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.
1
1
™
1
U.S. Patent Numbers
6,295,980
5,318,007 - 5,228,618
5,201,307 - 4,595,825
WARNING
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.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
For Your
Safety
• 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.
To
Consumer
Retain For
Future
Reference
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 • (919) 774-4151
10951 W. Los Angeles Ave., Moorpark, CA 93021
Rev. G 1-22-04 P/N 471048
• (805) 523-2400
Table of Contents
Introduction ............................................................................................................... 3
Important Notices ...................................................................................................................................................................... 3
Warranty Information ................................................................................................................................................................. 4
Operation .................................................................................................................... 4
Safety Rules .............................................................................................................................................................................. 4
Electronic Ignition Lighting/Operation - Natural ......................................................................................................................... 5
Electronic Ignition Lighting/Operation - Propane ....................................................................................................................... 6
Millivolt Lighting/Operation - Natural & Propane ........................................................................................................................ 7
Operating (Controls) .................................................................................................................................................................. 8
Indicator Light Description - Electronic Ignition Model ............................................................................................................... 8
Maintenance ............................................................................................................... 11
Maintenance Instructions ........................................................................................................................................................... 11
Relief Valve................................................................................................................................................................................ 11
Energy Saving Tips.................................................................................................................................................................... 11
Spring and Fall Operation .......................................................................................................................................................... 11
Winter Operation ....................................................................................................................................................................... 11
Chemical Balance ...................................................................................................................................................................... 12
Installation Instructions ............................................................................................ 13
2
Specifications .......................................................................................................................... 13
Water Connections.................................................................................................................. 14
Reverse Water Connections ...................................................................................................................................................... 14
Plumbing/Plumbing Connections ............................................................................................................................................... 14
Manual Bypass .......................................................................................................................................................................... 14
Below Pool Installation .............................................................................................................................................................. 14
Quick Flange Installation ........................................................................................................................................................... 15
Gas Connections ..................................................................................................................... 16
Gas Line Installation .................................................................................................................................................................. 16
Pipe Sizing Chart/Gas Pressure Requirements ......................................................................................................................... 16
Regulated Manifold Pressure Test ............................................................................................................................................. 16
Ventilation ................................................................................................................................ 17
Outdoor Installation Requirements ............................................................................................................................................ 17
Outdoor Cap Installation ............................................................................................................................................................ 17
Indoor Installation Requirements ............................................................................................................................................... 18
Installation on Floors Constructed of Combustible Materials ..................................................................................................... 19
Indoor Draft Hood Installation .................................................................................................................................................... 20
Electrical .................................................................................................................................. 20
Transformer Wiring Instruction .................................................................................................................................................. 20
Electrical Wiring Diagram .......................................................................................................................................................... 21
Remote Control Wiring .............................................................................................................................................................. 22
Trouble Shooting (General)....................................................................................... 23
MiniMax Plus Parts List & Exploded View ............................................................... 24-26
PowerMax Appendix .................................................................................................. A1-A9
PowerMax Parts List & Exploded View .................................................................... A10-A13
Warranty Information ................................................................................................. Back Cover
P/N 471048 Rev. G 1-22-04
3
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. The MiniMax Plus, also comes equipped with
PurexTriton’s nine function indicator lights (electronic ignition only) which show, at a glance, the proper functioning
of the heater. All electronic ignition MiniMax Plus heaters are designed with an intermittent ignition device (IID)
which eliminates the need for a standing pilot. The electronic ignition MiniMax Plus requires is an external power
source (120 VAC or 240 VAC) 50/60 Hz to operate. The millivolt MiniMax Plus has a self sustaining pilot and
requires NO external power source.
All MiniMax and PowerMax pool and spa heaters are year 2000 compliant.
*Unless noted otherwise, any references to the MiniMax Plus include the PowerMax (Induced Draft)
models. The wiring and venting of the PowerMax is covered in an appendix to this manual.
IMPORTANT NOTICES
...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. 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.
CAUTION
OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 68° F. WILL CAUSE
HARMFUL CONDENSATION AND WILL DAMAGE THE HEATER AND WILL VOID THE WARRANTY.
Do not use the heater to protect pools or spas from freezing if the final maintenance temperature desired is
below 68° F. as this will cause condensation related problems.
CODE REQUIREMENTS
The installation must conform with local codes or in the absence of local codes with the latest National Fuel Gas
Code, ANSI Z223.1, and the latest edition of the National Electrical Code, NFPA 70.
Installation in Canada to be made in accordance with the latest CAN/CGA-B149.1 or .2 and CSA C22.1 Canadian
Electric Code, part 1.
Rev. G 1-22-04 P/N 471048
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. History and
experience has shown that most heater damage is
caused by improper installation practices.
Operation
WARRANTY INFORMATION
The MiniMax Plus pool heater is sold with a limited
factory warranty. Specific details are described on
the back cover of this manual and a copy of the
warranty and warranty registration card are
included with the product. 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
the right to make improvements which change the
specifications of the heater without incurring an
obligation to update the current heater equipment.
SAFETY RULES
1. Spa or hot tub water temperatures should never
exceed 104° F (40° C). A temperature of 100° F
(38° C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subsequently
result in drowning.
3. Pregnant women beware! Soaking in water
above 102° F (39° C) can cause fetal damage
during the first three months of pregnancy
(resulting in the birth of a brain-damaged or
deformed child). Pregnant women should stick
to the 100° F (38° C) maximum rule.
WARNING
4. Before entering the spa or hot tub, the user
should check the water temperature with an
accurate thermometer. Spa or hot tub
thermostats may err in regulating water
temperatures by as much as 4° F (2.2° C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes or blood pressure
problems should obtain their physician's advice
before using spas or hot tubs.
6. Persons taking medication which induce
drowsiness, such as tranquilizers, antihistamines
or anticoagulants should not use spas or hot
tubs.
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the
appliance. Do not use this heater if any part has been under water. Immediately call a qualified service
technician to inspect the heater and to replace any part of control system and gas control which has been
under water.
P/N 471048 Rev. G 1-22-04
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. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try
to light the pilot by hand.
B. BEFORE OPERATING smell all around the
heater area for gas. Be sure to smell next to
the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any heater.
- 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.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off electric power to the heater.
4. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try
to light the pilot by hand.
5. Remove the control access door.
6. Push in gas control knob slightly and turn clockwise to “OFF”.
7. Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to the
next step.
8. Turn knob on gas control counterclockwise
to “ON”; see Figure 1.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, don't try to repair it.
Call a qualified service technician. Forced or
attempted repair may result in a fire or explosion.
D. Do not use this heater if any part has been under
water. Immediately call a qualified service
technician to inspect the heater and to replace
any part of the control system and any gas
control which has been under water.
E. The MiniMax Plus incorporates (9) nine
indicator lights to aid you in the operation of the
heater, and to assist in diagnosing a failure in the
heater’s function.
9. Replace the control access door.
10. Turn on the electrical power to the heater.
11. Set the thermostat to the desired setting.
12. If the heater will not operate, follow the instructions "To Turn Off Gas To Heater" and call your
service technician or gas supplier.
Gas
Inlet
Figure 1.
Gas control knob shown in “ON” position.
ON
OFF
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the heater if
service is to be performed.
3. Remove control access door.
Rev. G 1-22-04 P/N 471048
4. Push in gas control knob slightly and turn
clockwise to "OFF". Do not force.
5. Replace control access door.
Operation (contd.)
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.
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 cause personal injury, death, and property damage.
WHAT TO DO IF YOU SMELL GAS
- Do not try to light matches or lighter.
- Do not try to light any heater.
- Do not touch any electrical switch; do not
use any phone in your building.
- Shut off gas line at propane tank.
Safety Lockout:
- 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 tamper with the heater because it is
dangerous and voids all warranties.
6
This MiniMax Plus Propane Heater is equipped with a 100% safety lockout feature. If the pilot does not
light within a maximum of 90 seconds, lockout will occur.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off electric power to the heater.
4. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
5. Remove the control access door.
6. Push in gas control knob slightly and turn clockwise to “OFF”.
7. Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the safety
information on page 5. If you don't smell gas, go to
the next step.
8. Turn knob on gas control counterclockwise
to “ON”; see Figure 2.
9. Replace the control access door.
10. Turn on the electrical power to the heater.
11. Set the thermostat to the desired setting.
12. If the heater will not operate, follow the instructions "To Turn Off Gas To Heater" and call your
service technician or gas supplier.
Gas
Inlet
ON
OFF
Gas control knob shown in “ON” position.Figure 2.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the heater if
service is to be performed.
3. Remove control access door.
P/N 471048 Rev. G 1-22-04
4. Push in gas control knob slightly and turn
clockwise to "OFF". Do not force.
5. Replace control access door.
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. If you suspect a propane leak, lighting the heater can result in a fire or explosion
which can cause personal injury, death, and property damage.
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 air and will settle
on the floor.
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any heater.
- 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.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it. Call a qualified
service technician. Forced or attempted repair may
result in a fire or explosion.
D. Do not use this heater if any part has been under
water. Immediately call a qualified service
technician to inspect the heater and to replace any
part of the control system and any gas control which
has been under water.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off electric power to the heater.
4. Push in gas control knob slightly and turn clockwise to “OFF”.
Robertshaw Millivolt Gas Valve Honeywell Millivolt Gas Valve
Figure 3. Figure 4.
