MiniMax NT Heater Single Voltage
6800 Temperature Controller Retrofit Kit (472099)
Installation Instructions
Table of Contents
A. INSTALLATION ................................................................................................................ 2
B. WIRES IDENTIFICATION ............................................................................................... 2
C. WIRING .............................................................................................................................. 3
D. OPERATION ...................................................................................................................... 6
E. TROUBLESHOOTING ...................................................................................................... 7
F. RAIN PROTECTION ........................................................................................................ 9
G. PART LIST ........................................................................................................................ 10
WARNING
FOR YOUR SAFETY - READ BEFORE OPERATING
Warning:
This product must be installed and serviced by a professional service technician qualified in
pool/spa heater installation and maintenance. 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 these instructions; call (800) 831-7133.
Important Notice
Attention Installer.
This manual contains important information about the installation, operation and safe use of this
product. This information should be given to the owner/operator of this equipment.
Pentair Pool Products, Inc.
1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151
10951 W. Los Angeles Ave., Moorpark, CA 93021
Rev. B 4-16-02 1 P/N 472091
• (805) 523-2400
A. INSTALLATION
1. Turn off the electrical power to the heater.
2. Open the heater’s right door.
3. Disconnect all wires from the 7800 Temperature Controller and the Ignition Module.
4. Remove the left and right doors from the heater if necessary.
5. Remove six screws on the rear cover of the 7800 Temperature Controller.
(NOTE: Please discard the cover, not used.) Then, remove the cover, the PC board, and the front face carrier.
6. Install the 6800 Temperature Controller, (provided in the kit), by using four screws only. See Figure 1.
7. Remove two screws on existing Ignition Module and replace with new Ignition Module using the same two screws,
(provided in the kit).
Figure 1.
B. WIRES IDENTIFICATION
The following items are new wire assembly, (provided in the kit).
FEMALE TERMINAL
FEMALE TERMINAL
18.0"
FEMALE TERMINAL
18.0"
ORANGE
WHITE
WHITE
24.0"
FEMALE TERMINAL
WHITE
MALE TERMINAL
WHITE
WIRE #1
P/N 472104
WIRE #2
P/N 472105
18.0"
MALE TERMINAL
WIRE #3
P/N 472106
24.0"
FEMALE TERMINAL
FEMALE TERMINAL
FEMALE TERMINAL
FEMALE TERMINAL
WHITE
WHITE
18"
24.0"
30.0"
WHITE
D
E
R
FEMALE TERMINAL
WIRE #5
P/N 471129
MALE TERMINAL
WIRE #6
P/N 471763
18"
TERMINAL HOUSING
BLUE
ORANGE
FEMALE TERMINAL
WIRE #P11
P/N 471812
18"
FEMALE TERMINAL
18.0"
MALE TERMINAL
ORANGE ORANGE
FEMALE TERMINAL
MALE TERMINAL
WIRE #4
P/N 472107
18.0"
FEMALE TERMINAL
18"
ORANGE
14"
P/N 472091 2 Rev. B 4-16-02
C. WIRING
1. Look at the existing wiring diagram on the left door and find out what model of the NT heater you have from top
of wiring diagram.
NOTE
First check the three terminals on your blower. If there are male terminals, please cut them and replace with
female terminals, (provided in the kit).
• If you see “MiniMax NT 400 Low NOx” that means your heater is Single Voltage
Dual Speed (SVDS): Replace the new wiring diagram for SVDS. The label is provided in
the kit, (P/N 472084).
• Please see Figure 2 for SVDS and follow the instructions below exactly.
a. Reconnect existing wire P7 to J7, P9 to J9, and P10 to J10 respectively on the 6800 control board.
b. Reconnect the existing white wire from Low Gas Pressure Switch to “TH” on the Ignition Module.
c. Reconnect the existing 5-pin Mate-N-Lok Plug (with gray, black, white and blue wires) to Ignition Module.
