Pentair MiniMax Plus HP Installation Manual

AIR SOURCE UNIT

INSTALLATION MANUAL

POOL/SPA HEATERS, CHILLERS,

REVERSE CYCLE & COMMERCIAL MODELS

! 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.

! 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)

MiniMax Plus HP 1000 (XLS1000)

MiniMax Plus HP 230 (CP12)

FOR QUALIFIED TECHNICIANS ONLY

Part # 471950 Revision #E

© HydroTemp Manufacturing Co., Inc.

Note: Specifications may change without notice.

! WARNING

FOR PROFESSIONAL USE ONLY

Trained Technicians Only !

! WARNING

The following installation manual is for FACT OR Y AUTHORIZEDlicensed pr ofessional 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 CONDI-

TIONS THAT MAY EXIST:

1.ELECTROCUTION AND/OR FIRE DUE TO IMPROPER WIRING.

2.HAND AND HAIR ENTRAPMENT MAY OCCUR NEAR THE FAN LOCATED ON THE TOP OF THIS UNIT.

3.LOSS OF POOL WATER AND/OR FLOODING AND/OR PROPERTY DAMAGE.

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 ..................................................................	4 - 5
	.
	2. HEATER PLACEMENT & REQUIRED CLEARANCES ..........................................................	6 - 7
	Clearances for Airflow
	Condensate Drainage
	Heater Elevation
	Sprinkler Location
	3. PLUMBING & WATER FLOW .....................................................................
	Placement and Chemical Protection	8 - 19
	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	20 - 23
	Setting Water Pump Timer
	Confirming Water Flow at Bypass Manifold
	Operational Sequence Description
	Water Pressure Switch Check
	Freeze Protection Requirements
	5. ELECTRICAL WIRING AND SETUP ................................................................
	Bonding to Pool Shell	24 - 34
	Unit Specifications
	Electrical Connections-Access Description
	Electronic Thermostat & Diagnosis

Wiring Diagrams

Wiring Diagrams for Compool

6. TROUBLE SHOOTING GUIDE .....................................................................	35 - 36
7. WARRANTY AND DEALER SERVICE................................................................	37
8. GLOSSARY OF TERMS .........................................................	38.............-41

Manufactured for Pentair Pool Products by HydroTemp Mfg. Co., Inc.

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

TRANE® COMPRESSOR

with 410-A, the safe and clean refrigerant.

Quiet

High Volume

Fan With

Vinyl Coated

Guard

Product

Name Plate

Chemical

Warning Label

Sturdy Elevated

Fiberglass

Rust Proof

Bottom Provides

Easy Connect Proper Drainage

2 Inch Plumbing With

"Internal Automatic Bypass"

Up To 90 GPM

And

SCROLL

COMPRESSOR

Super Quiet & Highly Efficient Compressor Design

4

DESIGN ADVANTAGES

					lo w	n	@	42	50
						I				C
		A ir			F						FM
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					i
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	A
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	a
	Evapor										Fan
					Compressor
ead		Electrical Compartment
ation
a ll					Top View

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 elimi-

nate moisture as well.	This
exclusive design will substan-
tially extend the life cycle	of

the heater. The fiberglass cabinets is corrosion proof and is

much stronger than plastic cabinets.

Isolated

Electrical Air Flow Out

Compartment

T

H

E

R

M

O

S

T A

T

Fan

Bulkhead	Air Flow In
Air/Electrical/	@ 42004250	CFM
Mechanical	Compressor
Separation
Wall

Internal Automatic Bypass Free Flow 2" Plumbing

Automatically adjusts the water flow. Lowest water flow restriction available.

Heat Exchanger Special Cupronickel Alloy

Encased In A Block of Foam to Prevent Heat Loss & Corrosion

T

H

E

R

M

O

S

T A

T

	2" PVC
	Water IN
	20-90 GPM	2" PVC
	Internal
		Water OUT
	Automatic
	Bypass

See specification sheet to determine electrical breaker requirement.

