Pentair MiniMax NT Standard Series User Manual

MiniMax NT Standard Series

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.

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. A 1-2-02 P/N 472032

• (805) 523-2400

Table of Contents

Introduction ............................................................................................................... 3

Important Notices ...................................................................................................................................................................... 3

Code Requirements ................................................................................................................................................................... 3

Warranty Information ................................................................................................................................................................. 4

Operation .................................................................................................................... 4

Safety Rules .............................................................................................................................................................................. 4

HSI (Hot-Surface Ignition) Lighting/Operation ........................................................................................................................... 5

Installation Instructions ............................................................................................ 6

Specifications ............................................................................................................................................................................ 6

Installation — Electrical ............................................................................................................................................................. 7

Installation — Remotes (2 and 3 Wire) ...................................................................................................................................... 8 - 9

Installation — Wiring Diagram ................................................................................................................................................... 10

Installation — Water Connections.............................................................................................................................................. 11

Installation — Plumbing ............................................................................................................................................................. 11

Installation — Gas Line ............................................................................................................................................................. 12

Pipe Sizing Chart/Gas Pressure Requirements ......................................................................................................................... 12

Regulated Manifold Pressure Test ............................................................................................................................................. 12

Venting — Indoor Installations ................................................................................................................................................... 13 - 16

Venting — Outdoor Installations ................................................................................................................................................ 17

Basic Operation — General Description .................................................................................................................................... 18

Basic Operation — Safety Controls ...........................................................................................................................................19 - 20

Basic Operation — HSI Ignition Module .................................................................................................................................... 20

Thermostat (Programming & Layout) ........................................................................................................................................ 21

Temperature & Time Setting (Programming) .............................................................................................................................22 - 23

Maintenance ............................................................................................................................ 24

Maintenance Instructions ........................................................................................................................................................... 24

Pressure Relief Valve ................................................................................................................................................................ 24

Maintenance (Water Treatment) ................................................................................................................................................ 25

Trouble Shooting ....................................................................................................... 26

Normal Operation Sequence ..................................................................................................................................................... 26 - 27

Troubleshooting & Service......................................................................................................................................................... 27 - 28

Troubleshooting (General) ......................................................................................................................................................... 29

MiniMax NT Standard Parts List & Exploded View (Dual Voltage) ............................................ 30-31

Warranty Information ................................................................................................. Back Cover

P/N 472032 Rev. A 1-2-02

Introduction

MiniMax NT Standard

Pool and Spa Heaters

Congratulations on your purchase of a MiniMax NT Standard 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 NT Standard is a compact, lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe. The MiniMax NT Standard also comes equipped with the Pentair multifunction 7800 temperature controller which shows, at a glance, the proper functioning of the heater. All HSI (hot-surface ignition) MiniMax NT Standard heaters are designed with a direct ignition device (HSI) which eliminates the need for a standing pilot. The MiniMax NT Standard requires an external power source (120/240 VAC 50/60 Hz) to operate.

IMPORTANT NOTICES

...For the installer and operator of the MiniMax NT Standard 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.

Do not use the heater to protect pools or spas from freezing if the final maintenance temperature desired is below 60° 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. A 1-2-02 P/N 472032

Operation

This instruction manual provides operating instructions, installation and service information for the MiniMax NT Standard high performance heater. The information in this manual applies to the MiniMax NT Standard 200, 250, 300, and 400 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 NT Standard. History and experience has shown that most heater damage is caused by improper installation practices.

Operation

WARRANTY INFORMATION

The MiniMax NT Standard 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. A temperature of 100° F. 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 100° F. 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. 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.

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 472032 Rev. A 1-2-02

Operation (Lighting)

MINIMAX NT STANDARD HSI ELECTRONIC IGNITION LIGHTING/OPERATION

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 main burners. Do not try to light the burners 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 main burners. Do not try to light the burners by hand.

5. Remove the control access door.

6. Push in gas control knob slightly and turn clock-

wise to “OFF”. (If not on “OFF” position.)

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 NT Standard incorporates the

Pentair 7800 temperature controller 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.

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. A 1-2-02 P/N 472032

4. Push in gas control knob slightly and turn clockwise to "OFF". Do not force.

5. Replace control access door.

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 VENTILATION

15.50

7.35 2 in. SOCKET

24.05

30.63

Figure 2.

LEG

4 in. Kit

P/N 460506

5 in. Kit

P/N 460507

3.50

14.50

6.64

8.84

"A" DIM.

4.875

INDOOR VENTILATION

15.50

7.35

Ø4.88 Ø5.88

3.50

24.05

MODEL

200 250 24.63 300 400 34.13

"A" DIM.

