Pentair CH User Manual
Warning:
®
MiniMax CH
POOL & SPA HEATERS
OPERATION & INSTALLATION MANUAL
WARNING
FOR YOUR SAFETY - READ BEFORE OPERATING
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. C 1-22-04 P/N 472128
• (805) 523-2400
Table of Contents
Introduction ............................................................................................................... 3
Important Notices ...................................................................................................................................................................... 3
Warranty Information ................................................................................................................................................................. 4
Operation .................................................................................................................... 4
Safety Rules .............................................................................................................................................................................. 4
Millivolt Lighting/Operation - Natural & Propane ........................................................................................................................ 5
Operating (Controls) .................................................................................................................................................................. 6
Maintenance ............................................................................................................... 7
Maintenance Instructions ........................................................................................................................................................... 7
Relief Valve................................................................................................................................................................................ 7
Energy Saving Tips.................................................................................................................................................................... 7
Spring and Fall Operation .......................................................................................................................................................... 7
Winter Operation ....................................................................................................................................................................... 7
Chemical Balance ...................................................................................................................................................................... 8
Installation Instructions ............................................................................................ 9
2
Specifications .......................................................................................................................... 9
Plumbing Connections ........................................................................................................... 10
Plumbing/Valves ........................................................................................................................................................................ 10
Manual Bypass .......................................................................................................................................................................... 10
Below Pool Installation .............................................................................................................................................................. 10
Water Connections .................................................................................................................. 11
Reverse Water Connections ...................................................................................................................................................... 11
Insulating High Limits when Reversing Heads ........................................................................................................................... 11
Gas Connections ..................................................................................................................... 12
Gas Line Installation .................................................................................................................................................................. 12
Pipe Sizing Chart/Gas Pressure Requirements ......................................................................................................................... 12
Pipe Sizing Chart/Propane 2 Stage Regulation ......................................................................................................................... 13
Regulated Manifold Pressure Test ............................................................................................................................................. 13
Ventilation ................................................................................................................................ 14
Outdoor Installation Requirements ............................................................................................................................................ 14
Outdoor Cap Installation ............................................................................................................................................................ 14
Indoor Installation Requirements ............................................................................................................................................... 15
Installation on Floors Constructed of Combustible Materials ..................................................................................................... 16
Indoor Draft Hood Installation .................................................................................................................................................... 16
Electrical .................................................................................................................................. 17
Millivolt Wiring Diagram ............................................................................................................................................................. 17
Trouble Shooting (General) ....................................................................................... 18
MiniMax CH Parts List & Exploded View ................................................................. 19-21
MiniMax CH (150 IID Model) Appendix ..................................................................... A1-A9
MiniMax CH (150 IID Model) Parts List & Exploded View ....................................... A10-A12
Warranty Information ................................................................................................. Back Cover
P/N 472128 Rev. C 1-22-04
3
Introduction
MiniMax CH
Pool and Spa Heaters
Congratulations on your purchase of a MiniMax CH 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 CH 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 CH
is a millivolt heater and has a self sustaining pilot and requires NO external power source.
IMPORTANT NOTICES
...For the installer and operator of the MiniMax CH 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. C 1-22-04 P/N 472128
Operation (contd.)
4
This instruction manual provides operating instructions,
installation and service information for the MiniMax CH high
performance heater. The information in this manual applies to
the MiniMax CH 150, 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 CH. History
and experience has shown that most heater damage is caused by
improper installation practices.
WARRANTY INFORMATION
The MiniMax CH pool heater is sold with a limited factory
warranty. Specific details are described on the warranty
registration card which is 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 stateof-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.
PRODUCT IDENTIFICATION
To identify the heater, see rating plate on the inner front panel of the
heater. There are two designators for each heater, one is the Model
Number and the other is the Heater Identification Number (HIN).
a.Model Number:
Example: 400
st
through 3rd character indicated: Input rating (Btu/hr) X 1000
1
b. Heater Identification Number (HIN):
The following example simplifies the identification system.
123456
RTH004HCknalBMNknalB
1) HTR : Heater
2) (150, 200, 250, 300, 400) : Input rating (Btu/hr) X 1000
3) CH : MiniMax CH
4) Blank : Standard Model
5) N M : Gas type (Natural gas) & Ignition Device
6) Options :
Blank: Standard Model
ASME: ASME Certified (Bronze Headers)
ASHI: ASME Certified Bronze Header & High Altitude Rating
HALT: High Altitude Rating
CAN: Canadian Compliance
CANH: Canadian Compliance and High Altitude
Operation
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
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.
