1 MiniMax® Plus and PowerMax™ POOL & SPA HEATERS OPERATION & INSTALLATION 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. For additional free copies of this manual; call (800) 831-7133. To Consumer Retain For Future Reference U.S.
Table of Contents Introduction ............................................................................................................... 3 Important Notices ...................................................................................................................................................................... 3 Warranty Information ........................................................................................................................................................
Introduction MiniMax® Plus and PowerMax™* Pool and Spa Heaters Congratulations on your purchase of a MiniMax Plus 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 MiniMax Plus is a compact, lightweight and efficient gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe and has a built-in top.
Operation (contd.) 4 This instruction manual provides operating instructions, installation and service information for the MiniMax Plus high performance heater. The information in this manual applies to the MiniMax Plus 150, 195, 200, 250, 300, 350, and 400 natural gas and propane (LP) models. 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 MiniMax Plus.
Operation (contd.) 5 MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - NATURAL GAS FOR YOUR SAFETY: READ BEFORE LIGHTING WARNING 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. A.
Operation (contd.) 6 MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - PROPANE FOR YOUR SAFETY: READ BEFORE LIGHTING NOTE The MiniMax Plus propane models have special features for additional safety and protection. Read the safety instructions for natural gas (page 5) before proceeding. WARNING If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life and property damage.
Operation (contd.) 7 MINIMAX PLUS MILLIVOLT LIGHTING/OPERATION-NATURAL GAS & PROPANE FOR YOUR SAFETY: READ BEFORE LIGHTING WARNING 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.
Operation (contd.) 8 OPERATING (CONTROLS) Dual Temperature Control System - (Electronic and Millivolt Models) For convenience and economy all MiniMax Plus heaters are equipped with two thermostats on the front of the heater control panel; see Figure 7. THERMOSTAT ADJUSTMENT The knob with locking feature eliminates the need for constant thermostat adjustments. Set the knob pointer to the desired pool or spa temperature.
Operation (contd.) 9 SERVICE (SERVICE) The service light is off during normal operation of heater. The light only comes on if a problem with a control has occurred or when the heater is first firing. The problem must be investigated by the serviceman prior to attempts to fire the heater again. 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.
Operation (contd.
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 ventilation air. 2. Visually inspect the main burner and the pilot burner flame. The normal color of the flame is blue. When flame appears yellow, burners should be inspected and cleaned; see Figure 10. Blue Flame 3/8 to 1/2 in.
Maintenance (contd.) 12 CHEMICAL BALANCE RULE: 7.4 to 7.6 is a desirable pH range. It is essential to maintain correct pH, see Table 2. 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 years of trouble free service provided you keep your water chemistry in proper condition.
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. Outdoor installation - stackless Model "A" Dim "B" Dim 150 17 7/8 in. 6½ in.
Installation (contd.) 14 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 9/16 in. Socket and Wrench 1/2 in. & 9/16 in. Open Wrench 1. Remove the inspection plates. 2.
Installation (contd.) 15 WATER CONNECTIONS QUICK-FLANGE INSTALLATION INSTRUCTIONS Each MiniMax Plus Quick-Flange Accessory Kit contains the following items: One (1) Quick-Flange unit Two (2) 2 in. Rubber gaskets Four (4) 3/8 Bolts Four (4) 3/8 in. Washers Two (2) Plastic sleeves FOR 1½ & 2 in. SCHEDULE 40 PVC PIPE FOR 1½ & 2 in. COPPER PIPE Pipe Plastic Bushing Figure 13. Gasket/Sleeve 1. Insert plastic sleeves into the “Quick-Flange” inlet/outlet openings. 2. Slip the 2 in.
Installation (contd.) GAS CONNECTIONS 16 Pipe Sized For Length Of Run In Equivalent Feet 1/2 in. GAS LINE INSTALLATIONS Model Before installing the gas line, be sure to 150 check which gas the heater has been 195/200 designed to burn. This is important 250 because different types of gas require 300 different gas pipe sizes. The rating plate on the heater will indicate which gas the 350 heater is designed to burn.