21.63

27.63

INDOOR VENT ADAPTOR

P/N 460506

P/N 460507

4 in. Kit

5 in. Kit

LEG

DIMENSIONS IN INCHES

2.00

30.63

LEG

Figure 3.

LEG

6.64 "A" DIM.

8.84

14.50

4.875

MODEL

"A" DIM. 200 250 24.63 300 400 34.13

21.63

27.63

DIMENSIONS IN INCHES

P/N 472032 Rev. A 1-2-02

Installation (Electrical)

ELECTRICAL, for MiniMax NT Standard Heaters

Electrical Rating 50/60 Hz 120 / 240 Volts AC, single phase

NOTE

The MiniMax NT Standard heater is prewired for 240 volt AC connection using the “BROWN” female connector and the “WHITE” common male connector; see below, Figure 4. If you require the heater to be connected to 120 volts AC, remove the “BROWN” female connector from the “WHITE” common connector; now locate the “BLUE” female connector and plug it into the “WHITE” common connector.

When connecting the home wiring to the “Line Terminal Block” inside the junction box, follow the polarity as shown below. Connecting to 120 VAC, make sure that you connect the positive wire to the positive terminal (L), the neutral wire is connected to the neutral terminal (N) and the ground is connected to the ground terminal (GND); see below, Figure 5.

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.

BROWN

WHITE

COMMON MALE

CONNECTOR

TERMINAL BLOCK

FOR AC INPUT

120 / 240 VOLT SINGLE

PHASE "See Below"

GROUND CONNECTION

LINE TERMINAL BLOCK

GREEN WIRE

FM CONNECTOR

FOR USE WITH

240 VOLT AC

BLUE

FM CONNECTOR

FOR USE WITH

120 VOLT AC

Figure 4.

NEUTRAL / WHITE 120 VAC LINE #1 FOR 240 VOLT AC

POSITIVE LINE FOR 120 VOLTS AC LINE #2 FOR 240 VOLT AC

WHITE WIRE

BLACK WIRE

INTERNAL FACT ORY WIRES

Figure 5.

Rev. A 1-2-02 P/N 472032

Installation (Remotes)

TWO-WIRE OR THREE-WIRE REMOTE HOOK-UP

Before connecting the remote control system please read the following:

1. First turn the gas valve to the "OFF" position and power up the heater, now using the front buttons on the temperature controller, set the "SPA" and "POOL" temperature to the maximum setting, see Page 22.

2. Now turn the heater to the "OFF" mode by using the "OFF" button on the temperature controller, see Page 22 or by using the main power switch located on the bottom of the junction box.

3. With the heater in the "OFF" mode, locate the three tabs on the back of the temperature controller as viewed from the backside, see Figure 6.

4. • Two-wire remote with temperature control:

a) Using 3/16" female quick disconnect connectors, connect one

wire to the "GND" tab of the temperature controller, then the second wire to either the "SPA" or "POOL" tab.

Figure 6.

123

POOL

SPA

GND

b) Now return power to the heater but leaving the temperature controller in the "OFF" position,

see Page 22. (Note: If you used the main power switch to turn off the heater, now turn the main power switch on.) At this time the remote system has control over the heater, and will turn it on and off when called for by the remote system thermostat thus keep the pool and spa at the desired temperature.

2 WIRE REMOTE

5 A FUSE FOR AUX2 (PILOT DUTY ONLY)

AUX2

246

REMOTE

(AUX1)

POOL

SPA

PUMP/AUX2

BLOWER

GND

10 A

25O V

RELAY

10 A

25O V

RELAY

A.C LOAD (PUMP/AUX2) (PILOT DUTY ONLY)

BLOWER (POWER) LINE BLOWER (POWER) LINE

}

NOT USED

TEMPERATURE DISPLAY MODE

5 A

25O V

RELAY

1234 123 123456 12

2 1

C A

24 V

PV/MV

V P

E S

T FU

H LIMIT

PRESS

PUMP

PURGE

MODE

135

531

642

TPROBE

POWERLIMITSG VALVEIGN MODULE

24 VAC

AIR PRESS

REMOTE SWITCH CONTROLLER

Figure 7.

Three-Wire continued on next page.

P/N 472032 Rev. A 1-2-02

Installation (Remotes)

TWO-WIRE OR THREE-WIRE REMOTE HOOK-UP, (cont’d.)

