phone]
10951 W. Los Angeles Ave., Moorpark, CA 93021, USA • [phone] • [phone]
1
Consumer
Retain For
Future
Reference
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 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'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.
240 VAC NATURAL GAS/LP GAS
MODELS Natural Propane
200HD (210 MJ/h) 460946 460949
300HD (300 MJ/h) 460945 460948
400HD (400 MJ/h) 460944 460947
FOR YOUR SAFETY – Thisproductmustbeinstalledandserviced
by authorized personnel, qualified in pool/spa heater installation.
Improperinstallationand/oroperationcancreatecarbonmonoxide
gasandfluegaseswhichcancauseseriousinjury,propertydamage,
ordeath.Asanadditionalmeasureofsafety,PentairWaterPooland
Spa,Inc.stronglyrecommendsinstallationofsuitableCarbonMonoxide
detectors in the vicinity of this heater. Improper installation and/or
operationwillvoidthewarranty.

P/N 474131 Rev. B 2-26-10
2
Customer Service
If you have questions about ordering Pentair Water Pool and Spa®replacement parts, and pool
products, please use the following contact information.
Customer Service and Technical Support, AUS (AEST Time)
Phone:[phone]
Fax:[phone]
Notting Hill, Victoria, AUS (AESTTime)
Phone: [phone]
Customer Service and Technical Support, USA (8 A.M.to 4:30 P.M.Eastern/Pacific Times)
Phone: [phone]
Fax: [phone]
Sanford, North Carolina, USA (8 A.M.to 4:30 P.M.— Eastern Time)
Phone:[phone]
Fax:[phone]
Moorpark, California, USA (8 A.M.to 4:30 P.M.— PacificTime)
Phone:[phone]
Fax:[phone]
Web site
visit
www.pentairpool.com or www.staritepool.com or www.onga.com.au tofindinformationaboutPentair
products
© 2010 Pentair Water Pool and Spa, Inc. All rights reserved.
Pentair Water AU/NZ – Head Office – 2Redwood Drive,Notting Hill,VIC3168– AUS •[phone]
1620HawkinsAve., Sanford,NC 27330–USA• [phone]or(919)566-8000
10951WestLos AngelesAve.,Moorpark, CA93021– USA•[phone]or [phone]
This document is subject to change without notice.
Trademarks and Disclaimers:MasterTemp™, IntelliTouch™, EasyTouch™, and Pentair Water Pool and Spa®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.
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.

Rev. B 2-26-10 P/N 474131
3
Table of Contents
Section 1. Heater Identification Information ....................................................................... 4
Section 2. Introduction .......................................................................................................... 5
ImportantNotices................................................................................................................................................................................. 5
WarrantyInformation ............................................................................................................................................................................ 5
CodeRequirements.............................................................................................................................................................................. 6
ConsumerInformationandSafetyInformation ...................................................................................................................................... 6 - 8
GeneralSpecifications ......................................................................................................................................................................... 8
Section 3. Installation ............................................................................................................. 9
HeaterDescription................................................................................................................................................................................ 9
SequenceofOperation......................................................................................................................................................................... 9
Puttingthe HeaterintoService ............................................................................................................................................................ 9
Specifications ...................................................................................................................................................................................... 10
PlumbingConnections.......................................................................................................................................................................... 11
Valves .................................................................................................................................................................................................. 11
ManualBy-Pass .................................................................................................................................................................................. 11
Water Connections ............................................................................................................................................................................... 12
BelowPoolInstallation ......................................................................................................................................................................... 12
GasConnections ................................................................................................................................................................................. 13
Gas Pipe Sizing ................................................................................................................................................................................... 13
SedimentTrap/DripLeg ....................................................................................................................................................................... 13
Testing GasLeaks andGas Pressure .................................................................................................................................................. 14
GasPressureRequirements ................................................................................................................................................................ 14
OutdoorInstallation .............................................................................................................................................................................. 15
HeaterClearances................................................................................................................................................................................ 15
OutsideInstallationVentingGuidelines ................................................................................................................................................. 16
CorrosiveVaporsandPossibleCauses ................................................................................................................................................ 17
ControlPanelIndexing ......................................................................................................................................................................... 17
FinalInstallationCheck ........................................................................................................................................................................ 17
ElectricalConnections.......................................................................................................................................................................... 18
Fireman’sSwitchConnection/RemoteControlConnections.................................................................................................................. 19
MasterTempWiringDiagram................................................................................................................................................................. 20
ElectricalSchematicLadderDiagram ................................................................................................................................................... 21
Section 4. Operation............................................................................................................... 22
BasicSystemOperation ...................................................................................................................................................................... 22
HSI(Hot-SurfaceIgnition)Lighting/Operation ....................................................................................................................................... 22
OperatingInstructions .......................................................................................................................................................................... 23
To Turn Off Gas toAppliance............................................................................................................................................................... 23
SafetyControls .................................................................................................................................................................................... 24 - 26
Section 5. Troubleshooting ................................................................................................... 27
InitialTroubleshootingandTroubleshootingChart ................................................................................................................................. 27
HeaterWillNotFireTroubleshooting .................................................................................................................................................... 28- 31
LEDDiagnostics .................................................................................................................................................................................. 32- 33
Burner/HeatExchangerTroubleshooting ............................................................................................................................................ 34
Section 6. Maintenance.......................................................................................................... 35
CareandMaintenance.......................................................................................................................................................................... 35
PressureReliefValve........................................................................................................................................................................... 35
After Start-Up ...................................................................................................................................................................................... 36
Spring,FallandWinterOperation ......................................................................................................................................................... 36
MaintainingPoolTemperature ............................................................................................................................................................... 37
EnergySavingTips.............................................................................................................................................................................. 37
ChemicalBalance ................................................................................................................................................................................ 37 - 38
ReplacementParts .............................................................................................................................................................................. 39 - 43

