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Pentair PowerMax manual

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Table of contents for the manual

  • Page 1

    Rev . G 1-22-04 P/N 471048 1 1 FOR YOUR SAFETY - READ BEFORE OPERA TING W arning: 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. Do not store or use gasoline or other flammable vapors and liqui[...]

  • Page 2

    P/N 471048 R e v . G 1 - 2 2 - 0 4 2 T able of Contents Introduction ............................................................................................................... 3 Important N otices .............................................................................................................. .....................................[...]

  • Page 3

    Rev . G 1-22-04 P/N 471048 3 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 a[...]

  • Page 4

    P/N 471048 R e v . G 1 - 2 2 - 0 4 4 Operation 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 th[...]

  • Page 5

    Rev . G 1-22-04 P/N 471048 5 Operation (contd.) FOR YOUR SAFETY : READ BEFORE LIGHTING A. This heater is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERA TING smell all around the heater area for gas. Be sure to smell next to the floor because some gas is heavier than air [...]

  • Page 6

    P/N 471048 R e v . G 1 - 2 2 - 0 4 6 Operation (contd.) 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. MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERA TION - PROP ANE 1. STOP! Read the saf[...]

  • Page 7

    Rev . G 1-22-04 P/N 471048 7 Operation (contd.) FOR YOUR SAFETY : READ BEFORE LIGHTING A. This heater is equipped with a pilot which must be lighted manually . When lighting the pilot, follow these instructions exactly . B. BEFORE LIGHTING smell all around the heater area for gas. Be sure to smell next to the floor because some gas is heavier than [...]

  • Page 8

    P/N 471048 R e v . G 1 - 2 2 - 0 4 8 Knob Stopper Screw A OPERA TING (CONTROLS) Dual T emperature Control System - (Electronic and Millivolt Models) Operation (contd.) 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. Figure 8. THERMOST A T KNOB S[...]

  • Page 9

    Rev . G 1-22-04 P/N 471048 9 Operation (contd.) HEA T (HEA T) 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. SER VICE (SERVICE) The service light is off during normal operation of heater . The ligh[...]

  • Page 10

    P/N 471048 R e v . G 1 - 2 2 - 0 4 10 TROUBLESHOOTING (CONTROLS) - Continued Operation (contd.) PRESS PRESS HEATER FIRING - NORMAL OPERATION NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM PRESS PRESS THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING FRONT PANEL LEDS HEAT PRESS AUX SERVICE TRANSFORMER THERM POWER INCOM[...]

  • Page 11

    Rev . G 1-22-04 P/N 471048 11 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 . 2. V isually inspect the main burner and the pilot b[...]

  • Page 12

    P/N 471048 R e v . G 1 - 2 2 - 0 4 12 12 CHEMICAL BALANCE POOL AND SP A W A TER Y our 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. Three major items that can cause problems with your pool heater are im[...]

  • Page 13

    Rev . G 1-22-04 P/N 471048 13 Installation Instructions IMPOR T ANT 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,[...]

  • Page 14

    P/N 471048 R e v . G 1 - 2 2 - 0 4 14 PLUMBING CONNECTIONS The MiniMax Plus heater has the unique capability of direct schedule 40 PVC plumbing connections. A Quick-Flange has been included with the MiniMax Plus to insure conformity with PurexT riton’ s recom- mended PVC plumbing procedure. Other plumbing connections can be used. The instructions[...]

  • Page 15

    Rev . G 1-22-04 P/N 471048 15 Installation (contd.) W A TER CONNECTIONS QUICK-FLANGE INST ALLA TION INSTRUCTIONS Each MiniMax Plus Quick-Flange Accessory Kit contains the following items: One (1) Quick-Flange unit T wo (2) 2 in. Rubber gaskets Four (4) 3/8 Bolts Four (4) 3/8 in. W ashers T wo (2) Plastic sleeves FOR 1½ & 2 in. SCHEDULE 40 PVC [...]