• Three-wire remote:

a) Using 3/16" female quick disconnect connectors, connect the common wire to the "GND" tab of the

temperature controller, then connect the two remaining wires to the temperature controller corresponding to the remote control device, pool wire to "POOL" tab, spa wire to "SPA" tab.

b) Now return power to the heater. (Note: If you used the main power switch to turn off the heater, now

turn the main power switch on.) At this time, the remote system has control over the heater and if pool or spa temperature is below the temperature controller setting, then the heater will try to come on.

c) If you desire to reset the temperature settings of the temperature controller, the remote has to be in the

desired mode for you to change the particular setting. Example: You wish to raise or lower the pool temperature from the factory setting, you must have the remote system in the pool mode, if you wish to change the spa temperature, you must have the remote system in the spa mode.

5. Now turn on the gas valve to "OPEN" position, the heater is now ready to operate.

NOTE

The heater factory settings are 78° F. for the pool and 104° F. for the spa. When connecting a remote control to the MiniMax, 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. A Remote hook-up deactivates the selector keys on the front

thermostat display panel and gives selection control to the remote.

3 WIRE REMOTE

This icon is not a fault icon but instead indicates a remote switching device is connected to the Pentair Temperature Controller 7800, and has overriding selection control of Pentair Temperature Controller 7800.

5 A FUSE FOR AUX2 (PILOT DUTY ONLY)

531

246

REMOTE

(AUX1)

POOL

SPA

PUMP/AUX2

BLOWER

GND

AUX2

10 A

25O V

RELAY

10 A

25O V

RELAY

A.C LOAD (PUMP/AUX2) (PILOT DUTY ONLY)

BLOWER (POWER) LINE BLOWER (POWER) LINE

Figure 8.

}

NOT USED

TEMPERATURE DISPLAY MODE

25O V

RELAY

3 2 1

REMOTE POOL/OFF/SPA

THERMOSTAT SELECT SWITCH

POOL

SPA

COMMON

5 A

1234 123 123456 12

C A

24 V

PV/MV

T FU

H LIMIT

PRESS

PUMP

PURGE

MODE

135

642

POWERLIMITSG VALVEIGN MODULE

TPROBE

24 VAC

AIR PRESS

Rev. A 1-2-02 P/N 472032

Installation (Dual Voltage Wiring)

MiniMax NT Standard (ALL MODELS) HSI Electronic Ignition Wiring Diagram

(DUAL VOLTAGE)

240 VAC

120 VAC

BLK

WHT

GRN

BLOCK

TERM

BLK

WHT

GRN

WHT

BLK

WHT

BLK/WHT

THERMAL FUSE

WHT

RED

THERMAL SWITCHES

EXHAUST HIGH LIMIT

RED

HIGH LIMIT

THERMAL SWITCHES

345

BLK

(BRN)

CON-2F

GRN

GAS VALVE

WHT

RED

WHT

RED

WHT

RED

WHT

FOR 240 VAC

BLU

WHT

YEL

WHT

BLK

WHT

ORG

SWITCH

WATER PRESSURE

YEL

BLU

WHT

GRN

PUR

ORG

BLK

IGNITOR

HOT SURFACE

BLU

WHT

RED

PROBE

TEMPERATURE

SPDT EXTERNAL SWITCH

FLAME SENSOR

BURNER

GRY WHT

ORG

1 2

P11

4 1

P10

1 2 3

4 5 6

1 2

WHT

ORG

TFUSE GAS IGN

AIR

213

4 32112312345612

LIMITS VALVE MODULEPOWERTPROBE

PRESS SW.

REMOTE

BLOWER

RELAY

BLOWER

S1/120

123

POOL SPA COM

PUMP RELAY

WHT

FENWAL

IGN MODULE

GND

MV1

L2L1S1/240

LO/FS

WHT

BLU

RED

ORG

250V

RELAY

PENTAIR 7800

RELAY

AUX2

RELAY

250V

10A

250V

BLOCK

TERM

(BLU)

CON-2F

FOR 120 VAC

(WHT)

CON-2M

BLK

RED/WHT

RED

MiniMax NT STANDARD ALL MODELS WIRING DIAGRAM

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, 200˚ C TEMPERATURE RATING.

INTERCONNECTING WIRING TO APPLIANCE MUST CONFORM TO THE NATIONAL ELECTRICAL

CODE OR SUPERCEDING LOCAL (WIRING) CODES.

SHEET METAL

CHASSIS

TERMINATE SUPPLY SAFETY GROUND WIRE (GREEN) HERE

GROUND SCREW WITH PAINT CUTTING WASHER

BOND LUG

EXTERNAL

AIR PRESSURE SW.

WHT

P/N 472032 Rev. A 1-2-02

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