P/N 474131 Rev. B 2-26-10
4
To identify the heater, see rating plate on the inner front panel of the heater. There are two designators for each
heater, one is the Model Number and the other is the Heater Identification Number (HIN).
a. Heater Identification Number (HIN)
The following examplesimplifiestheidentificationsystem:
1) MT : MasterTemp
2) Model Size : (200, 300 or 400) : Input rating (Mega Joule [MJ]/hr)
3) Fuel Type : (LP = Propane gas or NA = Natural gas)
4) Construction : (HD = Heavy Duty Model)
Section 1. Heater Identification Information
Heater Identification Information
HEATER IDENTIFICATION INFORMATION — (HIN)
MT 200 NA HD
MT = MASTERTEMP
FUEL TYPE =
CONSTRUCTION =
MODEL SIZE = MJ INPUT = Mega Joule [MJ] / HR
H. I. N.
HEATER IDENTIFICATION NUMBER
ID DESIGNATOR FOR PENTAIR WATER POOL & SPA MASTERTEMP HEATERS
HD = HEAVY DUTY MODEL
NA = NATURAL GAS
LP = PROPANE GAS
Example:
1 2 3 4

Rev. B 2-26-10 P/N 474131
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MasterTemp (Australia)
Pool and Spa Heater (Indoor & Outdoor use)
Congratulations on your purchase of a MasterTemp high performance heating system. Proper installation and service of
your new heating system and correct chemical maintenance of the water will ensure years of enjoyment. The MasterTemp
is a compact, lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly
connected to schedule 40 PVC pipe. The MasterTemp also comes equipped with the Pentair Water Pool and Spa®
multifunction temperature controller which shows, at a glance, the proper functioning of the heater. All MasterTemp
heaters are designed with a direct ignition device, HSI (hot-surface ignition), which eliminates the need for a standing
pilot. The MasterTemp requires an external power source (240 VAC 50 Hz) to operate.
SPECIAL INSTRUCTIONS TO OWNER: Retain this manual for future reference. This instruction manual provides
operating instructions,installation andserviceinformation for theMasterTemphighperformanceheater.Theinformationin
this manual applies to all MasterTemp models. READ AND REVIEW THIS MANUAL COMPLETELY, it is very
important that the owner/installer read and understand the section covering installation instructions, and recognize the local
and state codes before installing the MasterTemp. Its use will reduce service calls and chance of injury and will lengthen
product life. History and experience has shown that most heater damage is caused by improper installation practices.
IMPORTANT NOTICES
THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE TECHNICIAN, QUALIFIED
IN POOL HEATER INSTALLATION.
...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 any more information, or if you have any questions regarding to this pool heater, please contact
Pentair Water AU/NZ, AUS – at 1800 664 266 • [phone] or Pentair Water Pool and Spa, Inc., USA – at
[phone] • [phone] • [phone].
WARRANTY INFORMATION
The MasterTemp pool heater is sold with a limited factory warranty. Specific details are described on the warranty
registration card which is included with the product.Return the warranty registration card after filling in the serial
number from the rating plate inside the heater.
Pentair Water Pool and Spa’s high standards of excellence include a policy of continuous product improvement
resulting in your state-of-the-art heater. We reserve the right to make improvements which change the specifications
of the heater without incurring an obligation to update the current heater equipment.
These heaters are designed for the heating of chlorine, bromine or salt system swimming pools and spas or
in non-stationary installations, and should never be employed for use as space heating boilers or general
purpose water heaters. 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.
CAUTION
OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 20°C. WILL CAUSE HARMFUL
CONDENSATION AND WILL DAMAGE THE HEATER AND VOID THE WARRANTY. Do not use the heater to protect
pools or spas from freezing if the final maintenance temperature desired is below 20°C., as this will cause condensation
related problems.
Introduction
Section 2. Introduction