Gas control knobs shown in “OFF” position.
NOTE
Knob cannot be turned from “Pilot to “OFF”” unless
knob is pushed in slightly. DO NOT FORCE.
5. Wait five (5) minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to the next step.
6. Push in gas control knob slightly and turn counterclockwise to “Pilot”.
7. Push the control knob all the way and hold in.
Immediately light the pilot with Presslite matchless
ignition system by pressing the red igniter button
(located at the panel next to the gas valve). Continue
to hold the control knob in for about one (1) minute
after the pilot is lit. Release knob and it will pop
back up. Pilot should remain lit. If it goes out, repeat
steps 4 through 7.
• If knob does not pop up when released, stop and
immediately call your service technician or gas
supplier.
• If the pilot will not stay lit
after several tries, turn the
gas control knob to “OFF”
and call your service
technician or gas supplier.
8. Turn knob on gas control
counterclockwise to
“ON”.
9. Replace the control access
door.
10. Set the thermostat to the
desired setting.
Figure 5.
Figure 6.
Pilot
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the heater if service is
to be performed.
3. Remove control access door.
Rev. G 1-22-04 P/N 471048
4. Push in gas control knob slightly and turn clockwise
to "OFF". Do not force.
5. Replace control access door.
Operation (contd.)
OPERATING (CONTROLS)
Dual Temperature Control System - (Electronic and Millivolt Models)
8
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;
see Figure 8.
The maximum setting can be adjusted by loosening the screw
"A" and turning the stopper dial to desired maximum setting.
Lock the setting by tightening the screw. The Mechanical
stop is under the knob. Ensure that the knob is stopping at the
correct position when the knob is rotated clockwise from a
lower temperature position. (See Thermostat Adjustment.)
NOTE
To eliminate error due to piping heat losses,
measure pool temperature with an accurate
thermometer directly at the pool or spa.
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.
If further adjustment is needed, rotate the knob until the
desired temperature is obtained. This knob position
corresponding to your desired maximum pool or spa
temperature may now be preset (locked) by the knob
stopper which prevents the knob from being turned beyond
the maximum temperature you set.
Knob Stopper
Figure 8.
Screw A
POWER (THERMOSTAT SELECT) SWITCH
The Pool/Off/Spa switch allows the heater to be turned off
when heating is not desired.
1. “Pool” position - Maintains selected pool
temperature.
2. “Off” position - Heater will not come on regardless
of drop in pool or spa temperature.
3. “Spa” position - This allows separate control of spa
water temperature.
INDICATOR LIGHT DESCRIPTION
The MiniMax Pool Heater provides nine status indicator lights, six can be seen from the front of the control panel which
help you understand the operation of the heater. If something should go wrong, the lights will aid in troubleshooting the
problem. Three additional lights can be seen after opening the control panel. These three lights give the service technician
advanced troubleshooting capability. All the LED lights are green with the exception of the red service LED.
POWER LIGHT (POWER)
The light is on at all times, in any switch position, indicating
24 VAC power is being supplied to the control circuit. If it
fails to light, no other light will be on. Possible causes are:
a) external power to the heater is disconnected, check
service panel circuit breaker or fuses; b) local circuit
breaker inside the transformer has tripped -- investigate
cause before resetting; c) transformer has failed.
THERMOSTAT (TSTAT)
This light is on when the thermostat contacts close, signaled
by the water temperature falling below the setpoint, calling
for the heater to fire to maintain the desired water
temperature.
P/N 471048 Rev. G 1-22-04
AUXILIARY (AUX)
This light is on when it indicates the remote switch contacts
are closed. This allows you to observe if your remote switch
is properly closing the heater control circuit. When shipped
from the factory a jumper is installed to maintain closed
circuit in the absence of a remote switch.
PRESSURE (PRESS)
This light is on when Spa/Pool Selector switch is on,
indicates the circulation pump is running properly. If
pressure light fails to light, the pump may have lost its
prime or water flow may be restricted by an inadvertently
closed valve or clogged filter or pump basket. If you have
determined that there is no water flow restriction to the
heater, you should call a qualified serviceman.
Operation (contd.)
9
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.
SYMBOL TABLE
SWITCH OR DEVICE
LED LIT
LED OFF
OPEN CIRCUIT
(BLOCK CURRENT)
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.
The diagrams that follow give examples of
troubleshooting a malfunctioning heater using the
assistance of the indicator lights.
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
IGNITION MODULE
THERM
AUX
PRESS
HEAT
THERM
AUX
INCOMING
LINE VOLTAGE
INCOMING
LINE VOLTAGE
TRANSFORMER
FRONT PANEL LEDS
TRANSFORMER
POWER
SERVICE
POWER
SERVICE
CIRCUIT
THERMOSTAT
RELAY
PWR TSTAT RMT PRESS
REMOTE PRESS TFUSE
SRVE
LIMIT SWITCHESBREAKER
HI TEMP
HI TEMP TFUSE
CLOSE IF
NO MV
IND GND VAL
MV HEAT
THERMOSTAT CIRCUIT BOARD
WATER AT SELECTED TEMPERATURE.... NORMAL OPERATION
OR POOL/OFF/SPA THERMOSTAT SELECT SWITCH OFF.... NORMAL OPERATION
IGNITION MODULE
GND VAL
CIRCUIT
BREAKER
PWR
THERMOSTAT
RELAY
TSTAT RMT
REMOTE
PRESS
PRESS
LIMIT SWITCHES
SRVE
HI TEMP
CLOSE IF
NO MV
HI TEMP
TFUSE
IND
HEAT
MVTFUSE
GAS VALVE
MV
MV
GAS VALVE
MV
MV
PRESS
HEAT
FRONT PANEL LEDS
THERMOSTAT CALLING FOR HEAT - PUMP OFF(NO PRESSURE) BLOCKS FIRING
NORMAL OPERATION
THERMOSTAT CIRCUIT BOARD
Rev. G 1-22-04 P/N 471048
Operation (contd.)
TROUBLESHOOTING (CONTROLS) - Continued
SYMBOL TABLE
THERM
AUX
PRESS
HEAT
INCOMING
LINE VOLTAGE
TRANSFORMER
FRONT PANEL LEDS
POWER
SERVICE
SWITCH OR DEVICE
RMT
OPEN CIRCUIT
(BLOCK CURRENT)
PRESS
PRESS
CIRCUIT
BREAKER
PWR
LED LIT
THERMOSTAT
RELAY
TSTAT
LED OFF
REMOTE
THERMOSTAT CIRCUIT BOARD
HEATER FIRING - NORMAL OPERATION
LIMIT SWITCHES
SRVE
HI TEMP
HI TEMP
CLOSE IF
NO MV
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
IND
TFUSE
TFUSE MV
IGNITION MODULE
GND
HEAT
10
VAL
GAS VALVE
MV
MV
THERM
AUX
PRESS
HEAT
INCOMING
LINE VOLTAGE
TRANSFORMER
POWER
SERVICE
FRONT PANEL LEDS
IGNITION MODULE
GND
CIRCUIT
BREAKER
PWR
THERMOSTAT
RELAY
TSTAT
REMOTE
RMT
PRESS
PRESS
THERMOSTAT CIRCUIT BOARD
LIMIT SWITCHES
SRVE
HI TEMP
HI TEMP
CLOSE IF
NO MV
IND
TFUSE
TFUSE MV
VAL
HEAT
THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING
NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM
IS IN THERMAL FUSE CIRCUIT
GAS VALVE
MV
MV
P/N 471048 Rev. G 1-22-04
Maintenance
MAINTENANCE INSTRUCTIONS
11
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
Figure 10.
Figure 9.
3/8 to 1/2 in.
Insulated
Electrode
ENERGY SAVING TIPS
1. If possible, keep pool or spa covered when not in
use. This will not only cut heating costs, but also
keep dirt and debris from settling in the pool and
conserve chemicals.
2. Reduce the pool thermostat setting to 78° F. or
lower. This is accepted as being the most healthy
temperature for swimming by the American Red
Cross.
3. Use an accurate thermometer.
4. When the proper maximum thermostat settings have
been determined, tighten the thermostat knob
stopper.
3. Keep the heater area clear and free from
combustibles and flammable liquids.
Relief Valve
In some installations, a
relief valve is required
on the MiniMax Plus.
Standard
Test the relief valve at
least once a year by
lifting the valve lever.
(A.S.M.E. version varies
slightly and has the relief
valve pre-installed at
factory.)
Figure 11.
A.S.M.E. Version
5. Set time clock to start circulation system no earlier
than daybreak. The swimming pool loses less heat at
this time.
6. For pools that are only used on the weekends, it is
not necessary to leave the thermostat set at 78° F.
Lower the temperature to a range that can be
achieved easily in one day. Generally, this would be
10° F. to 15° F., if pool heater is sized properly.
7. During the winter or while on vacation, turn the
heater off.
8. Set up a regular program of preventative
maintenance for the heater each new swimming
season. Check heat exchanger, controls, burners,
operation, etc.
SPRING AND FALL OPERATION
If the pool is being used occasionally, do not turn the heater
completely off. Set the thermostat down to 65° F. This
will keep the pool and the surrounding ground warm
enough to bring the pool up to a comfortable swimming
temperature in a shorter period of time.