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.
P/N 472128 Rev. C 1-22-04
Operation (contd.)
MINIMAX CH 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.
5
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”.
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.
TO TURN OFF GAS TO HEATER
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. C 1-22-04 P/N 472128
4. Push in gas control knob slightly and turn clockwise
to "OFF". Do not force.
5. Replace control access door.
Operation (contd.)
SPAPOOL
COLD COLDHOT HOT
OFF
POOL TEMP SPA TEMP
6
OPERATING (CONTROLS)
Dual Temperature Control System
For convenience and economy all MiniMax CH
heaters are equipped with two thermostats on the
front of the heater control panel; see Figure 5.
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 6.
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.)
Figure 5.
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.
POWER (THERMOSTAT SELECT) SWITCH
Figure 6.
Screw A
The Pool/Off/Spa switch allows the heater to be turned
off when heating is not desired.
1. “Pool” position - Maintains selected pool temperature.
Knob Stopper
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 or an alternate lower pool
temperature.
P/N 472128 Rev. C 1-22-04
Maintenance
MAINTENANCE INSTRUCTIONS
It is recommended that you check the following items at least
every six months and at the beginning of every swimming
season.
1. Examine the venting system. Make sure there are no obstructions in the flow of combustion and ventilation air.
2. Visually inspect the main burner and the pilot burner
flame. The normal color of the flame is blue. When flame
appears yellow, burners should be inspected and cleaned;
see Figure 8.
3. Keep the heater area clear and free from combustibles
and flammable liquids.
Blue Flame
Figure 7.
Figure 8.
7
Pressure Relief Valve
In some installations, a
pressure relief valve
(PRV) is required on the
MiniMax CH heater. To
install a PRV, carefully
drill a 3/8 in. hole in
center of 3/4 in. NPT
port (on main header)
being careful to drill
only thru wall at bottom
of 3/4 in. NPT port and
no deeper—now thread
in the 3/4 NPT PRV. (Sold separately.)
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.
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
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.
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 CH should not be operated out doors at temperatures below 0° F. for propane and -20° F. for natural gas. Where
freezing is 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 9.) 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.)
Rev. C 1-22-04 P/N 472128
Maintenance (contd.)
8
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 472128 Rev. C 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"
051.ni8/771.ni½6
002.ni8/702.ni½9
052.ni8/732.ni½21
003.ni8/762.ni½51
9
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.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.
Indoor installation - stack (USA only)
Outdoor shelter installation (Canada)
FRONT VIEW SIDE VIEW
"E" DIM.
ledoMmiD"A"miD"B"miD"C"miD"D"miD"E"
"C"
051.ni8/771.ni½6.ni31.ni¾25.ni6
"D"
DIM
DIM.
002.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.
GAS LINE
OPENING
28
7
10
8
1
"B" DIM.
5
2
"A" DIM.
TM
7
13
8
1
21
4.875
2
Rev. C 1-22-04 P/N 472128
10
POOL
HEATER
MANUAL
BY-PASS
CHECK
VALVE
TO
POOL
ISOLATION
VALVE
ISOLATION
VALVE
FILTER
FROM
POOL
CHECK
VALVE
PUMP
P/N 472128 Rev. C 1-22-04
Installation (contd.)
11
WATER CONNECTIONS
Reversible Inlet/Outlet Connection
The MiniMax CH 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
Screw Driver(s) - (Flathead & Phillips)
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.
INSULATING THE HIGH LIMITS
When Reversing Heads on the
MiniMax CH Heater
On the MiniMax CH heater there is insulation installed
by the factory on the return head side of the heaters.
This insulation is there so that if the heads are reversed
in the field, during initial installation of the heater, the
reflected heat from the flue collector will be insulated
from the high limits.
Return head in position before removal.
This view shows the insulation installed by the factory.
NOTE
There is no reason to remove the high-limit
and pressure switches or the thermister from the
front header during the reversing procedure, as
they will be in the proper location when
installed on the left side.
3. Disconnect the pressure switch wiring.
4. Disconnect the thermostat thermister leads from
the control board.
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 and reconnect thermister to the board.
Return head removed and new tube seals installed. Now
ready to accept the installation of the main head.
Lift the installation to allow the main head to be installed.
When head is placed into position, release the insulation;
it will now shield the high limits from the heat produced
by the flue collector.
8. Reinstall the inspection plates.
Rev. C 1-22-04 P/N 472128
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