P/N 474131 Rev. B 2-26-10
6
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. Proper installation, operation and maintenance of fuel-burning appliances in the home is the most important factor in reducing
carbon monoxide poisoning.
3. Be sure that fuel burning appliances such as heaters are installed by professionals according to manufacturer's instructions and codes.
4. Always follow the manufacturer's directions for safe operation.
5. Have the heating system (including vents) inspected and serviced annually by a trained service technician.
6. Examine vents regularly for improper connections, visible cracks, rust or stains.
7. Install battery-operated carbon monoxide alarms. The alarms should be certified to the requirements of the most recent UL, IAS,
CSAand IAPMO standard for carbon monoxide alarms. Test carbon monoxide alarms regularly and replace dead batteries.
WARNING
The U.S. Consumer Product Safety Commission warns that elevated water temperature can be hazardous.
See below for water temperature guidelines before setting temperature.
1. Spa or hot tub water temperatures should never exceed 40° C. A temperature of 37° C. is considered safe for a healthy adult.
Special caution is suggested for young children. Prolonged immersion in hot water can induce hyperthermia.
2. Drinking 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 the spa or hot tub, the user should check the water temperature with an accurate thermometer. Spa or hot tub
thermostats may err in regulating water temperatures by as much as -15° C.
5. Persons 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.
CODE REQUIREMENTS
Installationmustbe inaccordancewithalllocalcodesandordinances/orthelatesteditionoftheNational
Fuel Gas Code, AS 5601 and the National Electrical Standards, or standards and/or local codes.
The heater, when installed, must be electrically grounded and bonded in accordance with local codes.
Section 2. Introduction
DANGER
CARBON MONOXIDE GAS IS DEADLY – Exhaust from this pool heater contains toxic levels of carbon monoxide, a dangerous,
poisonous gas you cannot see or smell.
WARNING
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the heater. Do not
use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater
and to replace any part of control system and gas control which has been under water.

Rev. B 2-26-10 P/N 474131
7
SAFETY INFORMATION
Section 2. Introduction
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 “ “ symbol. Be sure to read and comply with all of the warnings and cautions.
DANGER — CARBON MONOXIDE GAS IS DEADLY
• • READ OWNERS MANUAL COMPLETELY BEFORE OPERATING. • •
THIS PRODUCT MUST BE INSTALLED AND SERVICED BY A PROFESSIONAL SERVICE
TECHNICIAN, QUALIFIED IN POOL HEATER INSTALLATION. Some jurisdictions require that
installersbelicensed.Checkwithyourlocalbuildingauthorityaboutcontractorlicensingrequirements.
Improper installation and/or operation could create carbon monoxide gas and flue gases which could
cause serious injury or death. Improper installation and/or operation will void the warranty.
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. IF YOU
EXPERIENCE ANY OF THE ABOVE SYMPTOMS, IMMEDIATELY TURN OFF THE POOL
HEATER,LEAVETHEVICINITYOFTHEPOOLORSPAANDGETINTOFRESHAIRIMMEDIATELY.
THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE
RESUMING OPERATION.
EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR DEATH.
Install this pool heater 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.
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 with an unconventional gas control valve that is factory set with a
manifold pressure of 11 ± 5 Pa. Improperinstallation,adjustment,alteration,service ormaintenance
can cause property damage, personal injury or loss of life. Installation or service must be performed
by a qualified installer, service agency or the gas supplier. If this control is replaced, it must be
replaced with an identical control.
Do not attempt to adjust the gas flow by adjusting the regulator setting.
WARNING — Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a
heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should
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 application
needs must be made by a Pentair dealer or other qualified agency using factory specified and
approved parts. The heater is available for use with natural gas or LP (propane) gas only. It is not
designed to operate with any other fuels. Refer to the nameplate for the type of gas the heater is
equipped to use.
• Use heater only with the fuel for which it is designed.
• If a fuel conversion is necessary, refer this work to a qualified service technician or gas supplier
before putting the heater into operation.

