Warning:If you do not follow these instructions exactly, a fire or explosion may result, causing
property damage, personal injury or loss of life.
!
WARNING
Improper installation, adjustment, alteration, service or maintenance may cause property damage, personal injury or
death. Installation and service must be performed by a qualified technician or service agency.
Models:
MiniMax Plus HP 400 (XLS400)
MiniMax Plus HP 600 (XLS600)
MiniMax Plus HP 800 (XLS800)
The following installation manual is for FACTORY AUTHORIZED- licensed professional trade use only !
The owner/user should review the following section for reference and knowledge needed to verify proper
installation for warranty validation. The owner/user should not attempt to perform any internal adjustments, electrical, plumbing or any installation procedures in this manual. The owner/user should never
open the access panel for any reason unless accompanied by a factory warranty representative.
Owners/users/installers should contact the factory service department for advice at
239-768-1555
!
WARNING
Always review the wiring schematic located inside the heater,
since it may have changed after this manual was printed !
!
WARNING
THE MISUSE OF THIS PRODUCT CAN RESULT IN SEVERE INJURY, DEATH,
OR PROPERTY DAMAGE. BE ADVISED OF THE FOLLOWING CONDITIONS THAT MAY EXIST:
1. ELECTROCUTION AND/OR FIRE DUE TO IMPROPER WIRING.
2. HAND AND HAIR ENTRAPMENT MAY OCCUR NEAR THE FAN LO CATED ON THE TOP OF THIS UNIT.
3. LOSS OF POOL WATER AND/OR FLOODING AND/OR PROPERTY DAM AGE.
4. DAMAGE AND/OR MISUSE TO THE PRODUCT RESULTING IN FAILURE
OR EXCESSIVE WEAR.
5. ALL ELECTRICAL WORK BY LICENSED PROFESSIONAL ONLY.
6. BACK OR BODY INJURY DUE TO MISHANDLING.
2
INSTALLATION MANUAL - TABLE OF CONTENTS
1. HEAT PUMP DESIGN FEATURES ..............................................................................................
Clearances for Airflow
Condensate Drainage
Heater Elevation
Sprinkler Location
3. PLUMBING & WATER FLOW ......................................................................................................
Placement and Chemical Protection
Chlorinator Location and Chemical Use
Standard Plumbing
Pool / Spa Combination Plumbing
Separate Pool / Spa Plumbing
Plumbing with Solar Panels
Commercial Applications
Water Flow Switch Options
4. START UP PRECAUTIONS ..........................................................................................................
Compressor Warm Up, Starting & Time Delay
Setting Water Pump Timer
Confirming Water Flow at Bypass Manifold
Operational Sequence Description
Water Pressure Switch Check
Freeze Protection Requirements
4 - 5
6 - 7
8 - 19
20 - 23
5. ELECTRICAL WIRING AND SETUP ..........................................................................................
Bonding to Pool Shell
Unit Specifications
Electrical Connections-Access Description
Electronic Thermostat & Diagnosis
Wiring Diagrams
Wiring Diagrams for Compool
7. WARRANTY AND DEALER SERVICE.......................................................................................
8. GLOSSARY OF TERMS ..............................................................................................................
Manufactured for Pentair Pool Products by HydroTemp Mfg. Co., Inc.
24 - 34
35 - 36
37
38-41
3
SPECIAL FEATURES
Separate Air Handling / Electric Compartment
An internal electrical compartment substantially reduces
future service from moisture and salt laden air flow.
Sturdy Rust Proof
Fiberglass Top
Non Fading
Large Aluminum & Copper
Lanced Fin
Evaporator Air Coil with
Vinyl Coil Guard
Automatic Diagnostics With
L.E.D. Display & Dual Pool/Spa
Electronic Thermostat
Optional Pool/Spa Wiring
Access Holes
Quiet
High Volume
Fan With
Vinyl Coated
Guard
Easy Connect
2 Inch Plumbing With
"Internal Automatic Bypass"
Up To 90 GPM
Product
Name Plate
Chemical
Warning Label
Sturdy Elevated
Fiberglass
Rust Proof
Bottom Provides
Proper Drainage
TRANE®
COMPRESSOR
with 410-A, the safe
and clean refrigerant.
