Pentair MiniMax Plus Service Manual
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Pentair MiniMax Plus Service Manual

Pentair MiniMax Plus Service Manual

Pool & spa heaters
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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.
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. C 12-1-00
MiniMax Plus
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.
Pentair Pool Products
1620 Hawkins Ave., Sanford, NC 27330
10951 West Los Angeles Ave., Moorpark, CA 93021
WARNING
WARNING
(919) 774-4151
•
(805) 523-2400
•
1
P/N 38033

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  • Page 1 MiniMax Plus POOL & SPA HEATERS SERVICE MANUAL WARNING 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.

  • Page 2: Table Of Contents

    Reinstalling Heat Exchanger ................................. Glossary ........................20 Troubleshooting ......................21-32 Electrical Wiring Diagram ................................Millivolt Wiring Diagram ................................. Test and Adjustments ....................35 MiniMax Plus Exploded View & Parts List............... 36-38 Warranty Information ....................Back Cover P/N 38033 Rev. C 12-1-00...

  • Page 3: Introduction

    MiniMax Plus Pools and Spa Heater ...For the installer and operator of the MiniMax Plus 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.

  • Page 4: Installation Tips

    Installation Tips DO NOT INSTALL HEATER UNDER ANY ROOF OVERHANG NOT HAVING A PROPER RAIN GUTTER. UTION UTION CAUTION UTION UTION DO NOT PLACE GAS SUPPLY LINE UNION COUPLING INSIDE OF HEATER JACKET. (Follow Recommendations of National Fuel Gas Code NFPA 54.) UTION UTION CAUTION...

  • Page 5: Dimensions

    Dimensions Outdoor installation - stackless " " " " B . n i ½ . n i HIGH PERFORMANCE HEATER . n i ½ . n i . n i ½ . n i . n i ½ . n i .

  • Page 6: Outdoor Installation Requirements

    Installation - Outdoors The heater should not be installed closer than 6 inches to Do not install the heater in locations which will permit any fences, walls or shrubs at any side or back, nor the accumulation of leaves or other combustible material closer than 18 inches at the plumbing side.

  • Page 7: Water Connections

    Water Connections The MiniMax heater has the unique capability of direct schedule 40 PVC plumbing connections. FOR 1½ & 2 in. SCHEDULE 40 PVC PIPE FOR 1½ & 2 in. COPPER PIPE Pipe Plastic Bushing Gasket/Sleeve NOTE Gasket Bolt the flange and gasket assembly to the header before gluing.

  • Page 8: Reversing Header Connections

    Reversing Header Reversible Inlet/Outlet Connections The MiniMax heater is factory assembled with right 4. Remove the return header bolts. side inlet/outlet water connections. The inlet/outlet header can be reversed for left side water connections without removing the heat exchanger. 1. Remove the inspection plates. 5.

  • Page 9: Air Requirements

    Air Requirements Vent Requirements Vent Installation A vent pipe extension of the same size must be connected to the draft hood and extended at least two (2) feet above any obstacle within a 10 foot radius of the vent. The vent should then be capped with an approved weather cap.

  • Page 10: Gas Connections

    Gas Requirements Gas Line Installations Pipe Sized For Length Of Run In Equivalent Feet Before installing the gas line, be sure to check which ¼ ½ fuel the heater has been designed to burn. This is important because different types of fuel require different pipe sizes.

  • Page 11: Electrical

    Transformer and Remote Wiring Electrical - Rating CAUTION NOTE If any of the original wiring supplied with the heater The heater must be electrically grounded and must be replaced, the installer must supply No. 18 bonded in accordance with local codes or in ab- AWG 105°...

  • Page 12: Electrical Wiring Schematic

    MiniMax Plus I.I.D. Wiring Schematic PLUG PLUG P/N 38033 Rev. C 12-1-00...

  • Page 13: Electrical Wiring Pictorial

    J BOX IID PILOT TRANSFORMER CHASSIS SHEET METAL HI TENSION WIRE BLUE IGNITION MODULE HILIMITS GAS VALVE PACFAB 6800 DUAL ELECTRONIC THERMOSTAT The wiring was crossed from the Switch to the Board and we used a Breaker (Reset) that was external to the Transformer.