P/N 474131 Rev. B 2-26-10
8
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. Consult local codes and fire protection authorities about specific installation requirements
and restrictions. Locate the heater away from propane gas storage and filling equipment as specified
by the Standard for the Storage and Handling of Liquefied Petroleum Gases (latest edition).
WARNING — Risk of fire. Do not place articles on, near or against the heater.
WARNING — Risk of burn hazard. To reduce the risk of injury, do not touch the side heater vent cover when the
heater is operating. Side heater vent covers are HOT and can burn when touched causing personal
injury. Do not allow children to play on or around heater or associated equipment.
WARNING — Risk of asphyxiation if exhaust is not correctly vented. Follow venting instructions exactly
when installing heater. Do not use a drafthood 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. The heater is supplied with an integral venting system for outdoor installation.
CAUTION —
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation. Wiring errors can also destroy the control board.
• Connect 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 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 operate the heater for more than five (5)
minutes with the access door panels removed.
• This heater is design certified by IAPMO as complying with the Standard for Gas Fired Pool Heaters, and is intended
for use in heating fresh water swimming pools or spas.
• The heater is designed for the heating of chlorine, bromine or salt system swimming pools and spas. It should NOT be
used as a space heating boiler, or general purpose water heater. The heater requires an external 240 VAC
single-phase electric power source.
• The heater should be located in an area where leakage of the heater or connections will not result in damage to the
area adjacent to the heater or to the structure. When such locations cannot be avoided, it is recommended that a
suitable drain pan, adequately drained, be installed under the heater. The pan must not restrict air flow.
• The heater may not be installed within 4M(13.1 ft) of the inside surface of a pool or spa unless it is separated by a solid
fence, wall or other permanent barrier.
Vent
Cover

Rev. B 2-26-10 P/N 474131
9
Section 3. Installation
Installation Instructions
Gas
Air
Mixer
Blower
Inlet
(Cold
Water)
Exhaust
Heating Coils
Outlet
(Mixed
Water) Burner
Figure 1.
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.
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.
HEATER DESCRIPTION
Figure 1 isa diagramof theheater showing howit operates. Precisely
matchedorificeplatesmetertheairandgasintothemixer.Theblower
draws the air and gas through the mixer and forces it into the burner’s
flame holder. A sealed heat exchanger surrounds the flame holder,
discharging exhaust gases out the flue.
Five (5) cm PVC water piping connects directly to the manifold/
header on the heat exchanger using 5 cm PVC slip unions provided
with the heater. The outer manifold remains cool; no heat sinks are
required.Athermalregulatorandaninternalbypassregulatethewater
flow through the heat exchanger to maintain the correct outlet
temperature. The heater operator control panel board assembly is
located on top of the heater.
SEQUENCE OF OPERATION
An electronic temperature sensing thermistor in the manifold adapter inlet controls the heater operation. When the inlet
water temperature 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 57° C (135° F), 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 60° C (140° F).
• the stack flue sensor (SFS), which shuts down the heater if the flue gas temperature reaches 260° C (500° F).
The air flow switch (AFS) senses the pressure drop across the air metering orifice.As soon as there is sufficient air flow,
theAFS closes, closing the circuit to the hot surface igniter (HSI), which ignites the fuel mixture. On a call for heat, the
blower and HSI are energized. In about 20 seconds, the gas valve opens and ignition occurs. The HSI then switches to a
sensing mode and monitors the flame.
The heater is equipped with a digital operating control that enables the user to pre-set the desired pool and spa water
temperatures. The control enables the user to select between pool and spa heating, and features a digital display that
indicates the water temperature.
PUTTING THE HEATER INTO SERVICE
If the heater is installed below the level of the pool, or more than 0.6 meters (2 feet) above pool level, the pressure switch
setting should be adjusted. See “WATER PRESSURE SWITCH” in the “SAFETY CONTROLS Section” (page 24) and
the “CAUTION” under “BELOW POOL INSTALLATION Section” (page 12).
Before putting the heater into service for the first time, follow the instructions under “BEFORE START-UP” (page 22) in
the front of this manual. Check for proper operation of the heater by following the steps under “OPERATION
INSTRUCTIONS.”
Damage to equipment caused by improper installation or repair will void the warranty.

P/N 474131 Rev. B 2-26-10
10
Section 3. Installation
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.
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")
TOPFRONT
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")
DIMENSIONS IN CENTIMETERS & INCHES