  • Page 16

    P/N 471048 R e v . G 1 - 2 2 - 0 4 16 16 Installation (contd.) GAS CONNECTIONS GAS LINE INST ALLA TIONS 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 [...]

  • Page 17

    Rev . G 1-22-04 P/N 471048 17 24" DOOR 18" 6" 6" VENTILA TION OUTDOOR INST ALLA TION ONL Y (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 u[...]

  • Page 18

    P/N 471048 R e v . G 1 - 2 2 - 0 4 18 INDOOR INST ALLA TION (USA ONL Y) OUTDOOR SHEL TER INST ALLA TION (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. A vent[...]

  • Page 19

    Rev . G 1-22-04 P/N 471048 19 e d i s t u O m o r F r i A l l A l e d o M n o i t s u b m o C r o f r i A . n I . q S n o i t a l i t n e V r i A . n I . q S 0 5 17 37 3 0 0 2 / 5 9 10 50 5 0 5 23 63 6 0 0 37 77 7 0 5 30 90 9 0 0 40 0 10 0 1 T able 1 1. T able 10. l e d o Md o o H t f a r D. o N t c u d o r P. a i D t n e V 0 5 15 1 H D7 2 2 0 6 4.[...]

  • Page 20

    P/N 471048 R e v . G 1 - 2 2 - 0 4 20 Screw (2 PLC's) HEA TER T op Cover Adaptor Draft Hood Installation (contd.) INDOOR DRAFT HOOD INST ALLA TION 1. T ake 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[...]

  • Page 21

    Rev . G 1-22-04 P/N 471048 21 RED WHT BLU MV PV/MV PV GAS VALVE MV/PV GND (BURNER) 24 V TH-W ( OPT ) SPARK THERMOSTAT CIRCUIT BOARD SPST. EXTERNAL ON/OFF SWITCH HIGH LIMIT THERMAL SWITCHES WATER PRESSURE SWITCH JUMPER REQUIRED IF NO REMOTE SWITCH CONTROL RELAY CLOSE ON CALL FOR HEAT POOL OFF SPA THERMOSTAT SELECT SWITCH TEMPERATURE PROBE GND MV IGN[...]

  • Page 22

    P/N 471048 R e v . G 1 - 2 2 - 0 4 22 SPA COM POOL TPROBE OUT RETURN 24 VAC HILMT IGNITION MOD EXT SWITCH THERMOSTAT CIRCUIT BOARD JUMPER REQUIRED IF NO 2 WIRE REMOTE SWITCH POOL/OFF/SPA FRONT PANEL THERMOSTAT SELECT SWITCH TFUSE VALVE PRESS SPA COM POOL TPROBE OUT RETURN 24 VAC HILMT IGNITION MOD EXT SWITCH THERMOSTAT CIRCUIT BOARD JUMPER REQUIRED[...]

  • Page 23

    Rev . G 1-22-04 P/N 471048 23 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. Pump not running Place pump in operation Pump air locked Check for leaks Filter dirty Clean filter Pump strainer clogged Clean strainer Defectiv[...]

  • Page 24

    P/N 471048 R e v . G 1 - 2 2 - 0 4 24 MINIMAX PLUS HEA TER - ALL MODELS HOT 39 38 37 25 35 34 41 10 14 24 40 20 16 17 18 19 8 11 22 42 44 1a 26 9 13 12 15 27 28 23 30 29 33 32 31 36 2 3 4 5 6 1 7 21 S P O T R E N N I . o N l e d o M. o N t r a P 5 14 2 0 0 7 4 0 0 25 2 0 0 7 4 0 5 26 2 0 0 7 4 0 0 37 2 0 0 7 4 0 5 38 2 0 0 7 4 0 0 49 2 0 0 7 4[...]