WINTER OPERATION
If the pool won't be used for a month or more, turn the
heater off at the main gas valve. For areas where there is
no danger of water freezing, water should circulate
through the heater all year long, even though you are not
heating your swimming pool. The MiniMax Plus should
not be operated out doors at temperatures below 0° F. for
propane and -20° F. for natural gas. Where freezing is
Rev. G 1-22-04 P/N 471048
possible, it is necessary to drain the water from the
heater. This may be done by opening the drain valve
located at the inlet/outlet header (see Figure 11.) allowing all water to drain out of the heater. It would be a
good practice to use compressed air to blow the water
out of the heat exchanger. (See additional notes under
Important Notices in Introduction on page 3.)
Maintenance (contd.)
12
12
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.
Three major items that can cause problems with your
pool heater are improper pH, disinfectant residual, and
total alkalinity. These items, if not kept properly balanced, can shorten the life of the heater and cause
permanent damage.
CAUTION
Heat exchanger damage resulting from chemical
imbalance is not covered by the warranty.
WHAT A DISINFECTANT DOES
Two pool guests you do not want are algae and bacteria.
To get rid of them and make pool water sanitary for
swimming - as well as to improve the water's taste, odor
and clarity - some sort of disinfectant must be used.
Chlorine and bromine are universally approved by health
authorities and are accepted disinfecting agents for
bacteria control.
RULE: 7.4 to 7.6 is a desirable pH range. It is essential
to maintain correct pH, see Table 2.
If pH becomes too high (over alkaline), it
has these effects:
1. Greatly lowers the ability of chlorine to destroy
bacteria and algae.
2. Water becomes cloudy.
3. There is more danger of scale formation on the
plaster or in the heat exchanger.
4. Filter elements may become blocked.
If pH is too low (over acid) the following
conditions may occur:
1. Excessive eye burn or skin irritation.
2. Etching of the plaster.
3. Corrosion of metal fixtures in the filtration and
recirculation system, which may create brown, blue,
green, or sometimes almost black stains on the
plaster.
4. Corrosion of copper in the heater, which may cause
leaks.
5. If you have a sand and gravel filter, the alum used as
a filter aid may dissolve and pass through the filter.
WHAT IS A DISINFECTANT
RESIDUAL?
When you add chlorine or bromine to the pool water, a
portion of the disinfectant will be consumed in the
process of destroying bacteria, algae and other oxidizable materials. The disinfectant remaining is called
chlorine residual or bromine residual. You can determine the disinfectant residual of your pool water with a
reliable test kit, available from your local pool supply
store.
You must maintain a disinfectant residual level adequate
enough to assure a continuous kill of bacteria or virus
introduced into pool water by swimmers, through the air,
from dust, rain or other sources.
It is wise to test pool water regularly. Never allow
chlorine residual to drop below 0.6 ppm (parts per
million). The minimum level for effective chlorine or
bromine residual is 1.4 ppm.
pH - The term pH refers to the acid/alkaline balance of
water expressed on a numerical scale from 0 to 14. A test
kit for measuring pH balance of your pool water is available from your local pool supply store; see Table 1.
Table 1.
Strongly Acid Neutral Strongly Alkaline
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Muriatic Acid has a pH of about 0. Pure water is 7
(neutral). Weak Lye solution have a pH of 13-14.
pH Chart
CAUTION: Do not test for pH when the chlorine
residual is 3.0 ppm or higher, or bromine residual
is 6.0 ppm or higher. See your local pool supply
store for help in properly balancing your water
chemistry.
RULE: Chemicals that are acid lower pH. Chemicals
that are alkaline raise pH.
Table 2.
6.8 7.0
Add Soda, Ash or
Sodium Bicarbonate
pH Control Chart
7.4 7.6
7.2
7.8 8.0 8.2 8.4
Add AcidMarginalIdealMarginal
ALKALINITY High - Low:
"Total alkalinity" is a measurement of the total amount
of alkaline chemicals in the water, and control pH to a
great degree. (It is not the same as pH which refers
merely to the relative alkalinity/acidity balance.) Your
pool water's total alkalinity should be 100 - 140 ppm to
permit easier pH control.
A total alkalinity test is simple to perform with a
reliable test kit. You will need to test about once a
week and make proper adjustments until alkalinity is
in the proper range. Then, test only once every month
or so to be sure it is being maintained. See your local
pool dealer for help in properly balancing the water
chemistry.
P/N 471048 Rev. G 1-22-04
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
ledoMmiD"A"miD"B"
13
051.ni8/771.ni½6
002/591.ni8/702.ni½9
052.ni8/732.ni½21
003.ni8/762.ni½51
053.ni8/792.ni½81
004.ni8/333.ni8/322
Table 3.
Outdoor installation - with vent kit
ledoMmiD"A"miD"B"miD"C"miD"D"
051.ni8/771.ni½6.ni¾7.ni¾93
002/591.ni8/702.ni½9.ni01.ni¾24
052.ni8/732.ni½21.ni01.ni¾24
003.ni8/762.ni½51.ni¼01.ni¾34
053.ni8/792.ni½81.ni31.ni¾74
004.ni8/333.ni8/322.ni71.ni¾15
Table 4.
TM
HIGH PERFORMANCE HEATER
32
5-1/2
"B" DIM.
"A" DIM.
3
1
21
2
FRONT VIEW SIDE VIEW
"E" DIM.
"E" DIM.
HIGH PERFORMANCE HEATER
TM
1
3
21
2
"D"
DIM
"C"
DIM.
28"
POWER PRESSURE HI-LIMITHEAT
POOL
HOT COLD COLD
SPA
POWERPOOL TEMPERATURE
5-1/2
OFF
HOT
SPA/AUXILIARY TEMPERATURE
"B" DIM.
"A" DIM.
Indoor installation - stack (USA only)
Outdoor shelter installation (Canada)
ledoMmiD"A"miD"B"miD"C"miD"D"miD"E"
DIM
"D"
28
GAS LINE
OPENING
"C"
DIM.
PRESSUREPOWER HEAT
HI-LIMIT
POOL
OFF
COLD
HOT
COLD
HOT
SPA
SPA/AUXILIARY TEMPERATURE
POOL TEMPERATURE
POWER
7
10
8
"B" DIM.
5-1/2
"A" DIM.
HIGH PERFORMANCE HEATER
TM
1
14
2
3
1
21
2
051.ni8/771.ni½6.ni31.ni¾25.ni6
002/591.ni8/702.ni½9.ni31.ni8/735.ni7
052.ni8/732.ni½21.ni31.ni8/735.ni7
003.ni8/762.ni½51.ni31.ni55.ni8
053.ni8/792.ni½81.ni31.ni65.ni9
004.ni8/333.ni8/322.ni71.ni¾06.ni01
Table 5.
Rev. G 1-22-04 P/N 471048
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
9/16 in. Socket and Wrench
1/2 in. & 9/16 in. Open Wrench
1. Remove the inspection plates.
2. Disconnect all wires from the high-limit
switches except the short jumper wire. The
exact order of the disconnection is not important.
3. Disconnect the pressure switch wiring.
4. Remove the temperature sensing bulb from the
in/out header. Note: You may cut the wire
bundle ties.
5. Exchange the in/out header with the return
header. Replace the heat exchanger tube seals
with new seals provided in the Quick-Flange
Accessory Bag.
6. Install the temperature sensing bulb by passing
the wires through the hole provided on the left
side of the brace panel. Route wires through the
support bracket.
7. Reconnect all the high limit wires. Reconnect
the pressure switch wiring. Route the wires
through the same hole as the thermostat sensor
wires.
8. Reinstall the inspection plates.
PLUMBING
VALVES
When any equipment is located below the surface of
the pool or spa, valves should be placed in the
circulation piping system to isolate the equipment
from the pool or spa.
Check valves are recommended to prevent back
siphon.
CAUTION
Exercise care when installing chemical feeders so
as to not allow back siphoning of chemical into the
heater, filters or pump.
14
POOL
HEATER
1
Optional.
2
Required when installation is below water level.
Required when flow rates exceed 120 gpm.
3
3
MANUAL
BY-PASS
1
CHECK
VALVE
TO
POOL
ISOLATION
VALVE
ISOLATION
VALVE
FILTER
FROM
POOL
CHECK
VALVE
PUMP
2
Figure 12.
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 PurexTriton’s recommended PVC plumbing procedure. Other plumbing
connections can be used. The instructions on page 13
show methods for successfully connecting plumbing to
the inlet/outlet header, with the Quick-Flange.
CAUTION
Before operating the heater on a new installation,
turn on the circulation pump and bleed all the air
from the filter using the air relief valve on top of the
filter. Water should flow freely through the heater.
Do not operate the heater unless water in the pool/
spa is at the proper level.
MANUAL BY-PASS
Where the flow rate exceeds the maximum 120
GPM, a manual bypass should be installed and
adjusted. After adjustments are made, the valve
handle should be removed to avoid tampering.
ledoM.niM*.xaM
05102021
002/59102021
05203021
00303021
05304021
00404021
dednemmocermumixamehtdeecxetonoD*
.gnipipgnitcennocehtrofetarwolf
Table 6.
BELOW POOL INSTALLATION
If the heater is below water level, the pressure
switch must be adjusted. This adjustment must be
done by a qualified service technician.
