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Pentair Pool Products MiniMax Plus, PowerMax MiniMax Plus HP Series Operation & Installation Manual

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MiniMax
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.
U.S. Patent Numbers
6,295,980
5,318,007 - 5,228,618
5,201,307 - 4,595,825
Warning: 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.
For Your
Safety
Rev. G 1-22-04
Plus
®
POOL & SPA HEATERS
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.
Pentair Pool Products, Inc.
1620 Hawkins Ave., Sanford, NC 27330
10951 W. Los Angeles Ave., Moorpark, CA 93021
PowerMax
and
WARNING
WARNING
(919) 774-4151
(805) 523-2400
1 1
1
To
Consumer
Retain For
Future
Reference
P/N 471048

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   Summary of Contents for Pentair Pool Products MiniMax Plus, PowerMax MiniMax Plus HP Series

  • Page 1

    Rev. G 1-22-04 Plus ® POOL & SPA HEATERS WARNING WARNING Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 • 10951 W. Los Angeles Ave., Moorpark, CA 93021 PowerMax (919) 774-4151 (805) 523-2400 •...

  • Page 2: Table Of Contents

    Table of Contents Introduction ... Important Notices ... Warranty Information ... Operation ... Safety Rules ... Electronic Ignition Lighting/Operation - Natural ... Electronic Ignition Lighting/Operation - Propane ... Millivolt Lighting/Operation - Natural & Propane ... Operating (Controls) ... Indicator Light Description - Electronic Ignition Model ... Maintenance ...

  • Page 3: Introduction, Important Notices

    If you need any more information, or if you have any questions regarding to this pool heater, please contact Pentair Pool Products, Inc. at (800) 831-7133. These heaters are designed for the heating of swimming pools and spas, and should never be employed for use as space heating boilers, general purpose water heaters, in non-stationary installations, or for the heating of salt water.

  • Page 4: Warranty Information, Operation, Safety Rules

    Return the warranty registration card after filling in the serial number from the rating plate inside the heater. Pentair Pool Products’ high standards of excellence include a policy of continuous product improvement resulting in your state-of-the-art heater. We reserve...

  • Page 5: Operating Instructions, To Turn Off Gas To Appliance

    Operation (contd.) MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - FOR YOUR SAFETY: READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life and property damage. 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 6

    Operation (contd.) MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - FOR YOUR SAFETY: READ BEFORE LIGHTING The MiniMax Plus propane models have special features for additional safety and protection. Read the safety instructions for natural gas (page 5) before proceeding. If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life and property damage.

  • Page 7: Lighting Instructions

    Operation (contd.) MINIMAX PLUS MILLIVOLT LIGHTING/OPERATION- FOR YOUR SAFETY: READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life and property damage. Since propane gas is heavier than air, escaping propane will accumulate and remain at ground level. Do not attempt to light the heater.

  • Page 8: Operating (controls)

    Operation (contd.) OPERATING (CONTROLS) Dual Temperature Control System - For convenience and economy all MiniMax Plus heaters are equipped with two thermostats on the front of the heater control panel; see Figure 7. Figure 7. THERMOSTAT KNOB STOPPER Each thermostat is equipped with a mechanical stop that can be locked or unlocked with use of a screwdriver to prevent temperatures in excess of that desired by the user;...

  • Page 9

    Operation (contd.) HEAT (HEAT) The heat light is on any time the thermostat has signaled a call for heat which initializes the ignition safety firing circuit -- the light comes on to indicate successful firing of the main burners. TROUBLESHOOTING (CONTROLS) Example of troubleshooting with the assistance of the indicator lights.

  • Page 10

    Operation (contd.) TROUBLESHOOTING (CONTROLS) - Continued TRANSFORMER INCOMING CIRCUIT LINE VOLTAGE BREAKER POWER THERM SERVICE PRESS HEAT FRONT PANEL LEDS TRANSFORMER INCOMING CIRCUIT LINE VOLTAGE BREAKER THERM POWER SERVICE PRESS THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING HEAT NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM FRONT PANEL LEDS...