Super Quiet & Highly Efficient Compressor Design
4
COMPRESSOR
And
SCROLL
W ATER SWITCH
CONTROL
POOL
SPA
T-STAT
LOW PRESS. HIGH PRESS.
MODE
MODE
READY
OK
ON
OKOK
Air Flow Out
Air Flow In
@ 4200 CFM
Bulkhead
Air/Electrical/
Mechanical
Separation
Wall
Isolated
Electrical
Compartment
Compressor
Fan
T
H
E
R
M
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W
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P
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ead
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5
0
Evapor
Compressor
Electrical Compartment
Top View
DESIGN ADVANTAGES
C
F
M
Fan
The electrical panel has an
isolated compartment, located
within the mechanical compartment to prevent corrosion.
The heat from the compressor
located just below the electrical compartment helps eliminate moisture as well. This
exclusive design will substantially extend the life cycle of
the heater. The fiberglass cabinets is corrosion proof and is
much stronger than plastic
cabinets.
4250
2" PVC
Water IN
20-90 GPM
Internal
Automatic
Bypass
Internal Automatic Bypass
Free Flow 2" Plumbing
Automatically adjusts the water flow.
Lowest water flow restriction available.
C
O
N
T
R
O
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P
O
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L
S
P
R
A
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A
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P
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S
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.
H
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.
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O
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O
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T
H
E
R
M
O
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T
A
T
Elevated
Fiberglass
2" PVC
Water OUT
Bottom Pan
for Proper
Condensation
Drainage.
Heat Exchanger
Special Cupronickel Alloy
Encased In A Block of Foam
to Prevent Heat Loss & Corrosion
T-STAT
L.E.D. Diagnostic Lights
Dual Thermostat
See specification sheet to determine
electrical breaker requirement.
5
INSTALLATION GUIDELINES
IMPORTANT NOTICE: The following are the installation requirements that must be followed in order to meet
the general factory specifications. The installer may engineer other types of installation techniques that are suited
for each particular installation, regarding placement and plumbing, but should still follow this basic format. The
factory warranty will not warrant other field installed options unless factory parts are used according to this
booklet. This information is intended for a licensed professional contractor only.
!
WARNING
The pool owner or operator should not attempt to perform or change any aspect of
the installation, because serious bodily injury and or electrocution may result.
HEATER PLACEMENT & CLEARANCE
CLEARANCE & AIR FLOW
Prepare a level area near the pool/spa filtering system.
Remove any plants or equipment that do not meet the
minimum clearance requirements for the side air inlets
or the top air discharge, see diagram on next page.
a
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l
C
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n
i
M
"
9
l
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C
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i
A
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o
t
a
Evapor
Bulkhead
Compressor
12" Min. Clearance On Sides
Electrical Compartment
24" to 36" Service Access Front
Make sure the air flow is not restricted in any way. Do
not install the unit in an area where the cooler discharge
air may accumulate and be drawn back into the unit.
Provide ventilation through containment walls or fencing for the air intake if needed.
CAUTION
!
Do not install this unit indoors or
in filtering system equipment rooms.
e
A
t
E
n
d
Fan
EQUIPMENT SLAB & PITCH
To support the heater, place
a concrete or fabricated slab
C
O
N
T
R
O
L
P
O
O
near the filtering system.
L
S
P
R
A
E
A
D
Y
W
A
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R
S
W
T
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T
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.
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S
.
O
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O
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T
H
E
R
M
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S
T
A
T
Whenever possible, the slab
should be placed at the same
level or some what above
the filtering system slab.
Make sure the slab does not
hold water and see that it is
1/4"
pitched no more than 1/4 inch away from the compressor end (front) of the heater. Pitch slab from
front to back 1/4" maximum and level from side
to side.