  • Page 25

    Rev . G 1-22-04 P/N 471048 25 MiniMax Plus (Only) Parts List M E T I N O I T P I R C S E D Y T Q 0 5 1 0 0 2 / 5 9 1 0 5 2 0 0 3 0 5 3 0 0 4 1) r o o d n i ( . y s s a t i k t n e V1 7 2 2 0 6 4 8 2 2 0 6 4 0 3 2 0 6 4 1 3 2 0 6 4 3 3 2 0 6 4 4 3 2 0 6 4 a 1) r o o d t u o ( . y s s a t i k t n e V1 7 3 2 0 6 4 2 2 2 0 6 4 3 2 2 0 6 4 4 2 2 0 6 4 5[...]

  • Page 26

    P/N 471048 R e v . G 1 - 2 2 - 0 4 26 MiniMax Plus (Only) Parts List, contd. M E T I N O I T P I R C S E D Y T Q 0 5 1 0 0 2 / 5 9 1 0 5 2 0 0 3 0 5 3 0 0 4 1 3n a x e L t u o / n i g n i h s u B2 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 2 3 " 2 t u o / n i r e b b u r , e v e e l S2 5 9 8 1 7 0 5 9 8 1 7 0 5 9 8[...]

  • Page 27

    Rev . G 1-22-04 P/N 471048 27 INST ALLER: AFFIX THESE INSTRUCTIONS T O OR ADJACENT T O POOL & SP A HEA TER Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151 10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400 A-1 PowerMax ™ Pool & Spa Heater OPERA TION & INST ALLA TION MANUAL (APPENDIX)[...]

  • Page 28

    P/N 471048 R e v . G 1 - 2 2 - 0 4 28 28 . O N L E D O MT U P N I H B M M U M I N I M A I D E G R A H C S I D ) s e h c n I ( 0 5 10 5 13 0 0 20 0 23 0 5 20 5 24 0 0 30 0 34 0 5 30 5 34 0 0 40 0 44 A-2 PowerMax ™ Pool and Spa Heater INTRODUCTION This manual provides information for the pr oper installation, operation and maintenance of the PowerM[...]

  • Page 29

    Rev . G 1-22-04 P/N 471048 29 A-3 MOUNTING ASSEMBL Y Follow these instructions if the PowerMax venting system was purchased as an assembly kit. 1. Remove the vent kit assembly (indoor). 2. Mount the plenum assembly on the flue collector top using the screw provided. 3. Connect the wire harness to the heater control box. Follow the instructions on p[...]

  • Page 30

    P/N 471048 R e v . G 1 - 2 2 - 0 4 30 30 A-4 VENTING The vent pipe must be the same size or larger than what is indicated in T able 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 [...]

  • Page 31

    Rev . G 1-22-04 P/N 471048 31 31 A-5 DIAGRAM 1) Detail H INDOOR INST ALLA TIONS PO WERMAX VENTING GUIDELINES vent terminated at least 24" abov e any object within 10 ft. V ent Cap Ridge Chimney 3 ft. min. 2 ft. min. 10 ft. 4' 7' 4' Air Supply V entilation Air Supply Combustion V ent Hood W alkway 3' 1' min. 1' min[...]

  • Page 32

    P/N 471048 R e v . G 1 - 2 2 - 0 4 32 A-6 (DIAGRAM 2) POWERMAX VENTING GUIDELINES OUTDOOR INSTALLATION STACK DIA. 3" POWERMAX OUTDOOR STACK KITS 4" 4" 4" 4" 3" KIT MODEL 471396 471396 471396 471396 471395 471395 PMX 400 PMX 350 PMX 300 PMX 250 MODEL PMX 150 PMX 200 B C D Optional Horizontal V enting. Must be the same d[...]