Rev. B 2-26-10 P/N 474131
11
PUMP
FILTER
POOL
HEATER MANUAL
BY-PASS
TO
POOL
GATE
VALVE
FROM
POOL
PLUMBING CONNECTIONS
The MasterTemp heater has the unique capability of direct
schedule 40 PVC plumbing connections. A set of bulkhead
fittingsisincludedwiththeMasterTemptoinsureconformity
withPentair’srecommendedPVCplumbingprocedure.Other
plumbingconnectionscanbe used.SeeFigure3forplumbing
connections.
CAUTION
Before operating the heater on a new installation, turn
on the circulation pump and bleed all the air from the
filter using the air relief valve on top of the filter. Water
should flow freely through the heater. Do not operate
the heater unless water in the pool/spa is at the proper
level. If a manual by-pass is installed, temporarily close it
to insure that all air is purged from the heater.
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. 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 chemical into the heater, filters
or pump. When chemical feeders are installed in the circulation of the piping system, make sure the feeder outlet line
is down stream of the heater, and is equipped with a positive seal noncorrosive “Check Valve”, (P/N R172288),
between the feeder and heater.
MANUAL BY-PASS
Where the water flow rate exceeds the maximum 454 LPM, a manual
bypass should be installed and adjusted. After installing the valve, adjust
the valve to bring the flow rate within the acceptable range. Then remove
the valve handle or lock it in place to avoid tampering. See Figure 4.
Section 3. Installation
Figure 3.
Table 1.
Cool water
Warm water out
Outlet to pool
Inlet to heater
1. Set Manual By-Pass Valve.
2. Remove Handle.
See page 35 for Pressure Relief Valve Installations.
Figure 4.
ledoM )MPG(MPL.niM *)MPG(MPL.xaM
002 )02(67 )021(454
003 )03(411 )021(454
004 )04(251 )021(454
dednemmocermumixamehtdeecxetonoD* .gnipipgnitcennocehtrofetarwolf

P/N 474131 Rev. B 2-26-10
12
Pool
Main
Drain Spa
From Pool 3-Way
Valve
3-Way
Valve
3-Way
Valve
Chlorinator
Heater
Pump
Check Valve
Filter
WATER CONNECTIONS
The heater requires proper water flow and pressure for its
operation.SeeFigure5fortherecommendedinstallation.The
filterpumpdischarges to thefilter,the filterdischargesto the
heater, and the heater discharges directly to the pool or spa.
A manual bypass valve should be installed across the heater
when the pump flow exceeds 454 LPM (120 GPM). See
“WATER FLOW RATE” on page 11 - Table 1 for setting of
the manual by-pass valve.
Make sure that the outlet plumbing from the heater contains
noshut-offvalvesorotherflow restrictionsthatcould prevent
flowthroughtheheater(exceptforbelowpoolasnotedbelow,
orwinterizingvalveswhereneeded).Toswitchflowbetween
the pool and spa, use a diverter valve. Do not use any valve
that can shut off the flow. Do not use a shut-off valve to
isolatetheheaterunlessitisbelowthelevelofthepoolorspa.
Install the chemical feeder downstream of the heater. Install
achemicalresistantone-waycheckvalvebetweentheheater
and the chemical feeder to prevent back-siphoning through the heater when the pump is off.
NOTICE: If the heater is plumbed in backwards, it will cycle continuously. Make sure piping from filter is not reversed
when installing heater.
Connect the heater directly to 5 cm PVC pipe, using the integral 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 to run the heater. Instead,
correct the installation.
Do not operate the heater while an automatic pool cleaner is also operating. If the circulation pump suction is plugged (for
example by leaves), there may not be adequate flow to the heater. Do not rely on the pressure switch in this case.
Local codes may require the installation of a pressure relief valve (PRV), see page 35 for “PRESSURE
RELIEF INSTRUCTIONS”.
BELOW POOL INSTALLATION
If the heater is below water level, the pressure switch must be adjusted. This adjustment must be done by a qualified
service technician.
See following CAUTION before installation.
CAUTION
BELOW OR ABOVE POOL INSTALLATION
The water pressure switch is set in the factory at 21 kPa (± 5 kPa). This setting is for a heater installed at pool level. If
the heater is to be installed more than 0.3 m above or below, the water pressure switch must be adjusted by a
qualified service technician. See page 24, Figure 22.
FLOW SWITCH
If the heater is installed more than 1.5 m above the pool or more than 1.2 m below the pool level, you will be beyond
the limits of the pressure switch and a flow switch must be installed. Locate and install the flow switch externally on
the outlet piping from the heater, as close as possible to the heater. Connect the flow switch wires in place of the
water pressure switch wires.
Section 3. Installation
Figure 5.