Installation (contd.) 17 VENTILATION STACK TYPE OUTDOOR VENT KIT OUTDOOR INSTALLATION ONLY (See additional instructions for outdoor PowerMax units in PowerMax Appendix) For outdoor installation with built in vent top, 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. Model Vent Cap Product No. Vent Dia.
Installation (contd.) 18 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.
Installation (contd.) 19 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. b) Construct a non-combustible base from masonry blocks as illustrated, see Figure 23.
Installation (contd.) 20 Draft Hood Top Cover Adaptor Screw (2 PLC's) INDOOR DRAFT HOOD INSTALLATION 1. Take out the louvered outer top piece after first removing the sheet metal screws, attaching it to the cabinet. 2. Install the adaptor (vent kit). 3. Install the top cover (vent kit). 4. Install the draft hood (vent kit). Use the provided screws to secure the vent assembly. HEATER Figure 24. Transformer Wiring Instruction ELECTRICAL, IID ELECTRONIC UNITS Electrical Rating 60 Hz 50/60 Hz 115 V.A.C.
BLK WHT/BLK WHT/RED RED GRN L2-1 L1-1 W1 POOL P5 COM P8 SPA P6 POOL OFF SPA J5 J8 J6 AUX. CONTACTS 1 P9 J9 TPROBE 1 THERMOSTAT SELECT SWITCH CLOSE ON CALL FOR HEAT CONTROL RELAY J3 J7 1 JI0 VLV PI0 BLK BLK P11 THERMOSTAT J11 CIRCUIT BOARD 1 IGN MODULE 1 J2 P7 TEMPERATURE PROBE GRN MV PV/MV PV IGNITION WIRE PV BLU 3 J4 24V P4 MV/PV ORG MV RED GRN IGNITION RETURN RED WHT BLU F2 THERMAL FUSE F1 WHT 4 25D K .032 D.
Installation (contd.) 22 MINIMAX WIRING DIAGRAM (MILLIVOLT) DUAL THERM (HONEYWELL ELECTRONIC) TH/PP PILOT GENERATOR WHT RED TH 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˚ TEMPERATURE RATING.
Troubleshooting - General Possible Cause Remedy Heater will not come on Automatic ignition system fails Check if electrical connections are correct and securely fastened – If YES, call serviceperson.
MINIMAX PLUS HEATER - ALL MODELS 39 H O T INNER TOPS M ode l No. Part No. 15 470024 200 470025 250 470026 300 470027 350 470028 400 470029 38 5 37 4 3 2 1a 25 21 36 35 6 1 33 7 32 31 34 27 28 22 23 26 30 29 9 41 13 12 10 15 42 14 24 44 40 20 16 17 18 P/N 471048 19 8 11 Rev.
MiniMax Plus (Only) Parts List ITEM D ESC R IPTION QTY 150 195/200 250 300 350 400 1 Vent ki t assy. (i ndoor) 1 460227 460228 460230 460231 460233 460234 1a Vent ki t assy.
MiniMax Plus (Only) Parts List, contd.
PowerMax™ 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 Rev.
PowerMax™ Pool and Spa Heater 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.
MOUNTING ASSEMBLY Follow these instructions if the PowerMax venting system was purchased as an assembly kit. 1. 2. 3. 4. 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. Mount the new top on the top of the heater. Using a #28 drill bit to drill the four holes on the right side of the heater for the mounting screws.
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. The total length of the horizontal run must not exceed an equivalent of 45 feet. For all cases, each 90-degree elbow reduces the maximum horizontal vent run by 8 feet and each 45-degree elbow in the vent run reduces the maximum vent run by 4 feet.