  • Page 33

    Rev . G 1-22-04 P/N 471048 33 A-7 RED WHT BLU MV PV/MV PV GAS VALVE MV/PV GND (BURNER) 24 V TH-W ( OPT ) SPARK THERMOSTAT CIRCUIT BOARD SPST. EXTERNAL ON/OFF SWITCH HIGH LIMIT THERMAL SWITCHES WATER PRESSURE SWITCH JUMPER REQUIRED IF NO REMOTE SWITCH CONTROL RELAY CLOSE ON CALL FOR HEAT POOL OFF SPA THERMOSTAT SELECT SWITCH TEMPERATURE PROBE GND MV[...]

  • Page 34

    P/N 471048 R e v . G 1 - 2 2 - 0 4 34 A-8 INSTRUCTION FOR WIRING A POWERMAX INDUCED DRAFT ASSEMBL Y TO A POOL HEA TER WITH IID IGNITION. W ARNING 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 sing[...]

  • Page 35

    Rev . G 1-22-04 P/N 471048 35 A-9 TO IGNITION FEMALE MODULE PIN 6 TAB FEMALE TO THERMOSTAT CIRCUIT BOAD ORANGE TAB 24V TAB MALE ORANGE BLUE 24 VAC RELAY WHITE COMMON GREEN SAFETY GROUND GREEN MOTOR FAN HEATER GROUND LUG BLACK 120 VAC ONLY HOT AIR PRESSURE BLACK BLACK SWITCH ORANGE TO GROUND MAIN CONTROL BOX. GRD Figure 4. WIRING DIAGRAM FOR POWERMA[...]

  • Page 36

    P/N 471048 R e v . G 1 - 2 2 - 0 4 36 A-10 1 38 37 25 21 33 32 31 29 30 23 28 27 34 7 6 5 4 3 2 22 9 13 12 15 14 40 16 17 18 19 8 11 20 10 35 36 POWERMAX HEA TER - ALL MODELS T N E V R O O D T U O L A N O I T P O 1 7 4 5 9 3 0 0 2 - 0 5 1 s l e d o M 1 7 4 6 9 3 0 0 4 - 0 5 2 s l e d o M[...]

  • Page 37

    Rev . G 1-22-04 P/N 471048 37 A-11 PowerMax Heater (Only) Parts List M E T I N O I T P I R C S E D Y T Q 0 5 1 0 0 2 / 5 9 1 0 5 2 0 0 3 0 5 3 0 0 4 1* ) e t e l p m o c ( t i K t n e V x a M r e w o P 18 4 0 0 6 4 9 4 0 0 6 4 0 5 0 0 6 4 1 5 0 0 6 4 2 5 0 0 6 4 1 2 2 0 6 4 s t r a p t n e m e c a l p e r t n e V x a M r e w o P ( , x i d n e p p A[...]

  • Page 38

    P/N 471048 R e v . G 1 - 2 2 - 0 4 38 A-12 PowerMax Heater (Only) Parts List, contd. M E T I N O I T P I R C S E D Y T Q 0 5 1 0 0 2 / 5 9 1 0 5 2 0 0 3 0 5 3 0 0 4 1 3n a x e L t u o / n i g n i h s u B2 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 4 4 5 0 7 0 2 3 " 2 t u o / n i r e b b u r , e v e e l S2 5 9 8 1 7 0 5 9 8 1 7[...]

  • Page 39

    Rev . G 1-22-04 P/N 471048 39 A-13 PowerMax Assembly Parts List M E T IN O I T P I R C S E DY T Q0 5 10 0 20 5 20 0 30 5 30 0 4 1m u n e l P1 9 3 1 0 7 40 4 1 0 7 41 4 1 0 7 42 4 1 0 7 43 4 1 0 7 44 4 1 0 7 4 2n o i t s u b m o c r e w o l B1 8 0 0 0 7 48 0 0 0 7 47 0 0 0 7 47 0 0 0 7 47 0 0 0 7 47 0 0 0 7 4 3e s a b & e d i s x o b l o r t n o[...]

  • Page 40

    P/N 471048 R e v . G 1 - 2 2 - 0 4 40 40 Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151 10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400 SAVE THESE INSTRUCTIONS.[...]