Rev. B 2-26-10 P/N 474131
13
GAS CONNECTIONS
GAS LINE INSTALLATIONS
The gassupplymustbeinstalledinaccordancewiththe GasInstallationCode,AS5601,asapplicable andallapplicablelocalcodes.
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. Table 2 below shows the recommended gas inlet pipe sizes required for the distance from the gas meter to
the heater. The table is for natural gas at a specific gravity of .65 and propane at a specific gravity of 1.55.
When sizing gas lines, calculate 0.9 additional meters of straight pipe for every elbow used. When installing the gas line, avoid
gettingdirt,greaseorother foreign materialinthe pipe asthis maycausedamagetothegasvalve,whichmayresultinheaterfailure.
The gas meter should be checked to make sure that it will supply enough gas to the heater and any other appliances that may
be used on the same meter. Insufficient gas supply will cause the heater to operate below its designed performance or not at
all. The gas line from the meter will usually be of a larger size than the gas valve supplied with the heater. Therefore a
reduction of the connecting gas pipe will be necessary. Make this reduction as close to the heater as possible. Gas supply
companies are increasingly supplying natural gas to new installations with 2.75 kPa; this means if the gas pressure is not
adjusted to the correct working pressure, the 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 disconnected from the gas supply piping system during any pressure testing
on that system, (greater than 3.5 kPa). The heater and its gas connection must be leak tested before placing the heater in
operation. Do not use flame to test the gas line. Use soapy water or another nonflammable method.
NOTE
A manual main shut-off valve must be installed externally to the heater.
WARNING
DO NOT INSTALL THE GAS LINE UNION INSIDE THE HEATER CABINET. THIS WILL VOID YOUR WARRANTY.
GAS PIPE SIZING
SEDIMENT TRAP/DRIP LEG
Installa sedimenttrap/driplegandunionlocatedoutsidethe
heater panels in accordance with National code
requirements.Donotusearestrictivegascock.Thesediment
trap/drip leg shall be either a tee fitting with a capped nipple
in the bottom outlet which can be removed for cleaning, as
illustrated in Figure 6, or an other device recognized as an
effective sediment trap/drip leg. All gas piping should be
tested after installation in accordance with local codes. Figure 6.
Section 3. Installation
Manual
Shut-off
Valve
Sediment
Trap/Drip Leg
Union
At least 22.9 cm (9")
At least 7.6 cm (3")
2.54 cm (1") Dia. or larger
(See "Recommended
Pipe Sizes" Chart)
46-61 cm of 1.91 cm
(18–24" of 3/4")
Gas line from
Valve
Bell
Reducer
Table 2.
eziSretaeH reteMehtmorfecnatsiD
m51ot0 m03ot61 m06ot13
002 mm52 mm23 mm23
003 mm23 mm23 mm04
004 mm23 mm04 mm05

P/N 474131 Rev. B 2-26-10
14
TESTING GAS LEAKS AND GAS PRESSURE
Table 3.
Before operating the heater, the heater and its gas connections must be leak tested. Do NOT use an open flame to test forleaks.Test
all gas connections for leaks with soapy water.
The heater and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of
that system at test pressures in excess of 3.5 kPa (1/2 psig).
The heater must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing
of the gas supply at test pressures equal to or less than 3.5 kPa (1/2 psig).
CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE
WARNING
Risk of fire and explosion. Improper installation, incorrect adjustment, alteration, service, or maintenance of the Combination
Gas Control Valve can lead to fire or explosion, causing loss of life, personal injury, and/or property damage. If it is necessary
to adjust the gas valve, this must be done by only by a qualified service 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 11 ± 5 Pa.
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 combination gas valve
incorporates dual shut-off
valves and a negative-
pressure regulator. For
proper operation, the
regulated pressure at the
outlet manifold of the valve
must be 11± 5 Pabelow the
reference pressure at the
blowermixerinlet,andthegas
valve ‘VENT’ tap must be
connected to the end cap air
orificeasshowninFigure7.
Do not attempt to
adjust the gas input by
adjusting the regulator
setting. The correct
gas regulator setting is
required to maintain proper combustion and must NOT be altered.
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
Section 3. Installation
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Pressure
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Figure 7.
Connection
forService Connection
for Test

Rev. B 2-26-10 P/N 474131
15
Section 3. Installation
OUTDOOR INSTALLATION
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. IF YOU EXPERIENCE ANY OF THE ABOVE
SYMPTOMS, IMMEDIATELY TURN OFF THE POOL HEATER, LEAVE THE VICINITY OF THE POOL OR SPAAND GET INTO
FRESH AIR IMMEDIATELY. THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE
RESUMING OPERATION.
EXCESSIVE CARBON MONOXIDE EXPOSURE CAN CAUSE BRAIN DAMAGE OR DEATH.
WARNING
Risk of explosion if a unit burning propane gas is installed in a pit or other low spot. Propane is heavier than air. Do not
install the heater using propane in pits or other locations where gas might collect. Consult your local building code officials to
determine installation requirements and specific installation restrictions of the heater relative to propane storage tanks and
filling equipment. Installation must meet the requirements for the Standard for the Storage and Handling 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
the heater constructed of hollow masonry blocks, not less than 100
millimeters (mm) thick (laid with ends unsealed and joints matched
for air circulation). Cover blocks with 0.75 mm (min.) galvanized
sheet metal, see Figure 8.
To avoid damage to the electronic components in the heater, take
care to prevent prolonged exposure to driving sources of water (such
as lawn sprinklers, heavy roof runoff, hoses, etc.). Avoid operation
in persistent, extreme, moist or salty environments.
In extreme weather, shut down the heater and disconnect the power
to it until the weather has moderated. In areas subject to hurricanes
orveryhighwinds,purchasethe BoltDownBracketKit, P/N 460738,
see Figure 9.
(Australia)
SHEET
METAL
BLOCKS
Hollow masonry blocks, not less than 100 mm thick, (laid with ends unsealed and joints
matched for air circulation). Cover blocks with 0.75 mm (min.) galvanized sheet metal.
152.4 mm Min.
152.4 mm Min.
BASE FOR USE ON
COMBUSTIBLE FLOORS
Lead
Anchor
For Heater mounting
bolts and clamps,
purchase separately
Bolt Down Bracket Kit,
Part No. 460738.
Figure 8.
Figure 9.