  • Page 14: Operation

    Starting Operation (I.I.D.) Natural / Propane Note: This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. SAFETY INFORMATION -- IF YOU SMELL GAS, FOLLOW THESE RULES: 5. Do not light matches or lighter. 1.

  • Page 15: Chemical Balance

    Pool and Spa Water If pH becomes too high (over alkaline), it has these effects: Your Pentair Pool Products pool heater was designed specifically for your spa or pool and will give you many 1. Greatly lowers the ability of chlorine to destroy years of trouble free service provided you keep your bacteria and algae.

  • Page 16: Maintenance

    In some installations, a relief valve is required period of time. on the MiniMax Plus. Test the relief valve at Winter Operation least once a year by lifting the valve lever. (A.S.M.E. version varies slightly and has the If the pool won't be used for a month or more, turn relief valve pre-installed at factory.)

  • Page 17: Burner Tray Removal

    Maintenance - Burner Tray Removal At some time during the life of a heater, you may 10. Remove each burner and check for any need to inspect and repair the parts of the heater that blockages. allows the gas to flow from the gas supply line into the burners.

  • Page 18: Desooting

    Maintenance - Desooting Common Causes of Sooting 1. Low gas pressure. 7. If flames burn clean, replace baffles, flue collector, and top. 2. Inadequate air supply or inadequate venting. 3. Foreign material in burners and orifices; dirt, CAUTION spider webs, etc. 4.

  • Page 19: Reinstalling Heat Exchanger

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

  • Page 20: Glossary

    Glossary 1. BURNER: A device for the final conveyance of gas, mean and include any fuel gas which is composed or a mixture of gas and air, to the combustion zone. predominantly of any of the following hydrocarbons, or mixtures of them: propane, propylene, normal 2.

  • Page 21: Troubleshooting

    Troubleshooting DIAGNOSTIC LIGHT OPERATION The circuit board in the MiniMax Plus uses lights that are wired in sequence with the controls. The MiniMax Plus still uses the same controls as the original MiniMax but this method of wiring is more helpful while trouble shooting.
  • Page 22 Troubleshooting DIAGNOSTIC LIGHTS 1. The POWER Light indicates voltage to the 5. The HEAT Light is attached to the MV (Main circuit board from the Transformer. On the Valve) terminal on the module. This terminal does previous MiniMax heaters, the voltage from the not receive voltage until a Pilot Flame has been transformer went through a switch and the established.
  • Page 23 Troubleshooting MiniMax Plus Troubleshooting/Check List 1. Look at the lights/which ones are on? 2. Check for correct voltage on both sides of the transformer. 3. Check Ignition wire connections on the module and the pilot ignitor. 4. Check position of pilot to the burner and check the components for correct spacing.
  • Page 24 DIAGNOSTIC LIGHTS SHOW Troubleshooting “POWER” ONLY! This list will suggest situations that might cause 4. Make sure the Thermostat knobs have been this symptom. turned to “Hot” - because the voltage must pass through the thermostat (potentiometer) first 1. Check water temperature - if the water has before going to any other control, if the reached the desired temperature, the thermostat potentiometers or thermistor is not working or...
  • Page 25 Troubleshooting Troubleshooting POWER / T-STAT ONLY! This list will suggest situations that might cause this symptom. 1. Remote Control switch “OFF” - switch remote to “Service” or “Manual” or remove remote control wiring and replace jumper wire on back of circuit board. 2.
  • Page 26 Troubleshooting POWER / T-STAT / AUX ONLY! This list will suggest situations that might cause this symptom. 1. Pump “OFF” - switch Pump on and make sure it primes. 2. Pump too small or worn out - minimum 30 G.P.M. to cause Pressure Switch to close. (Some 2-speeds will not produce 30 G.P.M., on low speed.) 3.
  • Page 27 Troubleshooting POWER / T-STAT / AUX / PRESS / SERVICE / This list will suggest situations that might cause this symptom. 1. Check the 3 lights on the back of the Circuit Board. These 3 lights are connected to 3 different controls in this order - #1 - High Limit.
  • Page 28 Troubleshooting THE SERVICE LIGHT This list will suggest situations that might cause this symptom. 1. The primary responsibility for the Service Light is to illuminate whenever there is a trial for pilot. After the Pilot Ignitor sparks, gas flows through the pilot orifice where it is ignited by the spark and a pilot flame is established, the spark goes out and the Service Light goes out.
  • Page 29 Troubleshooting PILOT FLAME - WON’T FIRE If the pilot flame has been established but the main burners won't fire: 1. Check for voltage at the Red wire (MV) on the gas valve. If there is 24VAC present, the gas valve should open allowing gas to flow to the main burners where the pilot will ignite the gas and you should have combustion.
  • Page 30 Troubleshooting CYCLES RAPIDLY 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 High Limit Switches (installed into the inlet/outlet header) are sensing a temperature of 150 degrees.
  • Page 31 MINIMAX MILLIVOLT HEATER TESTING Troubleshooting PILOT WON’T LIGHT When the pilot will not light or stay lit, there are five pos- sible causes: 1. A weak or defective pilot generator. 2. A plugged or partially plugged pilot orifice. 3. A short in the control wiring. 4.
  • Page 32 Troubleshooting MILLIVOLT PRESSURE SWITCH If heater fires when you jumper the pressure switch, When main burners shut down, the gas pressure increases in the pilot tube, until the pilot flame heats the switch is suspect. Before replacing the switch, make sure wire terminals are clean and tight, the the generator enough to cause the gas valve to open pressure switch tube is clear and the filter is clean.

