Pentair Pool Products MiniMax NT Series Service Manual
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Pentair Pool Products MiniMax NT Series Service Manual

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See also: Operation & Installation Manual
FOR YOUR SAFETY - READ BEFORE OPERATING
Warning:
If you do not follow these instructions exactly, a fire or explosion may
result, causing property damage, personal injury or loss of life.
For additional free copies of this manual; call (800) 831-7133.
Warning: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury or death. Installation and service must be
performed by a licensed qualified installer, service agency or the gas supplier.
For Your
Safety
Pentair Pool Products, Inc.
1620 Hawkins Ave., Sanford, NC 27330
10951 W. Los Angeles Ave., Moorpark, CA 93021
Rev. B 2-11-04
MiniMax
POOL & SPA HEATERS
SERVICE MANUAL
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.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or other appliances.
(919) 774-4151
•
(805) 523-2400
•
®
NT Series
WARNING
WARNING
1 1
1
P/N
NTSM03

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Summary of Contents for Pentair Pool Products MiniMax NT Series

  • Page 1 If you cannot reach your gas supplier, call the fire department. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances. Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 (919) 774-4151 •...

  • Page 2: Table Of Contents

    Table of Contents Introduction ..........................Important Notice ..................................Code Requirements ..................................Safety Rules ....................................Installation Tips ........................Dimensions ..........................Installation Outdoors/Indoors ....................Installation on Floors Constructed of Combustible Materials ....................... Gas Requirements ........................Gas Line Installations .................................. Sediment Traps ................................... Pipe Sizing for Gas Line Installations ............................

  • Page 3: Introduction

    NT Series Pool and Spa Heaters ..For the installer and operator of the MiniMax NT Series pool and spa 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.

  • Page 4: Safety Rules

    Safety Rules 1. Spa or hot tub water temperatures should never exceed 4. Before entering the spa or hot tub, the user should 104° F. A temperature of 100° F. is considered safe for check the water temperature with an accurate a healthy adult.

  • Page 5: Dimensions

    Dimensions OUTDOOR VENTILATION 15.50 7.35 2 in. SOCKET 24.05 30.63 MODEL "A" DIM. 14.50 21.63 24.63 27.63 34.13 4.88 8.84 "A" DIM. DIMENSIONS IN INCHES INDOOR VENTILATION 15.50 INDOOR VENT ADAPTOR 7.35 P/N 460506 4 in. Kit 2.00 2 in. SOCKET 5 in.

  • Page 6: Installation Outdoors/Indoors

    Installation - Outdoors/Indoors The heater should not be installed closer than 6 inches to any IMPORTANT! fences, walls or shrubs at any side or back, nor closer than 18 Under certain conditions, “heavy rains or unusually high winds”, inches at the plumbing side. A minimum clearance of 24 inches it may be necessary to install an outdoors vent.

  • Page 7: Gas Requirements

    Gas Requirements GAS LINE INSTALLATIONS CAUTION Before installing the gas line, be sure to check which The heater and any other gas appliances must be gas the heater has been designed to burn. This is disconnected from the gas supply piping system important because different types of gas require during any pressure testing on that system, (greater different gas pipe sizes.

  • Page 8: Pipe Sizing For Gas Line Installations

    Installation (Gas Line) Pipe Sized For Length Of Run In Equivalent Feet Table 1. c i b c i b ” 2 ” 4 ” 1 / 1 - ” 4 / 1 - ” 2 ” 2 / 1 - ”...

  • Page 9: Testing Gas Pressure

    Testing Gas Pressure Inlet Manifold . Push the power switch to “OFF”. 2. Turn the gas valve knob to “OFF”. 3. Remove 1/8 in. NPT plug on the outlet side of the valve and screw in the fitting from the Manometer kit. 4.

  • Page 10: Water Connections

    Water Connections PLUMBING CONNECTIONS The MiniMax NT Series heater has the unique capability of direct schedule 40 PVC plumbing connections. A set of bulkhead fittings is included with the MiniMax NT Series to insure conformity with Pentair’s recommended PVC plumbing procedure.

  • Page 11: Valves

    Water Connections, cont’d. CAUTION VALVES Exercise care when installing chemical feeders so When any equipment is located below the surface of as to not allow back siphoning of chemicals into the the pool or spa, valves should be placed in the heater, filters or pump.

