Sta-Rite 100 MV Installation Manual

Warning:

MiniMax 100 ( Marked)

ABOVE GROUND POOL & SPA HEATER

USERS & INSTALLATION MANUAL

IMPORT ANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

SA VE THESE INSTRUCTIONS

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.

Consumer

Retain For

Future

Reference

U.S. Patent Numbers 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.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances.

PacFab, Inc. Corporate Headquarters: 1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151 Western Operations: 10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400

Rev . A 2-4-2000 P/N 471438

TABLE OF CONTENTS:

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Important Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - iii

Users Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operating (Controls) / Heater Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chemical Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Indoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Flue Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Plumbing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Service Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Burner Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Soot Formation on the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Removing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Reinstalling the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Trouble Shooting (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Exploded View & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

P/N 471438 Rev. A 2-4-2000

Introduction

MiniMax 100 ( Marked)

ABOVE GROUND POOL AND SPA HEATERS

Congratulations on your purchase of a MiniMax 100 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 100 is a compact, lightweight and efficient gas fired high performance above ground pool and spa heater that can be connected to schedule 40 PVC pipe and has a built-in top. The heater includes the following features:

• Reliable direct-spark ignition (DSI) system available in propane or natural gas versions.

• Millivolt standing pilot versions in propane and natural gas, when no convenient line power is present.

• Fuel gas input of 100,000 btu/hr.

• Quiet and dependable operation from packaged burner system proven reliable in worldwide usage.

• Heat exchanger constructed of premium non-corroding materials including bronze headers standard.

• The controls have been designed to be very easy to troubleshoot and very easy to access and replace in the rare event of a malfunction-making the MiniMax 100 user friendly .

IMPORTANCE NOTICES FOR THE INSTALLER AND OPERATOR

Gas Safety (Installation and Use) Regulations, 1994 (as amended)

It is the law that all gas appliances are installed by competent persons in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety , to ensure that the law is complied with.

General Requirements

This appliance must be installed be a competent person, i.e. CORGI registered in accordance with the relevant requirements of the Gas Safety Regulations, current I.E.E. Regulations, Model Water Byelaws, Local Water Authority Byelaws and any relevant requirements of the local gas supplier, local authority and the relevant British Standard Codes of practice and Building Regulations. Manufacturers notes must not be taken in any way as overriding statutory obligations. T ypical documents include:

• BS. 6891; Installation of low pressure pipework.

• BS. 6644; Installation of Gas Fired Hot W ater Boilers 60kW to 2MW .

• CP341; W ater Supply .

• British Gas Publications:

• IM2; Purging Procedures of Non-domestic Gas Installations.

• IM5; Soundness T esting Procedures for Industrial and Commercial Gas Installations.

• IM11; Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters.

• Model W ater Byelaws.

Rev . A 2-4-2000 P/N 471438

SPECIFICATIONS - TECHNICAL D AT A

(NATURAL GAS MODELS ONLY)

CATEGORY

3B/P

GAS AND G31 @ 37mb. G31 @ 50mb. G30 @ 29mb. SUPPLY PRESSURE

BURNER PRESSURE mbar 21.0 21.0 21.0

(in.wg) (8.4) (8.4) (8.4)

HEAT INPUT GROSS kW 29.3 29.3 34.3

(Btu/h) (100,000) (100,000) (117,000)

NET kW 26.96 26.96 31.6

(Btu/h) (91,988) (91,988) (107,819)

HEAT OUTPUT kW 23.4 23.4 27.4

(Btu/h) (79,841) (79,841) (93,625) GAS RATE m FLUE GAS VOLUME m (4.5% CO

, 100°C)

/h 1.1 1.1 0.98

/h 101 101 119

INJECTOR DIAMETER mm 0.85 & (MARKING) (085) NUMBER OF INJECTORS 14 14 14 (BURNERS) MAXIMUM WATER PRESSURE 8

bar (psi) (125) MAXIMUM WATER FLOW 45 TEMP °C ELECTRICAL SUPPLY 230V - 50Hz

FUSED AT 5A. POWER 35W

WEIGHT (EMPTY) kg 38 38 38

(lbs) NOMINAL FLUE DIAMETER mm 125 125 125 (INDOOR INSTALLATION) (in.) (5) (5) (5)

Rev . A 2-4-2000 P/N 471438

Users Section

This instruction manual provides operating instructions, installation, and service information for the MiniMax 100 high performance heater . The information in this manual applies to the MiniMax 100 natural gas and L.P .G., DBI and millivolt standing pilot heater models.