P/N 471048 Rev. G 1-22-04
Installation (contd.)
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
15
FOR 1½ & 2 in. SCHEDULE 40 PVC PIPE
Pipe
Plastic Bushing
Figure 13.
Gasket/Sleeve
1. Insert plastic sleeves into the “Quick-Flange”
inlet/outlet openings.
2. Slip the 2 in. rubber gaskets over the plastic
sleeves.
3. Bolt the “Quick-Flange” to the header.
NOTE
Tighten the bolts evenly! Do not over tighten!
4. Use plumbers roll or medium grit sand paper and
clean the inlet/outlet openings of the “QuickFlange”. Use the same method to clean the 2 in.
PVC pipe. The sand paper will break up any
grease or contaminant that may not be cleaned
away with a primer.
5. Use 711 PVC glue (or equivalent) and follow the
manufacturer’s recommendations. Apply to the
inlet opening of the “Quick-Flange”. Do the
same to the PVC pipe and quickly insert the
pipe into the “Quick-Flange” and twist the pipe
a 1/4 turn. Do the same to the other opening of
the “Quick-Flange”.
6. For 1½ in. PVC pipe installations, first glue a 1½
in. X 2 in. sch 40 PVC bushing (not supplied or
shown) to the end of the pipe prior to gluing to
the “Quick-Flange”.
FOR 1½ & 2 in. COPPER PIPE
Figure 15.
Gasket
NOTE
You “DO NOT” need the plastic bushings.
*
1. Insert pipe into the inlet/outlet openings of the
“Quick-Flange”
2. Slip the rubber gaskets over the pipe, using the
supplied 2 in. rubber gasket for 2 in. copper pipe
or the 1½ in. rubber gasket (not supplied,
available from the factory) for the 1½ in. copper
pipe.
3. Bolt the “Quick-Flange” to the header.
Figure 14.
Rev. G 1-22-04 P/N 471048
*
Installation (contd.)
16
16
GAS CONNECTIONS
Pipe Sized For Length Of Run In Equivalent Feet
GAS LINE INSTALLATIONS
ledoM
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. Table 7,
shows which size pipe is required for the
distance from the gas meter to the heater. The table
is for natural gas at a specific gravity of .65 and
propane at specific gravity of 1.5.
When sizing gas lines, calculate three (3) additional
feet of straight pipe for every elbow used.
When installing the gas line, avoid getting dirt,
grease or other foreign material in the pipe as this
may cause damage to the gas valve, which may
result in heater failure.
The gas meter should be checked to make sure that
it will supply enough gas to the heater and any other
appliances that may be used on the same meter.
051
002/591
052
003
053
004
Table 7.
.ni2/1.ni4/3.ni1.ni¼1.ni½1.ni2
taNPLtaNPLtaNPLtaNPLtaNPLtaNPL
'01'04'05'051'051'006 ------
-'02'03'08'521'052'054'006 ----
-'01'02'05'07'051'052'005'006 ---
-- '01'03'05'001'002'053'004'006--
-- '01'02'03'07'521'052'052'005'005-
--- '01'02'06'001'051'002'054'004-
REGULATED MANIFOLD PRESSURE TEST
1. Attach the manometer to the heater jacket.
2. Shut off the main gas valve.
3. Remove 1/8 in. NPT plug on the outlet side of the
valve and screw in the fitting from the manometer kit.
4. Connect the manometer hose to the fitting.
5. Fire the heater.
6. The manometer must read 4 in. WC for natural gas,
11 in. WC for propane gas, while the heater is
operating.
7. For adjustment, remove the Regulator Adjustment
Cap and using a screwdriver turn the screw clockwise to increase - counterclockwise to decrease gas
pressure.
1/8" NPT Plug
(Inlet Press)
Regulator Adjustment Cap
The gas line from the meter will usually be of a
larger size than the gas valve supplied with the
heater. Therefore a reduction of the connecting gas
pipe will be necessary. Make this reduction as close
to the heater as possible.
Figure 16.
1/8" NPT Plug
(Manifold Press)
REGULATOR
ADJUSTMENT CAP
ON
OFF
The heater and any other gas appliances must be
disconnected from the gas supply piping system
during any pressure testing on that system, (greater
that ½ PSIG).
Figure 17.
PILOT
HONEYWELL
1/2 P.S.I.
PILOT
ADJ.
PRESS
TAP
The heater and its gas connection must be leak
tested before placing the heater in operation. Do not
use flame to test the gas line. Use soapy water or
another nonflammable method.
The use of Flexible Connectors (FLEX) is NOT
recommended as they cause high gas pressure drops.
CAUTION
A manual main shut-off valve must be installed
externally to the heater.
WARNING
Do not install the gas line union inside the heater
cabinet. This will void your warranty.
P/N 471048 Rev. G 1-22-04
MINIMAX PLUS GAS PRESSURE REQUIREMENTS*
Natural
Maximum inlet gas pressure 10 in. WC 14 in. WC
Minimum inlet gas pressure **5 in. WC 12 in. WC
Normal manifold pressure 4 in. WC 11 in. WC
** 6 WC for 400 model
*All Readings are taken with the heater fired. Any adjustments
made with heater off will give incorrect readings.
Table 8.
Propane
Installation (contd.)
17
VENTILATION
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.
IMPORTANT!
In an outdoor installation it is important to protect
your heater from water damage. Ensure water is
diverted from overhanging eves with a proper gutter/
drainage system. The heater must be set on a level
foundation for proper rain drainage.
Maintain minimum clearances as indicated below. Install
a minimum of 4 feet below, and 4 feet horizontally from
any opening to a building.
The heater should not be installed closer than 6 inches to
any fences, walls or shrubs at any side or back, nor
closer than 18 inches at the plumbing side. A minimum
clearance of 24 inches must be maintained at the front of
the heater.
STACK TYPE OUTDOOR VENT KIT
ledoMpaCtneV.oNtcudorP.aiDtneV
05151VO732064.ni6
002/59102VO222064.ni7
05252VO322064.ni7
00303VO422064.ni8
05353VO522064.ni9
00404VO622064.ni01
Outdoor Stack
Top Cover
Flue Adaptor
Inner Panel
Flue Collector
Table 9.
DOOR
24"
Figure 18.
6"
6"
18"
IMPORTANT!
When locating the heater, consider that high
winds can roll over or deflect off adjacent
buildings and walls. Normally, placing the
heater at least three feet from any wall will
minimize downdraft.
Unusually high prevailing wind conditions and
downdrafts may require the use of a stack type
outdoor vent kit (available at additional cost).
NOTE
This unit shall not be operated outdoors at
temperatures below 0o F. for propane and -20o F. for
natural gas.
Figure 20.Figure 19.
OUTDOOR VENT CAP INSTALLATION
The MiniMax Plus heater is shipped standard as an
outdoor stackless unit. To install the outdoor vent kit:
1. Take out the louvered outer top after first
removing all 1/4 in. sheet metal screws attaching
it along its perimeter to the cabinet. Set it aside.
2. Place the flue adaptor over the flue collector
opening. Temporarily, put the top cover, from the
kit, on with the label to the front of the heater.
Center the flue adaptor evenly inside the top cover
flue stack opening. Remove the top cover and
secure the centered flue adaptor to the inner panel
with the provided #8 x 1/2 in. drill qwik screws.
3. Place the top cover, with the hole for the stack, on
the heater cabinet.
4. Install the vent stack through the hole in the top
cover, over the flue adaptor top ring.
5. Using a 3/32 in. drill bit, position the “L” bracket
to hold the top cover and outdoor stack. Drill the
pilot holes through the “L” bracket holes to accept
the screws.
6. Secure the vent stack and the inner top with the #8
x 1/4 in. sheet metal screws through the “L”
brackets.
Rev. G 1-22-04 P/N 471048
Installation (contd.)
INDOOR INSTALLATION (USA ONLY)
OUTDOOR SHELTER INSTALLATION (CANADA)
(See additional instructions for outdoor
PowerMax units in PowerMax Appendix)
18
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 pipe extension of the same
size must be connected to the draft hood and
extended at least 2 feet higher than highest point
of the roof within a 10 foot horizontal radius, and
at least 3 ft. higher than the point at which it
passes through the roof, or as permitted by local
code; see Figures 21 and 22. The vent should
terminate with an approved vent cap (weather
cap) for protection against rain or blockage by
snow. Double-wall vent pipe and an approved
roof jack shall be employed through the roof
penetration. The use of double-walled type B vent
pipe is recommended.
The draft hood must be installed so as to be in the
same atmospheric pressure zone as the
combustion air inlet to the pool heater. The
certified (factory) draft hood
must not be
modified in any way and must be employed in
every indoor installation (with the exception of
the PowerMax units).
Installations in basements, garages, or
underground structures where flammable liquids
may be stored must have the heater elevated 18
inches from the floor using a non-combustible
base. The following minimum clearances from
combustible materials must be provided.
Side Front Back Top
Water Connection 18 in. 24 in.
Remaining 6 in. 6 in.
Ceiling Clearance 36 in.*
*To ceiling or roof.
Vent terminated at
least 24 in. above
any object within 10 ft.
10 ft.
Ridge
2 ft. min.
3 ft. min.