CONDENSATION DRAINAGE
The heat pump will precipitate water that drains from
the unit at a steady rate while it is running. This condensation is from the humidity in the outside air. The
more humidity, the more condensation it will produce. There are several drain ports in the bottom of
12" Min. Clearance On Sides
the unit, make sure they do not become clogged with
debris.
HEATER ELEVATION
If the heater is to be installed more than 6 feet above,
or more that 3 feet below the pool water level, you
may need to install an external flow switch as shown
in the plumbing section of this manual. If a solar
system or special equipment is in use, you may require either a special water pressure switch or the
use of an external flow
switch as shown in "Water
Flow Switch Section",
6
SPRINKLER LOCATION
Relocate or remove any sprinkler heads that have the
chance of spraying on or into the unit.
are absolutely no sprinkler heads near the heater that
will in any way spray on or into the heater. Sprinkler
damage is not covered under the warranty agreement. Make sure they are a sufficient distance away so
normal wind currents will not carry the mist to the heater.
The heater is designed to handle the wettest weather
conditions that are typical of rain and humidity, etc.
However, sprinkler heads force high pressure water into
the unit from the side at an odd angle. Most sprinkler
systems are connected to a well system. Most well water
is high in minerals, sulphur and other aggressive contaminates. These contaminates will leave a build up on
the evaporator coils and electronics causing corrosion
and hamper the efficiency. If you are located within 15
miles of the coast, salt may be in the well water also.
Make sure there
!
CAUTION
Chemicals should NOT be stored near the heater. The
fan may draw corrosive chemical vapor through the unit
causing damage. Do NOT store anything on top, underneath or around the heater. You will need access to the
disconnect breakers in the event of an emergency.
CLEANING
To clean the heater you should take a sponge and mild
soapy water and wipe the surfaces clean. Do not use a
pressurized garden hose to clean the heater. Never force
water into the unit from any direction. You may use a
garden hose at low pressure with no nozzle attachment
to rinse the air coils. Pour a mild liquid soap into the
water stream as you rinse the air coils. Clean the evaporator air coils at least 4 times a year. If you live near the
sea coast, you will need to clean at least 6 times a year
or more to remove salt and sand. Clogged evaporator
coils will reduce the efficiency of the unit and cause
corrosion. A professional should clean the coils periodically, every year or two.
ROOF CLEARANCE & RUN OFF
Be aware of roof slope and overhang above the heater.
Sharp sloping roofs without gutters will allow massive
amounts of rain water, mixed with debris from the roof
to be forced through the unit. Roof valleys that collect
run of f from two slopes are especially important to avoid.
If space is limited, determine if a gutter or down spout
is needed to protect the heater. Low roof overhangs may
obstruct the air flow out of the unit and require 48 inches
of clearance, See diagram below.
No water directly off
roof into heater
4 Feet
Evaporator Air Coils
7
PLUMBING & WATER FLOW
PLUMBING CONNECTIONS
Filtered Water “IN” on the LEFT front.
Heated Water "OUT" on the RIGHT front.
The plumbing inlets are "slip" p.v.c. pipe that will accept
a 2 inch p.v.c. glue fitting. The pipe is left plain so you
can adapt to your needs. Use p.v.c. cleaner to prime the
fitting and pipe. Use a quality medium body p.v.c. glue.
FOR PUMPS UP TO 2 H.P. OR 90 G.P.M. MAX.
SEE NEXT PAGE FOR LARGER WATER PUMPS.
1. PUMP
2. FILTER
3. HEATER
4. LOOP & CHECK
5. CHLORINATOR
6. RETURN TO POOL
Water
Pump
WATER OUT
WATER IN
Heater
Filter
3
2
4
!
WARNING
See mandatory chlorinator placement
and install of the loop & check valve.
INTERNAL
AUTOMATIC BYPASS
The heat pump in equipped with
a internal "Automatic Bypass"
valve. A variable rate spring
valve is used to regulate the water flow through the heat exchanger. Steady flow will be delivered over a wide range of flow
rates. This automatic valve can
handle a maximum flow rate of
90 gallons per minute.
The automatic valve will compensate for flow loss due to normal filter debris accumulation or
changes if flow due to valving
and other conditions.