  • Page 12: Reversing Headers

    Reversing Headers Reversible Inlet/Outlet Connection NOTE The MiniMax NT Series heater is factory assembled Do NOT remove the high-limit and pressure with right side inlet/outlet water connections. The switches or the thermistor from the front header inlet/outlet header can be reversed for left side water during the reversing procedure, as they will be in connections without removing the heat exchanger.
  • Page 13 Reversible Inlet/Outlet Connection, cont’d. 9. Install the temperature sensing probe by passing On the MiniMax NT Series heater there is insulation installed by the factory on the return head side of the the wires through the hole provided on the left heaters.

  • Page 14: Air Requirements

    INDOOR VENTING—General Requirements The vent pipe must be the same size or larger than specified adaptor. The MiniMax NT Series heaters are capable of a 360-degree discharge rotation and operate with a positive vent static pressure and with a vent gas temperature less than 400° F.
  • Page 15 (or grills). Vent Adaptor Air supply requirements below apply to all MiniMax NT Series heaters r i A r o f i t s r i A...
  • Page 16 Air Requirements (Indoor) P/N NTSM03 Rev. B 2-11-04...

  • Page 17: Venting - Outdoor Installations

    Air Requirements (Outdoor) OUTDOOR INSTALLATION ONLY (Outdoor Shelter Installation in Canada, see page For outdoor installation with an exhaust grill, the heater must be placed in a suitable area on a level, noncombustible surface. Do not install the heater under an overhang with clearances less than 3 feet from the top of the heater. The area under an overhang must be open on three sides.

  • Page 18: Electrical Wiring

    • The MiniMax NT Series heater is prewired for 240 volt AC connection using the “RED/BROWN” female connector and the “WHITE” common male connector; see below, Figure 15. If you require the heater to be connected to 120 volts AC, remove the “RED/BROWN”...

  • Page 19: Wiring Schematic For All Dual Voltage Blowers

    Electrical Installation (Dual Voltage Blowers) WIRING SCHEMATIC FOR ALL DUAL VOLTAGE BLOWERS 120 VOLTS AC 240 VOLTS AC WHITE LINE # 1 WHITE LINE # 1 YELLOW YELLOW CAP OFF JOINED ORANGE ORANGE JOINED BLACK BLACK LINE # 2 LINE # 2 PURPLE PURPLE BROWN...

  • Page 20: Wiring Diagram

    Electrical Installation (Dual Voltage Wiring) MiniMax NT Series HSI Electronic Ignition Wiring Diagram (DUAL VOLTAGE w/6800 Control Board) P/N NTSM03 Rev. B 2-11-04...

  • Page 21: Schematic For Remote Controls (2 And 3 Wire)

    THERMOSTAT SELECT SWITCH Figure 19. NOTE: When connecting a remote control to the MiniMax NT Series Heater, you must install the low voltage thermostat wires in separate conduit from ANY line voltage wires. Failure to follow these instructions will cause the thermostat relay to react erratically..

  • Page 22: Basic System Operation

    Basic System Operation TO OPERATE HEATER 1. Start pump, make sure the pump is running and is primed, to close water pressure switch and supply power to heater. Be sure the pool and/or spa is properly filled with water. 2. Follow the Lighting/Operating instructions on the following page. FIRING SEQUENCE 1.

  • Page 23: Starting Operation - Hsi Electronic Ignition Lighting/Operation

    Starting Operation (HSI) HSI ELECTRONIC IGNITION LIGHTING/OPERATION FOR YOUR SAFETY: READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not attempt to light the heater if you suspect a natural gas leak. Lighting the heater can result in a fire or explosion which can cause personal injury, death, and property damage.

  • Page 24: Chemical Balance

    Table 12. POOL AND SPA WATER If pH becomes too high (over alkaline), it Your Pentair Pool Products pool heater was designed has these effects: specifically for your spa or pool and will give you many 1.

  • Page 25: Maintenance

    2. Visually inspect the main burner and the hot surface In some installations, a pressure relief valve (PRV) is required ignitor. The normal color of the flame is blue. When flame on the MiniMax NT Series. appears yellow, burners should be inspected and cleaned. To install a PRV, carefully...

  • Page 26: Burner Tray Removal

    NOTE You can use this procedure if you have to change fuel-type—natural to propane or vice versa. The parts needed to convert the MiniMax NT Series are: Gas valve, main burner orifices, pilot orifice and module. MINIMAX NT (LOW NOx) VERSION P/N NTSM03 Rev.