Chimney
Vent
Cap
Roof
Jack
The heater must be located as close as practical to
a chimney or gas vent. The heater should be
Figure 21.
installed at least 5 feet away from the pool or spa.
The heater must be placed in a suitable room on a
non-combustible floor or on a non-combustible
Vent Cap and
Riser Furnished
by Installer
base and in an area where leakage from heat
exchanger or water connections will not result in
damage to the area adjacent to the heater or the
* Rise
Air Supply
Ventilation
structure. When such locations cannot be
avoided, it is recommended that a suitable drain
* 1” Rise Per Foot
Recommended
Air Supply
Gas Combustion
pan with adequate drainage, be installed under the
heater. The pan must not restrict air flow.
P/N 471048 Rev. G 1-22-04
Figure 22.
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.
19
b) Construct a non-combustible base from masonry
blocks as illustrated, see Figure 23.
Air supply requirements below apply to all
MiniMax heaters, including PowerMax versions.
edisnImorFriAllA
ledoM
051051051
002/591002002
052052052
003003003
053053053
004004004
Table 10.
ledoM
0517373
002/5910505
0523636
0037777
0530909
004001001
noitsubmoCrofriA
.nI.qS
noitsubmoCrofriA
.nI.qS
noitalitneVriA
.nI.qS
edistuOmorFriAllA
noitalitneVriA
.nI.qS
BASE FOR USE ON
COMBUSTIBLE FLOORS
T
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TM
R
E
T
A
E
H
E
C
N
A
M
R
O
F
R
E
P
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G
I
H
T
I
M
I
L
I
H
T
A
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H
E
R
U
S
S
E
R
P
D
L
L
O
O
R
C
E
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P
W
R
O
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T
A
F
R
F
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O
P
M
T
E
T
O
A
H
Y
P
R
S
A
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L
I
X
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R
A
E
/
A
W
P
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P
D
L
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R
U
T
A
R
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P
T
M
O
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H
T
L
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P
6" Min.
SHEET METAL
BLOCKS
HOLLOW MASONARY BLOCKS, NOT LESS THAN 4" THICK
(LAID WITH ENDS UNSEALED AND JOINTS MATCHED
FOR AIR CIRCULATION). COVER BLOCKS WITH
24 GA. (MIN.) GALVANIZED SHEET METAL.
Figure 23.
CAUTION
Chemicals should not be stored near the heater
installation. Combustion air can be contaminated by
corrosive chemical fumes which can void the warranty.
6" Min.
Table 11.
I
NSTALLATION ON FLOORS CONSTRUCTED
OF COMBUSTIBLE MATERIALS
The heater may be placed on a “combustible floor”
using either of the two methods listed below:
a) Use Listed Factory Non-combustible Base Kit
for use on combustible floors.
ledoMtiKesaBelbitsubmoC-noN
051983174
002/591093174
052193174
003293174
053393174
004493174
Table 12.
STACK TYPE INDOOR DRAFT HOOD KIT
The proper draft hood and adapter must be installed on
the heater as shown below and on page 20:
ledoMdooHtfarD.oNtcudorP.aiDtneV
05151HD722064.ni6
002/59102HD822064.ni7
05252HD032064.ni7
00303HD132064.ni8
05353HD332064.ni9
00404HD432064.ni01
Table 13.
Rev. G 1-22-04 P/N 471048
Installation (contd.)
20
Draft Hood
Top Cover
Adaptor
Screw
(2 PLC's)
HEATER
Figure 24.
ELECTRICAL, IID ELECTRONIC UNITS
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.
Transformer Wiring Instruction
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. 18 AWG 105° C. U.L. approved AWM low
energy stranded) copper wire or it's equivalent.
In Canada: wires must be CSA approved.
WARNING
The heater must be electrically grounded and
bonded in accordance with local codes or, in the
absence of local codes, with the latest national
electrical codes ANSI/NFPA No. 70.
In Canada: CSA standard C22.1 Canada Electrical
Code Part 1 and/or local codes.
Always use crimp type connectors when connecting
two wires.
This heater is equipped with a reversible junction box
to allow line voltage to be wired from either side.
Figure 25.
P/N 471048 Rev. G 1-22-04
Figure 26.
Installation (contd.)
MiniMax Plus Electronic Ignition Wiring Diagram
MV/PV
PV/MV
MV
GAS VALVE
PLUG
PV
MV
IGNITION MODULE
PLUG
PV
GND
(BURNER)
GND
24 V
TH-W
( OPT )
SPARK
21
SPARK IGNITER
MV
PV
GRN
PV/MV
MV/PV
MV
PV
F2
BLU
RED
WHT
IGNITION RETURN
GRN
THERMAL FUSE
F1
ORG
RED
BLU
WHT
MiniMax Plus WIRING DIAGRAM
RED
L1-2
L1-1
RED
WHT
L2-2
L2-1
WHT
W2
SWITCH
WATER PRESSURE
W1
WHT
ORG
INTERCONNECTING WIRING TO APPLIANCE MUST CONFORM TO THE NATIONAL ELECTRICAL
CODE OR SUPERCEDING LOCAL (WIRING) CODES.
THERMAL FUSE WIRING MUST BE REPLACED WITH UL OR CSA (IF CANADA) APPROVED
IF ORIGINAL FACTORY WIRING MUST BE REPLACED, INSTALLER MUST SUPPLY
WIRE, 18 GAUGE, 600V, 125 C TEMPERATURE RATING..
UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 105 C TEMPERATURE RATING.
CHASSIS
THERMAL SWITCHES
SHEET METAL
HIGH LIMIT
4
3
2
P11
1
3
2
PI0
1
6
5
4
P7
3
2
1
2
1
P4
IGNITION WIRE
J11
IGN MODULE
1
JI0
1
TFUSE
HLMT
J7
PRESS
1
J4
1
24V VLV
J3
J2
AUX.
CONTACTS
THERMOSTAT
CIRCUIT BOARD
J9
TPROBE
J5
POOL
J8
COM
J6
SPA
FOR HEAT
CONTROL RELAY
CLOSE ON CALL
PROBE
TEMPERATURE
BLK
BLK
P9
P5
P8
P6
POOL OFF SPA
THERMOSTAT SELECT SWITCH
GRN
T1
SHEET METAL
CHASSIS
TERMINATE SUPPLY SAFETY GROUND WIRE (GREEN) HERE
GROUND SCREW WITH PAINT CUTTING WASHER
EXTERNAL
BOND LUG
RED
WHT/RED
WHT/BLK
T2
BLK
25D K .032 D.C TAB
JUMPER REQUIRED IF NO REMOTE SWITCH
SPST. EXTERNAL ON/OFF SWITCH
Rev. G 1-22-04 P/N 471048
L
Installation (contd.)
22
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˚ TEMPERATURE RATING.
INTERCONNECTING WIRING TO APPLIANCE MUST
CONFORM TO THE NATIONAL ELECTRICAL
CODE OR SUPERCEDING LOCAL (WIRING) CODES.
MiniMax Plus Millivolt Wiring Diagram
After 1-15-01
REMOTE SWITCH DUAL THERM IID ONLY
JUMPER REQUIRED IF NO 2 WIRE REMOTE SWITCH
3 Wire Remote
OUT RETURN
EXT SWITCH
PILOT
TH/PP
TH
GAS VALVE
WHT
ORN
WHT
24 VAC
PP
PP
TH/PP
THERMOSTAT BOARD
PRESS
WHT
RED
TH
SEN
HILMT
GENERATOR
HI-LIMIT
POT
TFUSE VALVE
THERMOSTAT CIRCUIT BOARD
WHT
POT 1
SAFETY
SHUT-OFF
POT 2
SENSOR
IGNITION MOD
WHT
PRESS
SWITCH
POOL
SPA
WHT
OFF
WHT
THERMA
CUT-OFF
Figure 27.
REMOTE POOL/OFF/SPA
THERMOSTAT SELECT SWITCH
2 Wire Remote
JUMPER REQUIRED IF NO 2 WIRE REMOTE SWITCH
OUT RETURN
EXT SWITCH
SPA COM POOL TPROBE
24 VAC
PRESS
HILMT
TFUSE VALVE
THERMOSTAT CIRCUIT BOARD
SPA COM POOL TPROBE
FRONT PANEL
POOL/
OFF/SPA
THERMOSTAT SELECT SWITCH
IGNITION MOD
Figure 28.
FRONT PANEL
POOL/OFF/SPA
THERMOSTAT SELECT SWITCH
Figure 29.
NOTE: When connecting a remote control to the MiniMax Plus, you must install the low voltage
thermostat wires in separate conduit from ANY line voltage wires. Failure to follow these
instructions will cause the thermostat relay to react erratically..
P/N 471048 Rev. G 1-22-04
Troubleshooting - General
Possible Cause Remedy
Heater will not come on
Automatic ignition system fails Check if electrical connections are
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
23
correct and securely fastened –
If YES, call serviceperson.
Defective gas controls Call serviceperson
On-Off switch in "OFF" position Turn switch to "ON"
Heater Short Cycling (Rapid On and Off Operation)
Insufficient water flow Clean filter and pump strainer
Defective wiring Repair or replace wiring
Defective flow valve or out of adjustment Call serviceperson
Defective hi-limit and/or thermostat Call serviceperson
Heater Makes Knocking Noises,
Make sure all valves on system are open
Heater operating after pump has shut off Shut off gas supply and call serviceperson
Heater exchanger scaled Shut off gas supply and call serviceperson
CAUTION
Please consult the latest edition of the “MiniMax Plus Service Manual” for complete service and repair
instructions. Repairs should only be attempted by properly trained service personnel.