The male terminals of gray and blue wire connect to Hot Surface Igniter (HIS #1).
d. Connect new wire #P11 to J11. Then, connect the common female terminal, orange wire, to “IND” on the
Ignition Module; next, connect the common female terminal, (red/blue) wire, to “VAL” on the Ignition Module.
e. Connect existing wire P4 to J4 but using “splice” to connect new wire #1 (orange). The female terminal connect
to “24VAC” on Ignition Module.
st
f. Connect new wire #2 (white). The common male terminal connect to white wire of P11; the 1
connect to “GND” on the Ignition Module; the 2nd female terminal connect to “RET” on the Fan Board.
female terminal
g. Connect new wire #3 (white). The common male terminal connect to white wire of the Blower; the female
terminal connect to F1 terminal of Ignition Module; the other female terminal connect to Hot Surface Igniter (HIS #2).
h. Connect new wire #4 (orange). The common female terminal connect to “24 VAC” on the Fan Board; the
female terminal connect to “PC” on the Fan Board; the male terminal connect to orange wire of P11.
i. Connect the new wires #5 (white), from F2 of Ignition Module to Terminal Block #4.
j. Install the In-Line Fuse (provided in the kit) between the Hot Surface Ignitor (HSI #2) and the blower, see Wiring
Diagram (Figure 2).
• If you see “MiniMax NT 250 Low NOx” that means your heater is Single Voltage
Single Speed (SVSS): Replace the new wiring diagram for SVSS. The label is provided in
the kit, (P/N 472088).
• Please see Figure 3 for SVSS and follow the instructions below exactly.
a. Reconnect existing wire P7 to J7, P9 to J9, and P10 to J10 respectively on the 6800 control board.
b. Reconnect the existing white wire from Low Gas Pressure Switch to “TH” on the Ignition Module.
c Reconnect the existing 5-pin Mate-N-Lok Plug (with gray, black, white and blue wires) to Ignition Module.
The male terminals of gray and blue wire connect to Hot Surface Igniter.
d. Connect new wire #P11 to J11. Then, connect the common female terminal (orange) wire to the Air Pressure
Switch; then connect the female terminal (orange) wire to the “IND” on the Ignition Module; next, connect the
common female terminal (red/blue) wire to “VAL” on the Ignition Module; last, connect the female terminal
(white) wire to “GND” on the Ignition Module.
e. Connect existing wire P4 to J4 but using “splice” to connect new wire #1 (orange). The female terminal connect
to “24VAC” on Ignition Module.
f. Connect the new wires #5 (white) from F2 of Ignition Module to Terminal Block #4.
g. Connect the new wire #6 (white) from F1 of Ignition Module to the white wire of the Blower.
Rev. B 4-16-02 3 P/N 472091
FROM
TERM
BLOCK
GRN
1
ONLY
120 VAC
WHT
2
WHT
BLK
3
BLK
GREEN SCREW
ATTACH
GROUND
WIRE
HERE
GRN
(ON THE SIDE JACKET)
472084
TRANSFORMER
TERM
BLOCK
BLK
RED/WHT
RED
1
BLK/WHT
BLK
WHT
BLK
WHT
2
3
4
BLK
GAS VALVE
MV
WHT
BLU
THERMAL FUSE
WHT
WHT
MV
WHT
WHT
RED
5
GRN
WHT
RED
WHT
GRN
ORG
24VAC
FC
RED
BLK
FUSE
BLK
WHT
RET
FL
FH
PC
BLK
(HSI #2)
HOT SURFACE IGNITER
WHT
WHT
WHT
ORG
FAN BOARD
PL
PH
WHT
RED
BLK
WHT
BLOWER
WHT
WHT
F1
(HSI #1)
HOT SURFACE IGNITER
BURNER
FC2/FC1
BLU
WHT
ORG
IGN MODULE
J10 J11
VLV
GRY
IF ORIGINAL FACTORY WIRING MUST BE REPLACED,
INSTALLER MUST SUPPLY UL/CSA APPROVED WIRE
WITH 18 AWG, 600V, 105˚ C TEMP. RATING.
THERMAL FUSE WIRING MUST BE REPLACED WITH
INTERCONNECTING WIRING TO APPLIANCE MUST
CONFORM TO THE NATIONAL ELECTRICAL CODE OR
SUPERSEDE LOCAL (WIRING) CODES.
18 AWG, 600V, 150˚ C TEMP. RATING.
ORG
WHT
F2
24VAC
IGN MODULE
S1
L1
BLK
WHT
TH
GND
VAL
IND
S2
L2
ORG
WHT
WHT
BLU
WHT
BLU
RED
TEMP.
PROBE
(6800)
THERMOSTAT
CIRCUIT BOARD
WHT
WHT
Figure 2.