P/N 474131 Rev. B 2-26-10
16
VENTING GUIDELINES
OUTDOOR INSTALLATION
Vent Termination:
Must be installed at least 1500 mm away from
the building wall openings, and at the following
distances away from any door, window, or
gravity air inlet.
The heater must also have no obstructions above it.
Check local building codes
for setback requirements.
Force
Air Inlet
Property Line
1500 mm
1500 mm
1500 mm
1500 mm
SIDE VIEW
Building
Window
Exhaust Grill
(Vent)
1500 mm
1500 mm
Section 3. Installation
Figure 11.
WARNING
Risk of fire and explosion. Do not spray aerosols in the vicinity of the heater while it is in operation. Chemicals
should not be stored near the heater installation. Combustion air can be contaminated by corrosive chemical fumes
which can damage the heater and will void the warranty.
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.
• 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 overhang and the top of
the heater exhaust vent, see Figure 10. If the heater is under a roof or deck
overhang, the space around the heater must be open on three sides.
Forminimumexhaustventclearancesforbuildingopenings,seebelow Figure11.
Orient the heater for convenient access to the water connections and the gas
and electrical connections.
Check local building codes for setback (property line) requirements.
CAUTION
If installing the heater next to or near an air conditioning unit or a heat pump, allow a minimum of 91.4 cm
(36 in.) between the air conditioning unit and the heater.
1 meter (3 ft.) or more
Figure 10.

Rev. B 2-26-10 P/N 474131
17
Section 3. Installation
CONTROL PANEL INDEXING
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 the heater for easy access, see Figure 12.
1. Remove the bolts from the door panels. Remove both door access panels.
2. Remove the four corner screws that secure the top panel. Lift the top
panel upward to remove the top panel.
3. Rotate the top panel to the desired position located at 90° angles. Note
that the control panel must NOT be located on the side where the vent
is located.
4. Replace the top panel down onto the side panels. Be sure that there are no
wires caught under the panel.
5. Secure the top panel using the four corner screws.
6. Reattach the door access panels.
FINAL INSTALLATION CHECK
After installation, the installer MUST test and check that the heater is operating and
functioning properly.
Some building codes require that the heater be anchored to the equipment pad or platform to
withstand high wind pressures created during hurricanes.ABolt Down Bracket Kit, P/N 460738,
isavailablewithanchorclampsdesignedtoholdtheunittotheequipmentpadinhighwindconditions,
see Figure 13. Installation of the anchor clamps are recommended in all installations.
Door
Access
Panel
Top Panel
Door
Access Panel
Figure 12.
Lead
Anchor
For Heater mounting
bolts and clamps,
purchase separately
Bolt Down Bracket Kit,
Part No. 460738.
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Table 4.
Corrosive Vapors and Possible Causes
Figure 13.

P/N 474131 Rev. B 2-26-10
18
ELECTRICAL CONNECTIONS
ElectricalRating 50Hz 240 VoltsAC, single phase
Enclose the 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 240 VAC. It is not recommended to be connected to OR operate on a 208 VAC.
NOTE
• If any of the original wiring supplied with this heater must be replaced, installer must supply (No. 18AWG, 600V, 105° C. U.L.
approved AWM low energy stranded) copper wire or it’s equivalent.
Please read the boxes headed “IMPORTANT! READ ME FIRST!” on pages 27 and 31 before proceeding.
1. All wiring must be in accordance with all applicable codes
and must be wired by a licensed electrician to AS3000
Wiring rules.
2. The heater, when installed, must be electrically grounded and
bonded in accordance with local codes or, 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” wire rated for 35°C rise.
5. All line voltage wiring shall be enclosed in approved flexible
conduit, and shall be securely attached to the field wiring box
located inside the access door panel. The conduit or cable
connector at the field wiring box should contain an insulating
bushing or its equivalent to prevent abrasion of the wires as
they enter the box.
6. The filter pump should run continuously when the heater
is on, and for at least 15 minutes after the heater turns
off. Any switches in the pump circuit (including circuit breakers) that can disconnect the pump must also disconnect
the heater.
7. Do not wire single-pole switches, including protective devices, into a grounded line. The heater is not sensitive to
polarity.
Use the provided waterproof wire nuts when connecting the power supply.
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.
Section 3. Installation
Figure 14.
AC Plug
240 Volt