This heater is designed for the heating of fresh water swimming pools and spas, and should not be used for any other purpose.

The heater must only be installed in the open air or in a room separated from living rooms and provided with appropriate ventilation directly to the outside.

The heater must be used only in accordance with these instructions. Incorrect use is dangerous and invalidates all warranties and certification.

W ARRANTY INFORMA TION

The MiniMax 100 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 . For ordering parts, you should indicate model and serial numbers of the heater. If the parts are requested for warranty , you must also indicate the date of installation.

PacFab's high standards of excellence include a policy of continuous product improvement resulting in your state-of-the-art heater . W e reserve the right to make improvements which change the specifications of the heater without incurring an obligation to update current heater equipment.

Operation

SAFETY RULES

1. Spa or hot tub water temperatures should never exceed 40° C (104° F). A temperature of 38° C (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 39° C. (102° 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 38° C. (100° F.) maximum rule.

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

2.2° C. (4° F.).

5. Persons with 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.

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.

P/N 471438 Rev. A 2-4-2000

Users Section

MINIMAX 100 DIRECT-SPARK IGNITION LIGHTING/OPERA TIONNATURAL GAS & PROPANE

FOR YOUR SAFETY: READ BEFORE LIGHTING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

SAFETY INFORMATION - IF YOU SMELL GAS, FOLLOW THESE RULES

1. Shut off gas line or propane tank.

2. Immediately call your gas supplier from a

neighbour's phone.

3. Follow the gas supplier's instructions.

4. If you cannot reach your gas supplier, call the fire

brigade.

STOP! HAVE YOU READ THE SAFETY INFORMATION?

C. Do not use this appliance if any part has been

under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

D. Never store any materials within the vicinity of

the appliance or ventilation openings.

5. Do not light matches or lighter .

6. Do not try to light any appliance.

7. Do not touch any electric switch; do not use any

phone in your building.

8. Open all doors and windows. (Indoor)

OPERA TING INSTR UCTIONS

TO LIGHT THE APPLIANCE

1. Make sure pump is running and primed.

2. Push power switch on.

3. Set thermostat to desired setting.

4. The unit should spark and the burner should ignite.

5. In new installations where the gas line hasn't been bled, the ignition sequence may require resetting by interrupting the electrical supply following each failed ignition.

6. If the heater does not operate as it should, in a reasonable amount of time, read the Troubleshooting Guide portion of this manual or isolate gas supply and call a service technician at your gas supplier .

TO TURN THE APPLIANCE OFF

1. Set the thermostat to lowest setting and turn off power switch.

2. Turn off all electric power to the appliance if service is to be performed, (if applicable).

Rev . A 2-4-2000 P/N 471438

3. If the appliance is to be turned off during a period when frost is likely , consult your service engineer/gas supplier to take the appropriate action. (Drain the system.)

Users Section

MILLIV OL T LIGHTING/OPERATION- NA TURAL GAS & PROPANE

FOR YOUR SAFETY: READ BEFORE LIGHTING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

BEFORE OPERA TING: Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

NEVER store any materials within the vicinity of the appliance or ventilation openings.

SAFETY INFORMATION - IF YOU SMELL GAS, FOLLOW THESE RULES

1. Shut off gas line or propane tank.

5. Do not light matches or lighter .

SIT V alv e

2. Immediately call your gas supplier

from a neighbour's phone.

3. Follow the gas supplier's instructions.

4. If you cannot reach your gas supplier,

call the fire brigade.

STOP! HAVE YOU READ THE SAFETY INFORMATION?

6. Do not try to light any appliance.

7. Do not touch any electric switch;

do not use any phone in your building.

8. Open all doors and windows. (Indoor)

On - Off Knob

Figure 1.

TO LIGHT THE APPLIANCE

1. Push power switch off. Remove the front casing door. Twist the black knob on the gas valve anti-clockwise to the pilot position and release it.