IN
1
5
6
Chlorinator or
Chemical Feeder
CON
TROL
PO
OL
SP
R
AEA
D
YWATE
M
R
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S
D
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M
T
-O
ST
D
A
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T
LOW
PRE
SS.
HIG
H
O
P
K
RES
.
O
K
OK
O
K
THERMOSTAT
Water Inlets
"
d
l
o
C
m
p
e
"
T
R
˚
70 GPM "Cold"
50 GPM
Bypassed
0
2
M
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Hot & Cold
Mix Here
i
5
s
1
e
-
˚
0
1
t
"
H
o
t
"
Chlorinator Loop & 2 lb. Chem.
Resistant Check Valve
Free Flow
Flexible
Marine Grade
Cupronickel
Heat Exchanger
Encased in
Closed Cell Foam
Special
Compression Fitting
See chlorinator
placement guidelines.
Automatic Bypass Valve
Variable Rate Self Adjusting
up to 90 G.P.M.
OUT
8
HIGH RATE WATER PUMPS
EXCESSIVE FLOW BYPASS MANIFOLD
FOR LARGE 2 H.P. PUMPS OR OVER 90 G.P.M.
If the pool circulation pump is over 2 HP OR if the total
flow exceeds 90 GPM you will have to add the "excessive
flow valve" as shown here. Do not install a bypass valve
that will completely shut off flow to the heater, see "Shutdown Procedures".
Some larger water pumps may be restricted if the pipe size is
not adequate therefore reducing its overall flow rate. When
determining if you need an excessive bypass valve, one has to
consider the hydraulic restriction of the filter, valving, amount
of 90˚ fittings and the distance of pipe to the pool in the existing filtering system. If you have a 2 HP water pump that does
not exceed 90 G.P.M. considering the above, you may not need
the excessive bypass. Excessive water flow can damage the
heat exchanger. SPECIAL NOTE: See chlorinator placement instructions (Pg. 10).
IN
2" p.v.c. "T"
OUT
Bypass Pipe Size:
1.5" or 2" pipe @ 2 H.P.
2" pipe @ 3 +.H.P
2 H.P Pumps
Close Bypass 50%
All others must be set by flow meter.
See Commercial Plumbing Diagram
Close Bypass 25%
Ball Valve
@ 45 Deg.
3 H.P. Pumps
2" p.v.c. "T"
ADVANCED HEAT EXCHANGER DESIGN
This diagram is a cross section of the heat exchanger.
The seamless tube within another tube design transfers heat very efficiently.
The inner water tube is made of thicker resilient cupronickel metal alloy to help resist corrosive pool
water. The outer heavy gauge Freon™ tube is dipped
in a special weather proofing material.
"Excessive Flow Valve Manifold"
Do not valve in a manner that will totally
isolate heater from water flow.
CAUTION
!
BE SURE THE BYPASS VALVE IS
POSITIONED TO ALLOW REMOVAL OF
THE FRONT ACCESS PANEL!
Position the valve so that the access panel can be
easily removed, always check before final gluing. Angle the valve out 45˚ to provide adequate
clearance. You may use a Compool 2-way valve
or other type if desired. "Do not" use a brass
gate valve or a 3-way valve for bypass !
Heat Exchanger Cross Section
Closed Cell Insulation Foam
Hot
Refrigerant
Passage
Then, to insulate from heat loss and help prevent corrosion further, the heat exchanger is encased in a block
of special "closed cell" sealing foam.
Water Passage
Cupronickel
9
Metal Alloy
CHEMICAL PROTECTION PRECAUTIONS
!
CAUTION
NO CHEMICALS
IN SKIMMER !!!
Off Line
All Chlorinators Go Down Line of Heater !
In Line
OFF LINE TYPE
CHLORINATOR
MANDA TORY CHECK VALVE & LOOP
LOOP ABOVE
8" MIN.