  • Page 27: Desooting

    Maintenance - Desooting COMMON CAUSES OF SOOTING 1. Low gas pressure. For heavy soot accumulation which cannot 2. Inadequate air supply or inadequate venting. be successfully removed by merely 3. Foreign material in burners and orifices; dirt, spider brushing, the heat exchanger must be webs, etc.

  • Page 28: Reinstalling Heat Exchanger

    Maintenance - Reinstalling Heat Exchanger 1. Inspect fire box for damage or cracks that would allow 5. Reconnect the inlet and outlet flange to the headers (use heat to leak out into the outer cabinet and controls. new flange gaskets), be careful not to move the heat exchanger and break the seal.

  • Page 29: Troubleshooting

    Troubleshooting DIAGNOSTIC LIGHT OPERATION The circuit board in the MiniMax NT Series heater uses lights that are wired in sequence with the controls. The MiniMax NT Series heater still uses the same controls as the original MiniMax but this method of wiring is more helpful while troubleshooting.
  • Page 30 Troubleshooting DIAGNOSTIC LIGHTS 1. The POWER Light indicates voltage to the 5. The HEAT Light is attached to the MV Control Board from the Transformer. The (Main Valve) terminal on the Control Board. POWER light will be ON without pushing the This terminal does not receive voltage until Pool/Spa switch as long as there is power being the Hot Surface Igniter (HSI) has been ON for...
  • Page 31 Troubleshooting MiniMax NT Series Heater Troubleshooting/Check List 1. Look at the lights, which ones are on? Review Diagnostic Lights section on previous page. 2. Check for correct voltage on Secondary side of Transformer. Should be greater than 24 VAC at Orange Wire at 24 V position on Control Board.
  • Page 32 Troubleshooting DIAGNOSTIC LIGHTS SHOW “POWER” ONLY! 1. Check water temperature, if water has reached the desired temperature, the thermostat will cut off power to the module and the heater will stop firing. In this case the POWER Light would remain ON. 2.
  • Page 33 Troubleshooting Troubleshooting POWER / T-STAT ONLY! 1. Check that jumper has not come off of EXT SWITCH terminals. 2. Remove Wires to External Switch or Remote Control System and replace with jumper. If AUX Light comes ON, the problem is in External Switch or Remote Control System. 3.
  • Page 34 Troubleshooting POWER / T-STAT / AUX ONLY! 1. Be sure that Pump is ON and running with a full prime. 2. Is Pump Impeller clogged.* 3. Is Filter Dirty.* 4. Is Pump too small or worn out.* *30 GPM is required to close the Pressure Switch. Some 2 Speed pumps will not produce 30 GPM on Low Speed.
  • Page 35 Troubleshooting POWER / T-STAT / AUX / PRESS / SERVICE Fan Not Running 1. Check the 3 lights on the back of the Control Board. These 3 lights are connected to 3 different controls in this order: #1 – High Limit, #2 –...
  • Page 36 Troubleshooting POWER / T-STAT / AUX / PRESS / SERVICE Fan Running / HSI not energized and lock out occurs after 30 seconds 1. Check for 24VAC at TH terminal on Ignition Module. If none, check connections and wire and check for 24VAC at white wire terminal on Fan Vacuum Switch.
  • Page 37 Troubleshooting POWER / T-STAT / AUX / PRESS / SERVICE Fan Running / HSI Energized / No Gas to Burners 1. Check the green lights on back of Red Wires Control Board. If the “High Limit” Connect Here and “Thermal Fuse” are ON, (i.e. only one light is OFF), there is no voltage being supplied to the Control Board from the Valve...
  • Page 38 Troubleshooting POWER / T-STAT / AUX / PRESS HEAT (on then off) / SERVICE (off then on) Fan Running / HSI Energized / Burners ignite and the go off in 7 seconds or less 1. Check for 24 VAC at FS terminal on Ignition Module If none, Ignition Module is bad.
  • Page 39 TESTING THE Troubleshooting 6800 CONTROL BOARD CIRCUITRY 1. It is possible to bypass the 6800 Control Board and, therefore, the thermostat and Jumper safety circuits by installing a jumper from the Orange Wire on the 24V connector to the Orange Wire on the Ignition Module connector.
  • Page 40 Troubleshooting THE SERVICE LIGHT 1. The primary responsibility for the SERVICE Light is to illuminate whenever there is a problem that prevents the heater from firing (please see Diagnostic Lights explanation at the beginning of this section). However, it will also be ON during the Fan 15-second pre-purge and the 40-second Hot Surface Igniter heat up.
  • Page 41 Troubleshooting TESTING THE FAN VACUUM SWITCH 1. The Fan Vacuum Switch is a normally open switch that closes on a decrease of pressure in the fan exhaust housing. It then sends 24 VAC through the white wire to the Ignition Module at the TH terminal to start the ignition sequence.
  • Page 42 Troubleshooting RAPID CYCLING If the heater fires, shuts down and refires every 30-45 seconds and the Service Light comes ON and goes OFF alternately with the Heat Light, this indicates that the Inlet or Outlet High Limit Switch is sensing a temperature greater than 115° of 150° F., respectively. This is generally caused by a lack of water inside the heat exchanger, while the heater is firing.
  • Page 43 Troubleshooting PROPER COMPONENT VOLTAGES Pressure switch (water) ....................24 volts High limit switch (outlet) ....................24 volts High limit switch (inlet) ....................24 volts Thermal fuse (fusible link) .................... 24 volts Gas valve ........................24 volts Thermostat board ......................24 volts Transformer (secondary) ....................
  • Page 44 Troubleshooting CONTROL WIRE TERMINAL DESIGNATION IGN/120 – 120 volt supply for Hot Surface Igniter (only when supply is 120 volts) IGN/240 – 120 volt supply for Hot Surface Igniter (only when supply is 240 volts) L1 – (black wire) Line supply voltage to module (120 volts) L2 –...
  • Page 45 STEP-BY-STEP ELECTRICAL TROUBLESHOOTING OF THE MINIMAX NT SERIES HEATER w/6800 BOARD • Power to the heater should be configured properly at the terminal block, (for 120v the neutral lead always goes to the center lug of terminal block). • From the terminal block the power flows through the internal shut off switch at the bottom of the J-Box.
  • Page 46 STEP-BY-STEP ELECTRICAL TROUBLESHOOTING OF THE MINIMAX NT SERIES HEATER w/6800 BOARD • When the fan comes on, it transfers a low pressure (vacuum) to the fan-proving switch. This low pressure closes the fan-proving switch, which then allows 24vac to be supplied to the TH terminal on the ignition module.