Rev. B 2-26-10 P/N 474131
19
Figure 15.
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.
REMOTE CONTROL CONNECTIONS
1. Switch off power to heater at main circuit breaker panel.
2. Unbolt and remove the access door panels.
3. Open control box cover (see Figure 15).
4a.To connect a 2-Wire Control (such as Pentair’s IntelliTouch™or EasyTouch™)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. Connect wires from the controller or timer to the Fireman’s Switch.
Controller, timer or relay should be sized to handle 24VAC at 0.5Amp (because
it will be completing the 24VAC control board circuit on the heater as shown in
Figure 16). DO NOT apply line voltage to the Fireman’s Switch terminals. Use
18 gauge wire with a minimum 1.2 mm (3/64 in.) thick insulation rated for a
temperature rise of at least 105° C.
- Knock-outsareprovidedtoroutethewiresthroughthe
bottom of the control box and past the junction box.
4b. To connect a 3-Wire Control:
- Connect wires between the control board terminals
on the heater and the external relays, as shown in
Figure 17 on page 20. 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 17 on page 20) to
enable external control and to disable the heater
membrane pad’s “Pool ON” and “Spa ON” buttons
(the “OFF” key on the membrane pad remains
functional).
- Knock-outs are provided to route the wires through
the bottom and the top of the control box and past
thejunctionbox.
5. Close control box cover.
6. Re-install the access door panels.
Tocontrolheatersthatareoperatedinparallel,connectwiring
at same locations on heater as 2-Wire or 3-Wire Control. It
is imperative that each control circuit is isolated from the
other control circuits, to avoid that current will flow from
one heater to another through the control circuits.
NOTICE: The fuse for the Fireman’s Switch is a 1.25Amp
31.75 mm x 6.35 mm fast blow fuse, which is commonly
available.
GND
L1
GROUND (GND )
L2
JUNCTION
BOX
L1 L2
BM
FL
F1
L1
TRANS
F
I
R
E
M
A
N
S
S
W
I
T
C
H
Fireman's Switch
Completes the heater
24 Volt AC Control
Board Circuit.
DO NOT connect this
circuit to Line Voltage!
Y Y
R
W
G
Y
Y
TERMINAL BOARD
TRANS
TRANS
FUSE
FUSE
L2
Time Clock or Remote
(Purchase Separately –
Supplies Power to
Circulator Pump)
24VAC
24VAC
BK
O
O
BK
W
R
BK
R
W
12 Pin Receptacle
VAL
TH
IND
GND
24VAC
24VAC
FS
THERMISTOR
OPERATING CONTROL
DISABLE TOGGLE
ENABLE TOGGLE
MEMBRANE PAD
CONNECTION
9
1
J6
Figure 16.

P/N 474131 Rev. B 2-26-10
20
MASTERTEMP WIRING DIAGRAM
(3-WIRE SYSTEM)
Section 3. Installation
Plug –12 pin
240V – Red
JMP
1
JMP
1
External Control Interface Circuit Disabled,
Heater Membrane Pad Enabled
External Control Interface Circuit
Enabled, "Pool On" and "Spa On"
Keys Disabled. "OFF" Key on
Membrane Pad Remains Functional.
JMP3
CONNECTION DIAGRAM
AGS Switch
Stack Flue Sensor
Gas Valve
Air Flow Switch
Extra Switch 1
Hi-Limit Switch
Pressure Switch
VAL
TH
IND
GND
24VAC
24VAC
FS
THERMISTOR
OPERATING CONTROL
1
PS
HLS
ES1
AFS
AGS
SFS
GAS
MEMBRANE PAD
CONNECTION
Spa Line Common Line Pool Line
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
120VAC
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
YBK W
BL
GY
GY
GY
GY
BK
BK
WRR W
G
Y
R
R
Y
YY
W
BK
Y/W
WWRR
BLBL
OOOOPRPR
Y/R
Y/BL
Y/O
Y/W
Y
Y
Y
Y
Y
Y
YY Y Y
BR
BR
External Control Interface
Y
NOTICE: Touching any 24VAC wire, including
the Fireman's Switch wire, to the 240V
terminal while the heater is connected to line
power will immediately destroy the control
board and void the warranty.
BK
RGND
G
12 Position
Receptacle
1
Y/R
Y/BL
Y/O
Y/W
NA/LP
Models Only
61
J6
Figure 17.