Rev. G 1-22-04 P/N 471048
1a
MINIMAX PLUS HEATER - ALL MODELS
39
HOT
38
5
4
3
2
36
6
35
37
25
21
24
SPOTRENNI
.oNledoM.oNtraP
51420074
002520074
052620074
003720074
053820074
004920074
26
13
12
15
1
7
34
27
22
9
41
42
10
14
24
44
40
20
28
23
30
33
32
31
29
16
17
18
19
11
8
P/N 471048 Rev. G 1-22-04
MiniMax Plus (Only) Parts List
METI NOITPIRCSED YTQ 051 002/591 052 003 053 004
1)roodni(.yssatiktneV1722064 822064 032064 132064 332064 432064
a1)roodtuo(.yssatiktneV1732064 222064 322064 422064 522064 622064
2redaehnruteR1499070 499070 499070 499070 499070 499070
3rehsawtekcarB2612470 612470 612470 612470 612470 612470
4"2x"8/3HHtloB4937370 937370 937370 937370 937370 937370
5"2/11x61-"8/3tloB4614070 614070 614070 614070 614070 614070
6DO"1DI"8/3rehsaW4081270 081270 081270 081270 081270 081270
7teksaglaesebuT81159070 159070 159070 159070 159070 159070
8egatlovlaud-rekaerbtiucric/w-remrofsnarT1063174 063174063174063174063174063174
9sledoMDII-draobtiucrictatsomrehTcinortcelE1971074971074 971074 971074971074971074
01
11)stinUDII(xoBnoitcnuJ1221074 221074 221074 221074 221074 221074
21bonktatsomrehT2481074 481074 481074481074481074 481074
31)worhtelbuod&elopelgnis(rekcorhctiwS1681074681074681074681074681074681074
41
51tlovilliMroDII-rooD1864570 406570 884570 506570 606570 094570
61renrubdlofinaM1652070 525570 752070 625570 725570 852070
71
81
91
02renruB032070 032070 032070 032070 032070 032070
a02tekcarBtoliPhtiwrenruB1055074055074055074055074055074055074
12hctiwserusserP1091074 091074 091074 091074 091074 091074
22)etelpmoc(.yssarebmahcnoitsubmoC1858370 685570 758370 785570 885570 658370
32"4/3niardevlaV1431270 431270 431270 431270 431270 431270
42)ylnostinUtlovilliM(.yssaretingietilsserP1954570 954570 954570 954570 954570 954570
52edoClacoLroEMSA-#05"4/3feilerevlaV1831270 831270 831270 831270 831270 831270
62)ylnostinUtlovilliM(retemoitnetoP2876174 876174 876174 876174 876174876174
72
82teksagevlavwolF4510470 510470 510470 510470 510470 510470
922/12x61-"8/3tloB2294570 294570 294570 294570 294570 294570
03tiKegnalfkciuQ1482570 482570 482570 482570 482570 482570
saglarutaneludoM1485370 485370 485370 485370 485370 485370
sagenaporpeludoM1585370 585370 585370 585370 585370 585370
taNDII-)etelpmoc(.yssalenaplortnoC1592074692074792074892074 992074 781074
orPDII-)etelpmoc(.yssalenaplortnoC1789074889074989074099074199074299074
tlovilliM-)etelpmoc(.yssalenaplortnoC1020174 120174220174320174420174520174
DII-larutanevlavsaG1899370 899370 899370 899370 899370 899370
DII-enaporpevlavsaG1999370 999370 999370 999370 999370 999370
tlovilliM-larutanevlavsaG1754570 754570 754570 754570 754570 754570
tlovilliM-enaporpevlavsaG1854570 854570 854570 854570 854570 854570
DII-ebuttoliP1191570 191570 291570 291570 391570 391570
tlovilliM-ebuttoliP480670 480670 580670 580670 680670 680670
DII-)etelpmoc(larutan.yssayartrenruB1257370 994570 157370 005570 105570 057370
DII-)etelpmoc(enaporp.yssayartrenruB1609370 805570 509370 905570 015570 409370
tlovilliM-)etelpmoc(larutan.yssayartrenruB1394570 694570 494570 794570 894570 594570
tlovilliM-)etelpmoc(enaporp.yssayartrenruB1205570 505570 305570 605570 705570 405570
.AE2.AE3.AE4.AE5.AE6.AE7
)etelpmoc(dradnatS,.yssaevlavwolF1424174 424174 424174424174 424174424174
)etelpmoc(EMSA,.yssaevlavwolF1989370989370989370989370989370989370
25
Rev. G 1-22-04 P/N 471048
MiniMax Plus (Only) Parts List, contd.
METI NOITPIRCSED YTQ 051 002/591 052 003 053 004
13naxeLtuo/nignihsuB2445070 445070 445070 445070 445070 445070
23
33ffotuhSytefaS2710170 710170 710170 710170 710170 710170
43)tuo/ni(redaehniaM1589070 589070 589070 589070 589070 589070
53
63elffaB
73004noselffab)2(nwoddlohelffaB1018370 018370 018370 018370 018370 018370
83rotcelloceulF1468370 226570 368370 326570 426570 268370
93.yssapoTroodtuO1174074 274074 374074 474074 574074 674074
04)ylnostinusaGenaporP(dleihSkcabthgiL1387570 487570 587570 687570 787570 887570
14)sledomtlovilliM(tatsomrehTcinortcelE1776174776174776174 776174776174 776174
24)nruter(lenaP987370987370987370987370987370987370
34)tuo/ni(lenaP097370097370097370097370097370097370
44)sledomDII(-)eborp(rotsimrehT1081074081074081074081074081074081074
nwohStoN*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
repmuJ352270352270352270352270352270352270
"4/1x6wercS617170 617170 617170 617170 617170 617170
"2/1gnihsuB155070 155070 155070 155070 155070 155070
rotareneg-toliP1515170 515170 515170 515170 515170 515170
dleihsniartoliP1392174392174392174392174392174392174
stekcarb"L"3045470045470045470045470045470045470
hctalrooD042170042170042170042170042170042170
"2tuo/nirebbur,eveelS2598170 598170 598170 598170 598170 598170
"½1tuo/nirebbur,eveelS2922070 922070 922070 922070 922070 922070
)sdaehtuohtiw(regnahcxetaeH1254470 826570 154470 926570 036570 470470
)sdaehhtiw(regnahcxetaeH1463074 563074663074 763074863074 963074
.ae8.ae8.ae8.ae8.ae61.ae61
772070 955570 672070 065570 772070 872070
tekcarbgnitnuomcitsalP517070 517070 517070 517070 517070 517070
)etelpmoc(DIIssenraH-tiKeriW569074 569074569074 569074569074569074
ssenraheriwrofspilC772174772174772174772174772174772174
tlovilliM-tiKeriW115570 115570 115570 115570 115570 115570
HH"4/1x8wercS307170 307170 307170 307170 307170 307170
HH"2/1x8wercS896170 896170 896170 896170 896170 896170
"4/1x23-01wercS956170 956170 956170 956170 956170 956170
61/3x23-01wercS296570 296570 296570 296570 296570 296570
reppotsbonkmrehT2414074414074414074 414074414074 414074
'4/3x81-"61/5tloB2527370 527370 527370 527370 527370 527370
.ae3
ProN
larutanrenrubniamecifirO727370 727370 727370 727370 727370 727370
enaporprenrubniamecifirO827370 827370 827370 827370 827370 827370
DII-larutan-toliP1402174402174402174402174 402174402174
DII-enaporp-toliP1502174502174 502174 502174 502174 502174
tlovillim-larutan-toliP1292174292174292174292174292174292174
tlovillim-enaporp-toliP1192174192174192174192174192174192174
knilelbisuf-ffotuclamrehT1371570 371570 371570 371570 371570 371570
)sledomtlovilliM(etelpmoc)eborp(rotsimrehT1047174047174047174047174047174047174
)evlav-wolf(tnemelerewoP1871074871074871074871074871074871074
)ylno(edortceletoliP1823174823174823174823174823174823174
)sledomDII(lortnoctatsomreht,metS2181074181074181074181074181074181074
remrofsnartrofspilC517070517070517070517070517070517070
VM,tolip973QretpadatekcarB172174172174172174172174172174172174
.ae4
ProN
.ae5
ProN
.ae6
ProN
.ae7
ProN
26
.ae8
ProN
P/N 471048 Rev. G 1-22-04
PowerMax
OPERATION & INSTALLATION MANUAL
27
™
Pool & Spa Heater
(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
Rev. G 1-22-04 P/N 471048
A-1
• (805) 523-2400
28
28
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. 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.
CODE REQUIREMENTS
The installation must conform with local codes or in the absence of local codes with the
latest national fuel Gas Code, ANSI Z223.1.
Installation in Canada to be made in accordance with the latest CAN/CGA-B149.1 OR .2
and CSA C22.1 Canadian Electric Code part 1.