  • Page 47: Glossary

    Glossary 1. BURNER: A device for the final conveyance of gas, predominantly of any of the following hydrocarbons, or a mixture of gas and air, to the combustion zone. or mixtures of them: propane, propylene, normal butane or isobutane and butylenes. 2.

  • Page 48: Minimax Nt (Standard) Parts List & Exploded View (Dual Voltage)

    MINIMAX NT SERIES HEATER (Non-ASME Shown) (Dual Voltage w/6800 Controller) 22 27 P/N NTSM03 Rev. B 2-11-04...
  • Page 49 MiniMax NT STD w/6800 Controller Replacement Parts Item Description Quantity Exhaust Grill w/Gasket 472352 Gasket, Exhaust Grill 471701 Top Cover w/Posts 472353 472354 472355 472356 Exhaust Assembly 472373 472376 472373 Blower w/Gasket 472361 472362 472374 Gasket, Blower 471610 Flue Collector 472008 472007 472006...

  • Page 50: Minimax Nt Low Nox Parts List & Exploded View (Dual Voltage)

    MINIMAX NT LOW NOx HEATER (Non-ASME Shown) (Dual Voltage w/6800 Controller) P/N NTSM03 Rev. B 2-11-04...
  • Page 51 MiniMax NT LN w/6800 Controller Replacement Parts Item Description Quantity Exhaust Grill w/Gasket 472352 Gasket, Exhaust Grill 471701 Top Cover w/Posts 472353 472354 472355 472356 Exhaust Assembly 472357 472359 472357 472373 Blower w/Gasket 472361 472362 Gasket, Blower 471610 Flue Collector 472008 472007 472006...

  • Page 52: Save These Instructions

    52 40 SAVE THESE INSTRUCTIONS. Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 (919) 774-4151 • 10951 W. Los Angeles Ave., Moorpark, CA 93021 (805) 523-2400 • P/N NTSM03 Rev. B 2-11-04...

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