  • Page 11: Maintenance, Maintenance Instructions, Relief Valve, Energy Saving Tips, Spring And Fall Operation, Winter Operation

    Maintenance MAINTENANCE INSTRUCTIONS It is recommended that you check the following items at least every six months and at the beginning of every swimming season. 1. Examine the venting system. Make sure there are no obstructions in the flow of combustion and ventila- tion air.

  • Page 12: Chemical Balance

    Maintenance (contd.) CHEMICAL BALANCE POOL AND SPA WATER Your Pentair Pool Products pool heater was designed specifically for your spa or pool and will give you many years of trouble free service provided you keep your water chemistry in proper condition.

  • Page 13: Installation Instructions, Specifications

    Installation Instructions SPECIFICATIONS IMPORTANT NOTICE: 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.

  • Page 14: Water Connections, Manual Bypass, Below Pool Installation

    Installation (contd.) WATER CONNECTIONS Reversible Inlet/Outlet Connection The MiniMax Plus heater is factory assembled with right side inlet/outlet water connections. The inlet/ outlet header can be reversed for left side water connections without removing the heat exchanger. Reversing Water Connections Disassembly Tools needed: 1/4 in Nut Driver...

  • Page 15: Quick Flange Installation

    Installation (contd.) WATER CONNECTIONS QUICK-FLANGE INSTALLATION INSTRUCTIONS Each MiniMax Plus Quick-Flange Accessory Kit contains the following items: One (1) Quick-Flange unit Four (4) 3/8 Bolts Two (2) Plastic sleeves FOR 1½ & 2 in. SCHEDULE 40 PVC PIPE Figure 13. Gasket/Sleeve 1.

  • Page 16: Gas Connections, Gas Line Installation, Regulated Manifold Pressure Test

    Installation (contd.) GAS CONNECTIONS GAS LINE INSTALLATIONS 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.

  • Page 17: Ventilation

    Installation (contd.) VENTILATION OUTDOOR INSTALLATION ONLY (See additional instructions for outdoor Power- Max units in PowerMax Appendix) For outdoor installation with built in vent top, the heater must be placed in a suitable area on a level, noncombus- tible surface. Do not install the heater under an overhang with clearances less than 3 feet from the top of the heater.

  • Page 18

    Installation (contd.) INDOOR INSTALLATION (USA ONLY) OUTDOOR SHELTER INSTALLATION (CANADA) (See additional instructions for outdoor PowerMax units in PowerMax Appendix) All products of combustion and vent gases must be completely removed to the outside atmosphere through a vent pipe which is connected to the draft hood.

  • Page 19: Installation On Floors Constructed Of Combustible Materials

    Installation (contd.) NOTE The heater requires two uninterrupted air supply openings; one for ventilation and one to supply oxygen for proper gas combustion. The air supply openings should be sized according to Tables 10. and 11. Air supply requirements below apply to all MiniMax heaters, including PowerMax versions.

  • Page 20: Indoor Draft Hood Installation, Electrical, Transformer Wiring Instruction

    Installation (contd.) HEATER Figure 24. ELECTRICAL, IID ELECTRONIC UNITS Electrical Rating 60 Hz 115 V.A.C. or 230 V.A.C. 50/60 Hz 208 V.A.C. or 240 V.A.C. NOTE If any of the original wiring supplied with this heater must be replaced, installer must supply (No.

  • Page 21

    Installation (contd.) MiniMax Plus Electronic Ignition Wiring Diagram PLUG Rev. G 1-22-04 PLUG TFUSE HLMT PRESS P/N 471048...

  • Page 22

    Installation (contd.) MINIMAX WIRING DIAGRAM (MILLIVOLT) DUAL THERM (HONEYWELL ELECTRONIC) IF ORIGINAL FACTORY WIRING MUST BE REPLACED, INSTALLER MUST SUPPLY UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 105 C˚ TEMPERATURE RATING. THERMAL FUSE WIRING MUST BE REPLACED WITH UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 125 C˚...