ORG
J9
TPROBE
J5J8
POOLSPA COM
J6
ORG
P9
WHTWHTWHT
ORG
AIR PRESS. SW(HI)
WHT
OFF SPA
POOL
GRN
LOW GAS
PRESSURE SW.
RED
ORG
400˚F
EXHAUST HIGH LIMIT
ORG
WHT
RED
115˚F
HIGH LIMIT
ORG
WHT
SWITCH
WATER PRESSURE
150˚F
HIGH LIMIT
BLK
BLK/WHT
ORG
RED
RED/WHT
WHT
GRN
ORG
SPLICE
SPST EXTERNAL SWITCH
WHT
P4 P7 P10 P11
SW/HL/TFUSE
J4 J7
24V
J3
J2
JUMPER REQUIRED
IF NO REMOTE SWITCH
ORG
AIR PRESS. SW(LO)
MiniMax NT Low NOx Single Voltage Dual Speed (SVDS) W/6800 Control Board Wiring Diagram
P/N 472091 4 Rev. B 4-16-02
FROM
TERM
BLOCK
GRN
1
ONLY
120 VAC
WHT
2
WHT
BLK
3
BLK
(ON THE SIDE JACKET)
GREEN SCREW
ATTACH
GROUND
GRN
WIRE
HERE
472088
TRANSFORMER
TERM
BLOCK
BLK/WHT
BLK
RED/WHT
RED
1
WHT
BLK
WHT
3
2
BLK
GAS VALVE
MV
WHT
BLU
THERMAL FUSE
WHT
BLK
4
WHT
MV
WHT
RED
5
GRN
WHT
GRN
BLK
HOT SURFACE IGNITER
WHT
ORG
BLU
WHT
RED
BLOWER
WHT
WHT
BURNER
J10 J11
WHT
WHT
F1
F2
L1S2L2
S1
FC2/FC1
BLK
GRY
IGN MODULE
VLV
IF ORIGINAL FACTORY WIRING MUST BE REPLACED,
INSTALLER MUST SUPPLY UL/CSA APPROVED WIRE
WITH 18 AWG, 600V, 105˚ C TEMP. RATING
THERMAL FUSE WIRING MUST BE REPLACED WITH
INTERCONNECTING WIRING TO APPLIANCE MUST
CONFORM TO THE NATIONAL ELECTRICAL CODE OR
SUPERSEDE LOCAL(WIRING) CODES.
18 AWG, 600V, 150˚ C TEMP. RATING
ORG
ORG
24VAC
IGN MODULE
IND
GND
VAL
TH
ORG
WHT
WHT
WHT
BLU
WHT
BLU
RED
TEMP.
PROBE
(6800)
THERMOSTAT
CIRCUIT BOARD
WHT
WHT
Figure 3.
ORG
J9
TPROBE
J5
POOL
J8
COM
J6
SPA
WHT
P9
GRN
WHTWHTWHT
LOW GAS
PRESSURE SW.
OFF SPA
POOL
RED
ORG
400˚F
EXHAUST HIGH LIMIT
ORG
115˚F
HIGH LIMIT
ORG
RED
WHT
WHT
HIGH LIMIT
150˚F
BLK/WHT
MiniMax NT Low NOx Single Voltage Single Speed (SVSS) W/6800 Control Board Wiring Diagram
WHT
ORG
SWITCH
WATER PRESSURE
BLK
RED/WHT
RED
GRN
ORG
SPLICE
SPST EXTERNAL SWITCH
WHT
ORG
P4 P7 P10 P11
SW/HL/TFUSE
J4 J7
24V
J3
J2
JUMPER REQUIRED
IF NO REMOTE SWITCH
ORG
AIR PRESS. SW.
Rev. B 4-16-02 5 P/N 472091
D. OPERATION
Dual Temperature Control System
For convenience and economy all MiniMax NT heaters are
equipped with two thermostats on the front of the heater
control panel; see Figure 1.
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 4.
The maximum setting can be adjusted by loosening the screw "A"
and turning the stopper dial to desired maximum setting. Lock the
setting by tightening the screw. The Mechanical stop is under the
knob. Ensure that the knob is stopping at the correct position when
the knob is rotated clockwise from a lower temperature position.
(See Thermostat Adjustment.)
