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1
®
MiniMax 75 & 100
ABOVEGROUND POOL & SPA HEATERS
OPERATION & INSTALLATION MANUAL
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
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. Call (800) 831-7133
for additional free copies of these instructions.
To
Consumer
Retain For
Future
Reference
U.S. Patent Numbers
5,
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2 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operation . . . . . . . . . . . . . .
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3 Introduction ® MiniMax 75 & 100 ABOVEGROUND POOL AND SPA HEATERS Congratulations on your purchase of a MiniMax 100 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 100 is a compact, lightweight and efficient gas fired high performance aboveground pool and spa heater that can be connected to schedule 40 CPVC or ABS pipe and has a built-in top. Unless noted otherwi
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4 This instruction manual provides operating instructions, installation, and service information for the MiniMax 100 high performance heater. The information in this manual applies to the MiniMax 75, and 100, natural gas and propane, DSI; and MiniMax 100 millivolt standing pilot heater models. It is very important the owner/installer read and understand the section covering installation and recognize the local code and state codes before installing the MiniMax 100. History and experience have sh
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Operation (contd.) 5 MINIMAX 100 DIRECT-SPARK IGNITION 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. If you suspect a propane leak, lighting the heater can result in a fire or explo
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PILOT ADJ Operation (contd.) 6 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. If you suspect a propane leak, lighting the heater can result in a fire or explosion which can
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Operation (contd.) 7 OPERATING (CONTROLS) HEATER OPERATION DIRECT SPARK ELECTRONIC AND GENERAL The MiniMax 100 DSI employs a microprocessor MILLIVOLT MODELS based Direct Spark Ignition (DSI) system to light the For convenience and economy all MiniMax 100 main burner and therefore has no pilot. The ignition heaters are equipped with a thermostat on the front of circuit operates at 24 VAC and requires that line the heater control panel; see Figure 5. voltage 115/230 be supplied to the heater. Dire
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Operation - Heater (contd.) 8 Failure to Light- Lockout 1. Should the main burner fail to light, or flame is not Control Fault -Diagnostic LED Conditions detected during the trial-for-ignition (TFI) period Error Mode LED Indication the control will go into lockout and the valve will be turned off immediately. Internal Control Failure Steady on 2. Recovery from lockout requires a manual reset by Flame Sense Fault 2 flashes resetting the thermostat or turning off the ON/OFF Ignition Lockout 3 flas
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9 Operation - Heater (contd.) Proper Electrode Location Flame Sensor Current Check Flame current is the current which passes through Proper location of the ignition electrode assembly is the flame sensor to ground. The minimum flame important for optimum and safe system performance. current necessary to keep system from lockout is 0.7 The electrode assembly should be located as noted in microamperes. To measure flame current, connect Figure 6. The electrode assembly is NOT field DC microammeter
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10 Maintenance MAINTENANCE INSTRUCTIONS Blue Flame 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 (on millivolt models). The normal color of the flame is blue. When flame appears yellow, burners should be inspected and cleaned; see Figure 8.
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Maintenance (contd.) 11 CHEMICAL BALANCE If pH becomes too high (over alkaline), it has these effects: POOL AND SPA WATER 1. Greatly lowers the ability of chlorine to destroy Your Pentair Pool Products pool heater was designed bacteria and algae. specifically for your spa or pool and will give you many 2. Water becomes cloudy. years of trouble free service provided you keep your water chemistry in proper condition. 3. There is more danger of scale formation on the plaster or in the heat exchang
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12 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. The heater must be installed on a level surface consisting entirely of, or a combination of, noncombustible
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Installation (contd.) 13 PLUMBING CONNECTIONS PRESSURE SWITCH The pressure switch will keep the circuit open when the The MiniMax 100 heater has the unique capability of pump is not on and operating. When the filter pump direct schedule 40 or 80 CPVC/ABS/PVC plumbing turns on, the pressure switch closes the circuit and the connections. Either a Quick-Flange or Quick-Flange II heater will operate. When the heater is installed below (depending on model ordered) has been included with the water l
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Installation (contd.) 14 WATER CONNECTIONS QUICK-FLANGE II INSTALLATION INSTRUCTIONS FOR 1½ SCHEDULE 40 CPVC or ABS PIPE or SCHEDULE 80 PVC (you may adapt to SCH 40 PVC 12 inches beyond the Quick Flange II) (1½ in. npt x 1½ in. CPVC/ABS slip male adaptor may be required ) Figure 12. 1. Insert 2 in. rubber gaskets over 2 in. gasket retainer rings molded to bottom of Quick-Flange II; see Figure 12. 2. Bolt Quick-Flange II to header using supplied 3/8 in. bolts and 3/8 in. washers. 3. Using pipe d
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PILOT ADJ OFF VENT TH TH TP TP Regulator Adjustment Cap Installation (contd.) 15 GAS CONNECTIONS GAS LINE INSTALLATIONS REGULATED MANIFOLD Before installing the gas line, be sure to check which gas PRESSURE TEST the heater has been designed to burn. This is important 1. Attach the manometer to the heater jacket. because different types of gas require different gas pipe 2. Shut off the main gas valve. sizes. The rating plate on the heater will indicate which 3. Remove 1/8" NPT plug on the outle
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Installation (contd.) 16 VENTILATION OUTDOOR INSTALLATION 6 in. This heater is certified by International Approval Services (AGA & CGA) for outdoor installation. If the heater is installed in very cold areas proper precau- 6 in. tions are needed for freeze protection. The heater 24 in. must be placed in a suitable area on a level, noncom- bustible surface. Do not install heater under an overhang with clearances less than 3 feet from top of the heater. The area under an overhang must be open
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Installation - Ventilation (contd.) 17 INDOOR INSTALLATION NOTE The heater requires two uninterrupted air The installation of venting system should conform with supply openings; one for ventilation and one to the latest edition of ANSI Z223.1, the National Fuel supply oxygen for proper gas combustion; see Gas Code, and/or in Canada, CAN/CGA-B149.1 or .2 Figure 17. or applicable provision of the local codes. Minimum requirements for free air supply openings: All products of combustion and vent g
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Installation - Ventilation (contd.) 18 VENT TEST the terminal block located inside the junction box before removing the cord and strain relief from the cabinet. The Use the following steps to heater may be hard wired with either 120 or 240 VAC - perform a quick check of to convert to 240 VAC, change the transformer wiring your venting installation. connected to the output side of the terminal block first. Allow the heater to operate The heater must be grounded and the heater electrically for 15
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Installation (contd.) 19 MiniMax 100 Electronic Direct Spark Ignition Wiring Diagram MiniMax 100 ELECTRONIC WIRING DIAGRAM MODULE IF ORIGINAL FACTORY WIRING MUST BE REPLACED, INSTALLER MUST SUPPLY UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 150˚ C TEMPERATURE RATING. THERMAL FUSE WIRING MUST BE REPLACED WITH UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 150˚ C TEMPERATURE RATING.. INTERCONNECTING WIRING TO APPLIANCE MUST CONFORM TO THE NATIONAL ELECTRICAL CODE OR SUPERCEDING LOCA
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20 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 serviceman. Pump not running Place pump in operation Pump air locked Check for leaks Filter dirty Clean filter Pump strainer clogged Clean strainer Defective wiring or connection Repair or replace wires Defective pressure switch Replace Switch Defective gas controls Call serviceman On-Off switch in "OFF" pos