  • Page 23: Trouble Shooting (general)

    Troubleshooting - General Possible Cause Heater will not come on Automatic ignition system fails Pump not running Pump air locked Filter dirty Pump strainer clogged Defective wiring or connection Defective pressure switch Defective gas controls On-Off switch in "OFF" position Heater Short Cycling Insufficient water flow Defective wiring...

  • Page 24

    MINIMAX PLUS HEATER - ALL MODELS P/N 471048 Rev. G 1-22-04...

  • Page 25

    " 8 " 2 " 8 " 2 " 8 " 1 & v i l v i l v i l v i l " 4 i l s v i l " 4 v i l , . y , .

  • Page 26

    MiniMax Plus (Only) Parts List, contd. " ½ " l l i I I ( l l i " " " " " " l l i l l i I I ( " " P/N 471048 l l i Rev.

  • Page 27

    Pool & Spa Heater OPERATION & INSTALLATION MANUAL (APPENDIX) INSTALLER: AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO POOL & SPA HEATER Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 (919) 774-4151 • 10951 W. Los Angeles Ave., Moorpark, CA 93021 (805) 523-2400 •...

  • Page 28

    INTRODUCTION This manual provides information for the proper installation, operation and maintenance of the PowerMax pool and spa heater. Please read these installation and operation instructions thoroughly before attempting installation or operation of your pool and spa heater. GENERAL SPECIFICATION ...For the installer and operator of the PowerMax pool and spa heater.

  • Page 29: Pressure Switch

    MOUNTING ASSEMBLY Follow these instructions if the PowerMax venting system was purchased as an assembly kit. Remove the vent kit assembly (indoor). Mount the plenum assembly on the flue collector top using the screw provided. Connect the wire harness to the heater control box. Follow the instructions on page 5.

  • Page 30

    VENTING The vent pipe must be the same size or larger than what is indicated in Table 1. The PowerMax 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 31

    31 31 Rev. G 1-22-04 P/N 471048...

  • Page 32

    P/N 471048 Rev. G 1-22-04...

  • Page 33

    PowerMax Electronic Ignition Wiring Diagram PLUG Rev. G 1-22-04 PLUG TFUSE HLMT PRESS P/N 471048...

  • Page 34

    INSTRUCTION FOR WIRING A POWERMAX INDUCED DRAFT ASSEMBLY TO A POOL HEATER WITH IID IGNITION. Make sure all power is off before wiring the heater. The Power vent assembly only operates on a 120 VAC. The following instructions configure the power vent assembly to operate with the PowerMax on a single 120 VAC circuit.

  • Page 35

    WIRING DIAGRAM FOR POWERMAX KIT ORANGE BLUE MALE FEMALE FEMALE ORANGE TO IGNITION TO THERMOSTAT MODULE PIN 6 CIRCUIT BOAD Rev. G 1-22-04 AIR PRESSURE SWITCH BLACK BLACK GREEN 24 VAC RELAY MOTOR WHITE COMMON GREEN SAFETY GROUND TO GROUND MAIN CONTROL BOX.

  • Page 36

    POWERMAX HEATER - ALL MODELS P/N 471048 A-10 Rev. G 1-22-04...

  • Page 37

    PowerMax Heater (Only) Parts List l i a t l o " 8 " 2 - " " 2 " 8 " 1 c r i t i u c r i D I I i t c t a t .

  • Page 38

    PowerMax Heater (Only) Parts List, contd. i h s / n i " 2 / n i " ½ f f o n i ( ) t u t i w h t i e l f f e l f f f f a s e l e u l...

  • Page 39

    PowerMax Assembly & c i l . t f i t l . t f Rev. G 1-22-04 PowerMax Assembly Parts List A-13 P/N 471048...

  • Page 40: Save These Instructions

    40 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 471048 Rev. G 1-22-04...

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