  • Page 33: Electrical Wiring Diagram

    MiniMax Electronic Wiring MAY 1991 - 1997 POWER THERMOSTAT BOARD SWITCH POOL SENSOR POT 2 POT 1 TRANSFORMER LINE 24VAC VOLTAGE SAFETY SHUT-OFF HI-LIMIT POWER SWITCH THERMAL CUT-OFF (OPTION) TERMINAL CONNECTOR 24V GND PV PV/MV PRESSURE SWITCH POWER PRESS HEAT SERVICE LIGHT LIGHT...

  • Page 34: Millivolt Wiring Diagram

    MiniMax Millivolt Wiring BEFORE 1-15-01 MINIMAX WIRING DIAGRAM (MILLIVOLT) DUAL THERM ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS HEATER MUST BE REPLACED. INSTALLER MUST SUPPLY (NO. 18 AWG 105˚ C U.L. & C.S.A. FOR CANADA) COPPER WIRE. PILOT LEGEND: WHT: WHITE GENERATOR...

  • Page 35: Test And Adjustments

    Tests and Adjustments 1. Push power switch off. 2. Turn gas valve knob off. 3. Remove pressure tap plug. 4. Attach the Manometer. 5. Turn gas valve knob on. 6. Push power switch on. 7. Fire heater and read Manometer. MiniMax Gas Pressure Requirements Natural Propane...

  • Page 36: Minimax Plus Exploded View & Parts List

    MINIMAX PLUS HEATER - ALL MODELS - Replacement Parts P/N 38033 Rev. C 12-1-00...
  • Page 37 MiniMax Plus (Only) Parts List t i k . y s n i ( ) r o t i k . y s ) r o t l o " 8 " 2 t l o - " " 2 "...
  • Page 38 MiniMax Plus (Only) Parts List, contd. g n i e e l , e v " 2 e e l , e v ½ " f f o n i a n i ( ) t u ) s d...
  • Page 39 NOTES Rev. C 12-1-00 P/N 38033...
  • Page 40 MiniMax Plus and PowerMax Heaters Limited Warranty Your MiniMax Plus pool heater is another quality product from Pentair Pool Products Inc. and is backed by the following warranty. 1. The following parts are warranted for 5 years from date of purchase: The MiniMax Plus and PowerMax cabinet and combustion chamber, the main burners and burner manifold, the inlet/outlet header and the return header.

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