TO
POOL
CHLORINATOR
2 LB
CHEMICAL
RESISTANT
CHECK VALVE
(PN# 888-018)
FROM
HEA TER
The chemical resistant check valve and loop MUST
be installed with all types of chlorinators to prevent chlorine migration to the heater. The loop
should extend at least 8 inches above the chlorinator
top. The chemical resistant check valve should be
placed on the pipe leading "up" to the chlorinator.
Therefore, the weight of the water above the check
valve will hold it closed even if the spring is weak or
damaged. Mount the check valve as low as possible.
Be sure to keep the chlorinator, pump and filter lid orings lubricated with silicone grease to insure a good
seal. If it looses its seal, it will allow the chlorine to
migrate to the heater when the system shuts off. The
loss of vacuum will allow reverse flow.
10
IN LINE TYPE
CHLORINA TOR
Insulated Heat
Exchanger
!
Air leaks or suction leaks that allow air into the system will
cause turbulence and damage to the sacrificial fittings. Correct immediately ! Do not add isolation valves unless required
for seasonal shut down & freeze pr otection procedures. Stagnant water left in the heat exchanger can cause corrosion !
CAUTION
CHLORINATOR PLACEMENT & CHEMICAL USE
Chlorinator placement, water balance and where chemicals are added are very important aspects of installation.
The failure to protect the unit from chemical damage which is not covered under the warranty.
PROTECT HEAT EXCHANGER
You want to prevent any chemicals from running
through the piping and heat exchanger of the heater.
Eliminate chlorinating devices which inject chlorine solution through the suction side of the filtering system,
thus the chlorine passes through the heat exchanger at
full strength before it has a chance to mix and dilute
with the rest of the pool water. Do not add isolation
valves unless done for seasonal shut down & freeze
protection procedures. Stagnantwater left in the heat
exchanger can cause corrosion !
CHLORINE MIGRATION
Some chlorinating devices will back siphon when the
system is shut off, therefore allowing the chlorine solution from a chlorinator to flow through the heat exchanger causing damage. You have to make sure your
filtering system does not have a vacuum leak that would
allow the system to lose prime. When this happens,
water will move backwards through the chlorinator thus
moving the chlorine solution into the heat exchanger.
CHLORINATOR PLACEMENT
A) All chlorinators should have a chemical resistant "check valve and a loop" plumbed at least 8
inches above the chlorinator, between it and the
heater, as far down line from the heater as possible.
B) Never plumb a chlorinator into the suction side
of the circulation pump.
C) Do not use chemicals through the skimmer basket.
D) All automatic chemical feeders should be as far
down line of the heaters water flow as possible.
E) Off line type chlorinators should be tapped into
the plumbing only as shown on the diagram. See
pool/spa combinations that require special placement.
F) Do not install a chlorinator in at a higher elevation than the heater itself even if a loop and check
valve is used. This may allow chlorine to migrate to
the heat exchanger. Chlorinator should be the lowest point in the system.
ADDING CHEMICALS
Do not place any chemicals in the skimmer throat.
Chlorine tablets placed in the skimmer will allow a
concentrated solution of chlorine to pass through
the heat exchanger. Do not place any chemicals in
the pump lint trap cavity or filter. Do not over load
chlorinator feeder cavity. Excessive amounts of
chlorine tablets will increase the chance of migration of acidic and concentrated chlorine to the heat
exchanger causing damage. 25% of maximum is
suggested.
When adding any chlorine make sure that the pH
does not drop below 7.4 and the alkalinity does not
drop below 90 p.p.m. Fiberglass pools, spa & liner
pools PH & chlorine levels are difficult to maintain.
Please be advised heater damage may occur if minimum water balance levels are not maintained.
COMMERCIAL FEEDERS
In a commercial pool situation where there is a vacuum
type filter system is used in conjunction with a surge
tank, there are exceptions to chemical injection. Some
liquid chlorine (sodium hypochlorite) feeders and liquid muriatic acid feeders will inject their solutions into
the surge tank on the suction side of the unit. As long
as the liquid chlorine and, muriatic acid is diluted with
75% water in a supply tank and fed at a slow enough
rate, you can allow this type of chemical injection to
take place. As long as the water in the surge tank has
not conflicted with the chemical values described in
this booklet. You should test the surge tank while the
feeders and circulation pumps are running, just as you
would the pool water. Then adjust the solution or rate
of feed accordingly.