NOTE
To eliminate error due to piping heat losses,
measure pool temperature with an accurate
thermometer directly at the pool or spa.
THERMOSTAT ADJUSTMENT
The knob with locking feature eliminates the need for constant
thermostat adjustments. Set the knob pointer to the desired pool
or spa temperature.
POWER (THERMOSTAT SELECT) SWITCH
The Pool/Off/Spa switch allows the heater to be turned off
when heating is not desired.
1. “Pool” position - Maintains selected pool temperature.
2. “Off” position - Heater will not come on regardless
of drop in pool or spa temperature.
3. “Spa” position - This allows separate control of spa
water temperature.
Knob Stopper
Figure 4.
Screw A
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.
INDICATOR LIGHT DESCRIPTION
The MiniMax Pool Heater provides nine status indicator lights, six can be seen from the front of the control panel which help you
understand the operation of the heater. If something should go wrong, the lights will aid in troubleshooting the problem. Three
additional lights can be seen after opening the control panel. These three lights give the service technician advanced troubleshooting
capability. All the LED lights are green with the exception of the red service LED.
POWER LIGHT (POWER)
The light is on at all times, in any switch position, indicating 24
VAC power is being supplied to the control circuit. If it fails to
light, no other light will be on. Possible causes are: a) external
power to the heater is disconnected, check service panel circuit
breaker or fuses; b) local circuit breaker inside the transformer
has tripped -- investigate cause before resetting; c) transformer
has failed.
THERMOSTAT (TSTAT)
This light is on when the thermostat contacts close, signaled by
the water temperature falling below the setpoint, calling for the
heater to fire to maintain the desired water temperature.
AUXILIARY (AUX)
This light is on when it indicates the remote switch contacts are
closed. This allows you to observe if your remote switch is
properly closing the heater control circuit. When shipped from
the factory a jumper is installed to maintain closed circuit in the
absence of a remote switch.
PRESSURE (PRESS)
This light is on when Spa/Pool Selector switch is on, indicates
the circulation pump is running properly. If pressure light fails
to light, the pump may have lost its prime or water flow may be
restricted by an inadvertently closed valve or clogged filter or
pump basket. If you have determined that there is no water
flow restriction to the heater, you should call a qualified
serviceman.
P/N 472091 6 Rev. B 4-16-02
INDICATOR LIGHT DESCRIPTION, (cont’d.)
HEAT (HEAT)
The heat light is on any time the thermostat has signaled a
call for heat which initializes the ignition safety firing circuit -
- the light comes on to indicate successful firing of the main
burners.
SERVICE (SERVICE)
The service light is off during normal operation of heater.
The light only comes on if a problem with a control has
occurred or when the heater is first firing. The problem must
be investigated by the serviceman prior to attempts to fire
the heater again.
The diagrams that follow give examples of troubleshooting a malfunctioning heater using the assistance of the indicator lights.
E. TROUBLESHOOTING
Example of troubleshooting with the assistance of the indicator lights.
SYMBOL TABLE
INCOMING
LINE VOLTAGE
TRANSFORMER
CIRCUIT
LED LIT
SWITCH OR DEVICE
LED OFF
REMOTE PRESS TFUSE
OPEN CIRCUIT
(BLOCK CURRENT)