The PowerMax Induced Draft Pool and Spa Heater is a fan assisted balanced flue gas
combination, the field installation kit is designed for application to the PurexTriton
Pool and Spa Heater Electronic Ignition Models 150 to 400. The PowerMax is
approved for both indoor and outdoor installation using either natural gas or propane.
The unit operates in both vertical and horizontal reduced vent pipe locations, in both
the new and existing installations, and for applications such as through the (side) wall
venting.
.ONLEDOMTUPNI
HBM
0510513
0020023
MUMINIM
AIDEGRAHCSID
)sehcnI(
0520524
0030034
0530534
0040044
Table 1.
P/N 471048 Rev. G 1-22-04
A-2
MOUNTING ASSEMBLY
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 page 5.
4. 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. The
front and back side of the top will snap into the
heater with no screws.
Figure 1.
DESCRIPTION OF SYSTEM OPERATION
29
SYSTEM OPERATION:
1. Set the thermostat to the lowest setting.
2. Push the power switch off. The electric power supply requirement is:
• 115 volts 60 Hz, 1 Ph, 1.5 Amp
3. Remove the door.
4. Push in the gas control knob slightly and turn clockwise to “OFF”.
5. Wait (5) minutes to clear out any gas. If you then smell gas STOP. Follow the safety information.
If you don’t smell gas, go to the next step.
6. Turn the knob on the gas control counterclockwise to “ON”.
7. Replace the door.
8. Make sure the pump is running and is primed.
9. Push the power switch on.
10. Set the thermostat to the desired setting.
• a. Fan motor starts, draft proving switch closes.
• b. Ignition module energized.
• c. Check for spark at the gas pilot.
11. The pilot should spark and then ignite, then the main burners will ignite.
12. Heater will operate until the desired temperature is reached.
AIR PRESSURE SWITCH
PRESSURE SWITCH
OPERATION
The air pressure switch is a safety device to insure that
the blower is operating and has been designed to monitor
the vacuum (negative) pressure within the fan housing.
The air pressure switch is in the ignition module circuit
and the ignition module does not operate unless the
switch is closed.
Rev. G 1-22-04 P/N 471048
Figure 2.
A-3
30
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. 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. See Table 2 for the maximum vent lengths using a 90
degree and 45 degree elbows. The PowerMax induced-draft pool and spa heater uses positive pressure to push
flue gases through the vent pipe to the outside. This requires a completely sealed vent system--single wall vent
pipe with sealed-seams and joints may be used. Flue gases under positive pressure may escape into the dwell-
ing with any cracks or loose joints in the vent pipe, or improper vent installation. The vent pipe must be of a
sealed-seam construction such as those listed for use with category III appliances. Alternately, single wall or
double-wall type B duct which has had duct seams and joints permanently sealed using cements or other suitable
means which are rated for use at the flue gas temperatures of 325° F. and are permanent are acceptable. The use
of listed thimbles, roof jacks and/or side vent terminals are required; and the proper clearances to combustible
materials must be maintained in accordance with type of vent pipe employed- in the absence of a clearance
recommendation by the vent pipe manufacturer, the requirements of the Uniform Mechanical Code should be
met. The ventilation air and combustion air requirements for the PowerMax heaters are identical to the
requirements for the Standard MiniMax heaters of the same output capacities and can be found in the main
section of the Operation/Installation Manual, page 18. It is recommended that vent runs over 18 feet be insu-
lated to reduce condensation related problems and/or the use of a condensate trap in the vent run close to the
heater may be necessary in certain installations such as cold climates. The PowerMax is suitable for through-the-
wall venting. (Refer to page A-5, diagram 1.).
Recommended sources for Side-wall vent hood terminals include: The Field Controls Co. (2308 Airport Road,
Kingston, NC 28501, (800) 742-8368) and Tjernlund Products Inc. (1601 Ninth Street, White Bear Lake, MN
55110, (800) 255-4208)--consult manufacturer for model information and availability.
CAUTION
Do NOT combine exhaust vent pipes to a common exhaust vent in multiple unit installations. Run separate vent pipes.
)teef(nuRtneVtnelaviuqEmumixaMdecudeR
swoble°09lanoitiddA
wobletsrifretfa
ytitnauQhtgneLmumixaMytitnauQhtgneLmumixaM
)latot2(173)latot2(114
)latot3(292)latot3(273
)latot4(312)latot4(333
Table 2.
P/N 471048 Rev. G 1-22-04
A-4
swoble°54lanoitiddA
wobletsrifretfa
Figure 3.
C
31
31
1' min.
above grade
H
1' min.
F
1' min.
Vent Hood
F
Air Supply
Ventilation
E
B
DIAGRAM 1)
3'
Recommended sources for
side wall Vent Hood; see page A-4,
Section Venting.
Vent Hood
D
4'
G
Air Supply
Combustion
4'
A
G
7'
INDOOR INSTALLATIONS
POWERMAX VENTING GUIDELINES
Vent
10 ft.
vent terminated at
least 24" above
any object within 10 ft.
Cap
Ridge
2 ft. min.
J
3 ft. min.
K
L
Chimney
Detail H
Vent Hood
must be not less than 7 ft. above public walkways.
Walkway
must extend at least 3 ft. higher than the
point at which it passes through the roof,
or as permitted by local code.
must use a double-wall vent pipe through
the roof penetration.
J
K
Vent termination for side wall installations:
A
must terminate with an approved (listed)
roof jack, storm collar, and vent/weather cap.
L
Vent for roof penetration installations:
4 ft. below
4 ft. horizontally
1 ft. above
must be at least 3 ft. above any outside air intake located within a 10 ft. radius.
must NOT be within 3 ft. of an inside corner of the structure.
must be at least 1 ft. above grade.
must be located the following distances away from any door, window, or gravity air inlet:
D
E
B
C
F
Vent pipe extension:
must be the same diameter as the
vent connector.
must be suitable for use with category III
appliances which have flue gas temperatures
of less than 400 deg. F.
may use a single wall vent pipe with
permanently sealed seams and joints.
(Tables 10 and 11, on page 19.)
Air Supply
See Air Supply Requirements Tables.
G
Rev. G 1-22-04 P/N 471048
A-5
471396
471395
471395
KIT MODEL
471396
471396
32
471396
A
3"
STACK DIA.
Property Line
4'
B
E
Check local building codes
for setback requirements.
E
4'
POWERMAX OUTDOOR STACK KITS
MODEL
PMX 150
G
4"4"3"
PMX 300
PMX 250
PMX 200
4"
4"
PMX 400
PMX 350
(DIAGRAM 2)
3'
C
1'
4'
D
OUTDOOR INSTALLATION
POWERMAX VENTING GUIDELINES
6 in.
min.
F
G
Outdoor
Stack Kit
4 ft. below, or
4 ft. horizontally, or
1 ft. above
Must be located the following distances away
air inlet located within a 10 ft. radius.
from any door, window, or gravity air inlet:
B
D
C
Must be not less than 7 ft. above public walkways.
Must be at least 3 ft. above any forced
Vent T ermination:
A
Walkway
Optional Horizontal Venting.
The Vent Pipe:
Must be the same diameter
as the vent connector.
Must be suitable for use with Category III
Appliances which have flue gas temperatures
F
of less than 400 deg. F.
P/N 471048 Rev. G 1-22-04
A-6
PowerMax Electronic Ignition Wiring Diagram
MV/PV
MV
GND
PV
GND
24 V
PV/MV
MV
GAS VALVE
PLUG
PV
(BURNER)
IGNITION MODULE
PLUG
TH-W
( OPT )
SPARK
33
SPARK IGNITER
MV
PV
GRN
PV/MV
MV/PV
MV
RED
WHT
WHT
ORG
PV
BLU
4
3
2
1
3
2
1
6
5
4
3
2
1
2
1
ORG
F2
BLU
RED
WHT
IGNITION RETURN
GRN
THERMAL FUSE
F1
POWERMAX WIRING DIAGRAM
INTERCONNECTING WIRING TO APPLIANCE MUST CONFORM TO THE NATIONAL ELECTRICAL
CODE OR SUPERCEDING LOCAL (WIRING) CODES.
THERMAL FUSE WIRING MUST BE REPLACED WITH UL OR CSA (IF CANADA) APPROVED
IF ORIGINAL FACTORY WIRING MUST BE REPLACED, INSTALLER MUST SUPPLY
WIRE, 18 GAUGE, 600V, 125 C TEMPERATURE RATING..
UL OR CSA (IF CANADA) APPROVED WIRE, 18 GAUGE, 600V, 105 C TEMPERATURE RATING.
RED
CHASSIS
SHEET METAL
HIGH LIMIT
RED
L1-2
THERMAL SWITCHES
L1-1
WHT
L2-2
L2-1
WHT
W2
SWITCH
WATER PRESSURE
W1
IGNITION WIRE
PROBE
TEMPERATURE
P11
PI0
P7
P4
J11
IGN MODULE
1
JI0
1
TFUSE
HLMT
J7
PRESS
1
J4
1
24V VLV
J3
J2
AUX.