Never place chlorine tablets in the surge tank. Never
allow a tablet type chlorinator to inject solution into
the surge tank under any circumstance.
MINIMUM WATER BALANCE
PH.......................................7.4 to 7.8
Chlorine/Bromine..............1 to 5 ppm
Total Alkalinity............90 to 120 ppm
Calcium Hardness.......250 to 400 ppm
11
!
CAUTION
!
CAUTION
STANDARD PLUMBING 1 OR 2 UNITS
The following diagram is for standard plumbing of either one or two units. Plumb the unit in "after" the filter and
"before" the chlorinator. SPECIAL NOTE: See chlorinator placement instructions in this manual (Pg. 10).
Be advised that if your circulation pump is over 2 HP OR if the total flow exceeds 90 GPM, you will have to add
the "excessive flow valve" as shown below. Some larger water pumps may be restricted if the pipe size is not
adequate therefore reducing its overall flow rate. When determining if you need an excessive bypass valve, one
has to consider the hydraulic restriction of the filter, valving, amount of 90˚ fittings and the distance of pipe to the
pool in the existing filtering system. If you have a 2 HP water pump that does not exceed 90 G.P.M., considering
the above, you may not need the excessive bypass See the diagram shown at the bottom of this page. Excessive
water flow will damage the heat exchanger.
2
Up to 90 Gallons
Per Minute
Maximum Flow
Per Unit Before
Optional Exterior
Bypass Is
Required.
SINGLE UNIT INSTALLATION
TWO UNIT INSTALLATION
"Vertical"
*
NOTE:"EXCESSIVE WATER
FLOW VALVE" PUMPS OVER 2
HP OR 90 GPM
* NOTE:"MUST BE ADDED WHEN THE
TOTAL FLOW IS OVER 90 GALLONS
PER MINUTE * USE IF WATER PUMP IS
OVER 2 H.P.
12
POOL & SPA COMBO PLUMBING
Heating a connected pool and spa spill over with one heater. For a single pump system.
The following is a schematic of the suggested plumbing set up when using the standard dual thermostat kit. This
design is used for pool/ spa combinations where the pool and spa are connected via a spill over, when one filtering
pump is used to circulate the water to either the pool or spa. The motorized valves turn to isolate the pool or spa
when the dual thermostat is activated by the user. The motorized valves shown, can be manual if automatic
operation is not desired. See "Dual Thermostat Kit". Note the chlorinator placement to protect the heater. A
separate hydrotherapy pump is suggested for newly constructed pools to eliminate restriction to the spa jets.
Remember
::
: If the water pump is larger than 2 HP the excessive water flow valve may be needed.
::
Manual
3-Way
Valve
Motor
Driven
3-Way
Valve
::
:
"Note Chlorinator Placement"
::
13
"Vertical"
SEPARATE POOL & SPA PLUMBING
Heating a separate pool & spa, "without" a spill over, with one heater. Two pump system.
The following schematic is the suggested plumbing set up when using the dual thermostat kit. This design is for
"separate" pool and spa combinations, where the two are totally isolated from one another. The motorized valve
turns so that the heater is isolated to either the pool or the spa when the dual thermostat is activated by the user. The
motorized valves shown can be manual if automatic operation is not desired. Please note the 10 pound spring
valve and ball valve used as a bypass when the valves are turning. This will eliminate the possibility of "dead
heading" by the user.
NOTE: An exchange of water between the pool & spa may occur. This will depend on pump size, pipe size
and equipment distances. The possibility of the spa flooding over or draining should be considered. Most
commercial pool/spa codes do not allow this type of plumbing set up.
"Vertical"
"Vertical"
In
Out
Remember: If either water pump is over 2 HP,
the excessive water flow valve will be needed.
14
Manual
3-Way
Valve
Motor
Driven
3-Way
Valve
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