LIMIT SWITCHESBREAKER
HI TEMP
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
IGNITION MODULE
IND GND VAL
GAS VALVE
MV
MV
THERM
AUX
PRESS
HEAT
THERM
AUX
PRESS
HEAT
INCOMING
LINE VOLTAGE
FRONT PANEL LEDS
TRANSFORMER
FRONT PANEL LEDS
POWER
SERVICE
POWER
SERVICE
THERMOSTAT
RELAY
PWR TSTAT RMT PRESS
SRVE
HI TEMP TFUSE
CLOSE IF
NO MV
MV HEAT
THERMOSTAT CIRCUIT BOARD
WATER AT SELECTED TEMPERATURE.... NORMAL OPERATION
OR POOL/OFF/SPA THERMOSTAT SELECT SWITCH OFF.... NORMAL OPERATION
IGNITION MODULE
GND VAL
CIRCUIT
BREAKER
PWR
THERMOSTAT
RELAY
TSTAT RMT
REMOTE
PRESS
PRESS
LIMIT SWITCHES
SRVE
HI TEMP
HI TEMP
CLOSE IF
NO MV
TFUSE
IND
HEAT
MVTFUSE
THERMOSTAT CIRCUIT BOARD
THERMOSTAT CALLING FOR HEAT - PUMP OFF(NO PRESSURE) BLOCKS FIRING
NORMAL OPERATION
GAS VALVE
MV
MV
Rev. B 4-16-02 7 P/N 472091
E. TROUBLESHOOTING, (cont’d.)
THERMOSTAT
RELAY
TSTAT
LED OFF
THERM
AUX
INCOMING
LINE VOLTAGE
TRANSFORMER
POWER
SERVICE
CIRCUIT
BREAKER
PWR
LED LIT
SYMBOL TABLE
REMOTE
RMT
SWITCH OR DEVICE
OPEN CIRCUIT
(BLOCK CURRENT)
PRESS
PRESS
SRVE
HI TEMP
LIMIT SWITCHES
HI TEMP
CLOSE IF
NO MV
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
TFUSE
TFUSE MV
IND
IGNITION MODULE
GND
HEAT
VAL
GAS VALVE
MV
MV
PRESS
HEAT
THERM
AUX
PRESS
HEAT
INCOMING
LINE VOLTAGE
FRONT PANEL LEDS
TRANSFORMER
FRONT PANEL LEDS
POWER
SERVICE
THERMOSTAT CIRCUIT BOARD
HEATER FIRING - NORMAL OPERATION
IGNITION MODULE
IND
GND
CIRCUIT
BREAKER
PWR
THERMOSTAT
RELAY
TSTAT
REMOTE
RMT
PRESS
PRESS
THERMOSTAT CIRCUIT BOARD
LIMIT SWITCHES
SRVE
HI TEMP
HI TEMP
CLOSE IF
NO MV
TFUSE
TFUSE MV
VAL
HEAT
THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING
NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM
IS IN THERMAL FUSE CIRCUIT
GAS VALVE
MV
MV
P/N 472091 8 Rev. B 4-16-02
F. RAIN PROTECTION
NOTE
Please ignore the following steps in Section F if the heater has been installed with a rain protection shield.
1. Using the silicon tube (provided in the kit) to seal the 3 sides of the edge. See Figure 5.
WARNING
The edges of the heater door can be sharp. Handle heater door with care when trimming the plastic studs. Failure
to do so could result in lacerations from the heater door.
2. Using a knife, slightly trim the plastic stud, (if required), and push it through the plastic barrier. Then insert the
pushnuts, included in the kit, onto the plastic stud in order to hold the plastic barrier, (see Figure 5).
TRIM THE STUD FIRST, THEN HOLD THE SHIELD
BY PUSHING THE NUT THROUGH THE STUD.
SEAL THESE 3 SIDES WITH SILICON
Figure 5.
Rev. B 4-16-02 9 P/N 472091
G. PARTS LIST
P/N Description Quantity
071925 Quick Connector, 1/4 in. Female 3
471129 Wire #5, White, Female x Female 1
471706 Pushnut 2
471763 Wire #6, White, Female x Male 1
471812 Wire #P11, White/Red/Blue/Orange, with Terminal Housing 1
472059 Barrier (Rain Shield) 1
472060 Silicon Tube 1
472084 Label, Wiring Diagram, NT LN SVDS, Model 400 Only 1
472086 Temperature Controller Assembly, 6800 1
472088 Label, Wiring Diagram, NT LN SVSS, Models 200/250/300 1
472091 Instruction Sheet, 6800 Retrofit Kit 1
472094 Splice (Self-Stripping Electrical Tap Connector) 1
472096 In-Line Fuse, 5 Amp. 1
472103 Ignition Module, 2466H-676-223 1
472104 Wire #1, Orange, Female 1
472105 Wire #2, White, Female x Female x Male 1
472106 Wire #3, White, Female x Male x Male 1
472107 Wire #4, Orange, Female x Female x Male 1
Save These Instructions Together With Your Existing
Operation & Installation Manual
For Future Reference.
P/N 472091 10 Rev. B 4-16-02
This page is blank.
Rev. B 4-16-02 11 P/N 472091
Pentair Pool Products, Inc.
1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151
10951 W. Los Angeles Ave., Moorpark, CA 93021
P/N 472091 12 Rev. B 4-16-02
• (805) 523-2400
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