CONTROL POOL SPA

READY		MODE	MODE	L.E.D. Diagnostic Lights
W ATER SWITCH	T-STAT	LOW PRESS.	HIGH PRESS.
OK	ON	OK	OK

Elevated

Fiberglass

Bottom Pan

Dual Thermostat

for Proper Condensation Drainage.

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 injur				y and or	electr	ocution may r	esult.

HEATER PLACEMENT & CLEARANCE

CLEARANCE & AIR FLOW

EQUIPMENT SLAB & PITCH

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.

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To support the heater, place
a concrete or fabricated slab
near	the filtering system.
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 com-
pressor 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 the unit, make sure they do not become clogged with debris.

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.

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.		Make sure there
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	agree-

ment. 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

4 Feet

Evaporator Air Coils

! 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 evapo-

rator 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 off 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

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

! 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

WATER OUT

WATER IN

Heater

Filter

3

Water

Pump

2

4

1

5

6

Chlorinator or

Chemical Feeder

Chlorinator Loop & 2 lb. Chem.

Resistant Check Valve

	d"
	"Col
70	GPM

50 Bypassed

GPM

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	Free Flow
	Flexible	Marine Grade
	Water Inlets
		Cupronickel
		Heat Exchanger
		Encased in
		Closed Cell Foam

Special

Compression Fitting

	See chlorinator	Automatic Bypass Valve
	placement guidelines.	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:		2" p.v.c. "T"
				Ball Valve
	1.5" or 2" pipe @ 2 H.P.
				@ 45 Deg.
	2" pipe @ 3 +.H.P
		2 H.P Pumps		3 H.P. Pumps
	Close Bypass 50%			Close Bypass 25%

All others must be set by flow meter.

See Commercial Plumbing Diagram

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 cor-		Water Passage
rosion further, the heat exchanger is encased in a block
		Cupronickel
of special "closed cell" sealing foam.
	9	Metal Alloy

CHEMICAL PROTECTION PRECAUTIONS

NO CHEMICALS

IN SKIMMER !!!

! CAUTION

All Chlorinators Go Down Line of Heater !

In Line

Off Line

OFF LINE TYPE	IN LINE TYPE
CHLORINATOR	CHLORINATOR

MANDA	T OR Y CHECK VALVE & LOOP
LOOP ABOVE
	8" MIN.				2 LB
					CHEMICAL
					RESISTANT
					CHECK VALVE
					(PN# 888-018)	Insulated Heat
						Exchanger
TO					FROM
POOL					HEATER
	CHLORINATOR
The chemical resistant check valve and loop MUST
be installed with all types of chlorinators to pre-
vent 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.						! CAUTION
Be sure to keep the chlorinator, pump and filter lid o-
rings lubricated with silicone		grease	to insure	a good		Air leaks or suction leaks that allow air into the system will
						cause turbulence and damage to the sacrificial fittings. Cor-
seal. If it looses	its seal,	it will	allow the	chlorine to
						rect immediately ! Do not add isolation valves unless required
migrate to the heater when the system shuts off.				The
						for seasonal shut down & freeze protection procedures. Stag-
loss of vacuum will allow reverse flow.					10	nant water left in the heat exchanger can cause corrosion !

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 ex-

changer causing damage. Y ou 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.

! CAUTION

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 mini-

mum 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 liq-
uid 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.

! CAUTION

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.....................................
Chlorine/Bromine..............	1 to 5 ppm
Total Alkalinity............	90 to 120 ppm
11 Calcium Hardness.......	250 to 400 ppm

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.

SINGLE UNIT

"Vertical"

INST ALLATION

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.

TWO UNIT

INST ALLATION

*NOTE:"EXCESSIVE WATER

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 lar ger than 2 HP the excessive water flow valve may be needed.

"Note Chlorinator Placement"

13

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"

Manual	Motor
3-Way	Driven
Valve	3-Way
	Valve

In

Out

Remember: If either water pump is over 2 HP,
the excessive water flow valve will be needed	.