CONTACTS
THERMOSTAT
CIRCUIT BOARD
J9
TPROBE
J5
POOL
J8
COM
J6
SPA
FOR HEAT
CONTROL RELAY
CLOSE ON CALL
BLK
BLK
P9
P5
P8
P6
POOL OFF SPA
THERMOSTAT SELECT SWITCH
GRN
T1
CHASSIS
SHEET METAL
TERMINATE SUPPLY SAFETY GROUND WIRE (GREEN) HERE
GROUND SCREW WITH PAINT CUTTING WASHER
EXTERNAL
BOND LUG
RED
WHT/RED
Rev. G 1-22-04 P/N 471048
WHT/BLK
T2
SPST. EXTERNAL ON/OFF SWITCH
BLK
25D K .032 D.C TAB
JUMPER REQUIRED IF NO REMOTE SWITCH
ORG
ORG
A-7
SWITCH
AIR PRESSURE
BLUE
24 VAC RELAY
FAN
MOTOR
GRN
BLK
120 VAC
WHT
34
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.
If the Field installation is supported and the installed heater operates from 230 VAC, there must be a
separate 120 VAC service ran for the Power vent assembly.
1. Route the PowerMax wiring through a corner opening into the lower compartment area.
2. Disconnect the orange wire from the ignition module pin 6 (24V) and connect it to the orange wire from
the air pressure switch.
3. Connect the blue wire from the air pressure switch to the ignition module pin 6 (24V).
4. The green wire that comes from the relay connect to the same place ignition module is grounded in the
main control box.
5. Twist the red and white/red tracer wires from the transformer with the white wire from the fan motor.
Using a wire nut, connect the common wire from the 120 VAC line circuit with these wires.
6. Twist the black and white/black tracer wires from the transformer with the black wire from the fan motor.
Using a wire nut, connect the hot wire from the 120 VAC line circuit with these wires.
7. Connect the branch circuit’s safety ground wire (green) to the heater ground lug.
(Refer to Figure 4.)
CAUTION
The heater must be electrically grounded and bonded in accordance with the local codes or, in absence of
local codes, with the latest national codes ANSI/NFPA No. 70.
P/N 471048 Rev. G 1-22-04
A-8
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
WIRING DIAGRAM FOR POWERMAX KIT
35
Rev. G 1-22-04 P/N 471048
Figure 4.
A-9
POWERMAX HEATER - ALL MODELS
1
36
38
5
4
3
TNEVROODTUOLANOITPO
13
12
15
002-051sledoM
004-052sledoM
9
6
22
10
14
174
593
174
693
2
36
35
7
34
27
28
21
23
25
37
30
33
32
31
29
40
20
16
17
18
19
11
8
A-10
P/N 471048 Rev. G 1-22-04
PowerMax Heater (Only) Parts List
METI NOITPIRCSED YTQ 051 002/591 052 003 053 004
1*)etelpmoc(tiKtneVxaMrewoP
straptnemecalpertneVxaMrewoP(
,xidneppAxaMrewoPnideliated 31-A )
2redaehnruteR1499070 499070 499070 499070 499070 499070
3rehsawtekcarB2612470 612470 612470 612470 612470 612470
4"2x"8/3HHtloB4937370 937370 937370 937370 937370 937370
5"2/11x61-"8/3tloB4614070 614070 614070 614070 614070 614070
6DO"1DI"8/3rehsaW4081270 081270 081270 081270 081270 081270
7teksaglaesebuT81159070 159070 159070 159070 159070 159070
8egatlovlaud-rekaerbtiucric/w-remrofsnarT1063174 063174 063174 063174 063174 063174
9DII-draobtiucrictatsomrehT1971074971074971074 971074 971074971074
1840064 940064 050064 150064 250064 122064
37
01
11xoBnoitcnuJ1221074 221074 221074 221074 221074 221074
21bonktatsomrehT2481074481074 481074481074481074481074
31).T.D.P.S(rekcorhctiwS1681074681074681074681074681074681074
41
51.yssa-rooD1864570 406570 884570 506570 606570 094570
61renrubdlofinaM1652070 525570 752070 625570 725570 852070
71
81DII-ebuttoliP1191570 191570 291570 291570 391570 391570
91
02renruB032070 032070 032070 032070 032070 032070
a02tekcarbtoliPhtiwrenruB1055074055074055074055074055074055074
saglarutaneludoM1485370 485370 485370 485370 485370 485370
sagenaporpeludoM1585370 585370 585370 585370 585370 585370
taNDII-)etelpmoc(.yssalenaplortnoC1883074983074 093074193074293074 393074
orPDII-)etelpmoc(.yssalenaplortnoC1930174040174140174240174340174440174
DII-larutanevlavsaG1899370 899370 899370 899370 899370 899370
DII-enaporpevlavsaG1999370 999370 999370 999370 999370 999370
DII-)etelpmoc(larutan.yssayartrenruB1257370 994570 157370 005570 105570 057370
DII-)etelpmoc(enaporp.yssayartrenruB1609370 805570 509370 905570 015570 409370
.AE2.AE3.AE4.AE5.AE6.AE7
12hctiwserusserP1091074 091074 091074 091074 091074 091074
22)etelpmoc(.yssarebmahcnoitsubmoC1858370 685570 758370 785570 885570 658370
32"4/3niardevlaV1431270 431270 431270 431270 431270 431270
52edoClacoLroEMSA-#05"4/3feilerevlaV1831270 831270 831270 831270 831270 831270
72
82teksagevlavwolF4510470 510470 510470 510470 510470 510470
922/12x61-"8/3tloB2294570 294570 294570 294570 294570 294570
03tiKegnalfkciuQ1482570 482570 482570 482570 482570 482570
Rev. G 1-22-04 P/N 471048
)etelpmoc(dradnatS,.yssaevlavwolF1424174424174424174 424174424174424174
)etelpmoc(EMSA,.yssaevlavwolF1989370989370989370989370989370 989370
A-11
PowerMax Heater (Only) Parts List, contd.
METI NOITPIRCSED YTQ 051 002/591 052 003 053 004
13naxeLtuo/nignihsuB2445070 445070 445070 445070 445070 445070
"2tuo/nirebbur,eveelS2598170 598170 598170 598170 598170 598170
23
"½1tuo/nirebbur,eveelS2922070 922070 922070 922070 922070 922070
33ffotuhSytefaS2710170 710170 710170 710170 710170 710170
43)tuo/ni(redaehniaM1589070 589070 589070 589070 589070 589070
)sdaehtuohtiw(regnahcxetaeH1254470 826570 154470 926570 036570 470470
53
)sdaehhtiw(regnahcxetaeH1463074 563074 663074763074 863074 963074
.ae8.ae8.ae8.ae8.ae61.ae61
63elffaB772070 955570 672070 065570 772070 872070
73004,053noselffab)2(nwoddlohelffaB1018370 018370 018370 018370 018370 018370
83rotcelloceulF1468370 226570 368370 326570 426570 268370
38
04)ylnostinusaGenaporP(dleihSkcabthgiL1387570 487570 587570 687570 787570 887570
nwohStoN*
*
*
*
*
*
"4/1x6wercS617170 617170 617170 617170 617170 617170
*
*
*
"2/1gnihsuB155070 155070 155070 155070 155070 155070
*
*
*
*
tekcarbgnitnuomcitsalP517070 517070 517070 517070 517070 517070
DII)evlavsag(ssenraH-tiKeriW569074 569074569074569074569074569074
HH"4/1x8wercS307170 307170 307170 307170 307170 307170
HH"2/1x8wercS896170 896170 896170 896170 896170 896170
"4/1x23-01wercS956170 956170 956170 956170 956170 956170
"61/3x23-01wercS296570 296570 296570 296570 296570 296570
reppotsbonkmrehT2414074 414074414074414074414074414074
)evlavwolf(tnemelerewoP1871074871074871074871074871074871074
"4/3x81-"61/5tloB2527370 527370 527370 527370 527370 527370
.ae3
ProN
.ae4
ProN
.ae5
ProN
.ae6
ProN
.ae7
ProN
larutanrenrubniamecifirO727370 727370 727370 727370 727370 727370
.ae8
ProN
*
*
*
*
DII-larutan-toliP1402174 402174 402174 402174 402174 402174
DII-enaporp-toliP1502174 502174 502174 502174 502174 502174
ffotuclamrehT1371570 371570 371570 371570 371570 371570
*
*
P/N 471048 Rev. G 1-22-04
enaporprenrubniamecifirO827370 827370 827370 827370 827370 827370
)sledomDII(etelpmoc)eborp(rotsimrehT1081074081074081074081074081074081074
)sledoMDII(lortnoctatsimreht,metS2181074181074181074181074181074181074
A-12
PowerMax Assembly
39
PowerMax Assembly Parts List
METINOITPIRCSEDYTQ051002052003053004
1munelP1931074041074141074241074341074441074
2noitsubmocrewolB1800074800074700074700074700074700074
3esab&edisxoblortnoC1133074133074133074133074133074133074
4potxoblortnoC1733074733074733074733074733074733074
5gnirretpadA1633074633074623074623074623074623074
6esabretpadA1433074433074523074523074523074523074
7ebutrebburenociliS1823074823074823074823074823074823074
8yaleR1010074010074010074010074010074010074
9
9
hctiwSerusserP
.tf0004otleveLaeS
1900074900074900074900074900074900074
hctiwSerusserP
edutitlAhgiH
.tf0008-0004leveLaeS
1824174824174824174824174824174824174
Rev. G 1-22-04 P/N 471048
A-13
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
P/N 471048 Rev. G 1-22-04
• (805) 523-2400
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