Rev. G 1-22-04 Detail H Chimney 3 ft. min. L K J A-5 may use a single wall vent pipe with permanently sealed seams and joints. must be suitable for use with category III appliances which have flue gas temperatures of less than 400 deg. F. must be the same diameter as the vent connector. Vent pipe extension: L must terminate with an approved (listed) roof jack, storm collar, and vent/weather cap. K must use a double-wall vent pipe through the roof penetration. J must extend at least 3 ft.
P/N 471048 F 6 in. min. A-6 Walkway Must be suitable for use with Category III Appliances which have flue gas temperatures of less than 400 deg. F. Must be the same diameter as the vent connector. The Vent Pipe: F Optional Horizontal Venting. Outdoor Stack Kit G 4' C A 3' Must be not less than 7 ft. above public walkways. A Must be at least 3 ft. above any forced air inlet located within a 10 ft. radius.
A-7 GRN WHT FAN MOTOR 120 VAC BLK 24 VAC RELAY SWITCH J3 POOL P5 COM P8 SPA P6 POOL OFF SPA J5 J8 J6 AUX. CONTACTS 1 J7 P9 J9 TPROBE 1 THERMOSTAT SELECT SWITCH CLOSE ON CALL FOR HEAT CONTROL RELAY J2 J4 24V 1 JI0 VLV BLK BLK P11 THERMOSTAT J11 CIRCUIT BOARD 1 TEMPERATURE PROBE PV BLU GRN MV PV/MV PV IGNITION WIRE MV/PV ORG MV RED GRN IGNITION RETURN RED WHT BLU F2 THERMAL FUSE F1 WHT IGN MODULE 1 25D K .032 D.
INSTRUCTION FOR WIRING A POWERMAX INDUCED DRAFT ASSEMBLY TO A POOL HEATER WITH IID IGNITION. WARNING 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. Take care as wiring errors may burn-out the transformer and blower motor.
AIR PRESSURE SWITCH ORANGE WIRING DIAGRAM FOR POWERMAX KIT BLACK BLACK GREEN 24 VAC RELAY GRD FAN MOTOR HEATER GROUND LUG ORANGE BLUE WHITE COMMON GREEN SAFETY GROUND MALE TAB FEMALE TAB ORANGE TO THERMOSTAT CIRCUIT BOAD BLACK HOT 120 VAC ONLY FEMALE TAB TO GROUND MAIN CONTROL BOX. TO IGNITION MODULE PIN 6 24V Figure 4. Rev.
POWERMAX HEATER - ALL MODELS 1 38 5 37 4 3 OPTIONAL OUTDOOR VENT 2 25 471395 Models 150 - 200 471396 Models 250 - 400 21 36 35 6 33 7 32 31 34 27 22 28 23 30 29 9 13 12 10 15 14 40 20 16 17 18 P/N 471048 A-10 19 8 11 Rev.
PowerMax Heater (Only) Parts List ITEM DESCRIPTION 1 QTY 150 195/200 250 300 350 400 1 460048 460049 460050 2 PowerMax Vent Kit (complete)* (Power Max Vent replacement parts detailed in PowerMax Appendix, A-13) Return header 1 070994 070994 070994 070994 070994 070994 3 Bracket washer 2 074216 074216 074216 074216 074216 074216 4 Bolt HH 3/8" x 2" 4 073739 073739 073739 073739 073739 073739 5 Bolt 3/8" - 16 x 1 1/2" 4 070416 070416 070416 070416 070416 070416 6 Washer 3/8" ID
PowerMax Heater (Only) Parts List, contd.
PowerMax Assembly PowerMax Assembly Parts List ITEM D ESC R IPTION QTY 150 200 250 300 350 400 1 Plenum 1 470139 470140 470141 470142 470143 470144 2 Blower combusti on 1 470008 470008 470007 470007 470007 470007 3 C ontrol box si de & base 1 470331 470331 470331 470331 470331 470331 4 C ontrol box top 1 470337 470337 470337 470337 470337 470337 5 Adapter ri ng 1 470336 470336 470326 470326 470326 470326 6 Adapter base 1 470334 470334 470325 47
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.