2. Make sure pump is running and primed.

3. Push in and retain fully depressed the black knob on the gas control. At the same time, repeatedly operate the piezo spark generator to produce a spark at the pilot burner. When the pilot has been lit, keep the black knob depressed for a further 20 seconds. If the pilot does not remain alight when the black knob is released, twist the knob clockwise then release it. Wait at least three minutes then repeat the procedure from step 5.

4. In new installations where the gas line hasn't been bled, the pilot may be slow to light.

5. When this pilot flame is established, turn knob anti-clockwise and turn the power on. Set the thermostat to the desired setting and the main burner should light. Refit casing door.

6. If the heater does not operate satisfactorily, consult the T roubleshooting Guide portion of this manual.

TO TURN THE APPLIANCE OFF

FOR SHORT PERIODS

Set the thermostat to its lowest setting, wait two minutes, then turn the power off. (Turn off all electric power to the appliance if a service is to be performed.)

NOTE: The appliance is fitted with a thermo-electric flame failure device therefore the pilot and gas cock must not be turned off except for long term shut-down, emergencies, or servicing.

If the appliance is to be turned off during a period when frost is likely, consult your service engineer/gas supplier to take the appropriate action. (Drain the system.)

FOR LONG PERIODS

Set the thermostat to it's lowest setting, wait two minutes, then turn the power off. Twist the black button on the gas valve clockwise then release it. Turn off the gas cock.

NOTE: If severe weather (frost) conditions are anticipated during a period, shutdown the heater and system must be completely drained. Consult your service engineer/gas supplier to take the appropriate action. (Drain the system.)

P/N 471438 Rev. A 2-4-2000

Users Section

OPERA TING (CONTR OLS)

DIRECT SPARK ELECTRONIC AND MILLIVOLT MODELS

For convenience and economy all MiniMax 100 heaters are equipped with a thermostat on the front of the heater control panel; see Figure 2. The Pool/Off/Spa switch allows the heater to be turned off when heating is not desired.

1. "ON" position - Maintains selected pool temperature.

2. "OFF" position - Heater will not come on regardless of drop in pool temperature.

SELECTOR DIALS

The selector dial (knob) eliminates constant thermostat adjustments. Set the spa dial at the desired spa temperature.

NOTE

To eliminate error due to piping heat losses, measure pool temperature with an accurate thermometer directly at the pool or spa.

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.

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 2.

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.

HEA TER OPERATION

GENERAL

The MiniMax 100 DBI employs a microprocessor based Direct Spark Ignition (DSI) system to light the main burner and therefore has no pilot. The ignition circuit operates at 24 VAC and requires that a 230 VAC (50Hz) line voltage be supplied to the heater.

The MiniMax 100 MV (Millivolt) requires no external power source and the control circuit derives all its power from the energy generated from the standing pilot/thermopile generator combination.

The MiniMax 100 DSI Control utilizes a microprocessor to continually and safely monitor, analyze, and control the proper operation of the gas burner. The DSI Control features LED diagnostics, automatic one hour reset, and flame current test pins. The LED is located on the DSI.

CONTROLS OPERATION

Heat Mode

1. When a call for heat is received from the thermostat supplying 24 volts to TH/W , the control will reset, perform a self check routine, and flash the diagnostic LED for up to four seconds. After a brief delay the gas valve is energized and the ignition electrode begins to spark for the four (4) second trial for ignition period.

2. When flame is detected during the trial for ignition, sparking is shut-off immediately and the gas valve remains energized. The thermostat and main burner flame are constantly monitored to assure the system continues to operate properly .

a.When the thermostat is satisfied and the demand

for heat ends, the main valve is de-energized immediately.

(DBI SYSTEM)

OVERHEAT THERMOSTAT

A manual reset overheat thermostat is fitted on the RHS of the unit adjacent to the flow header .

Figure 2.

If the appliance will not light, press the overheat reset button before contacting a service engineer.

If the overheat condition persists, contact a service engineer or your gas supplier.

Rev . A 2-4-2000 P/N 471438

Knob Stopper

Screw A

Users Section

Failure to Light- Lockout (DBI Models Only)

1. Should the main burner fail to light, or flame is not detected during the trial for ignition period the control will go into lockout and the valve will be turned off immediately .

2. Recovery from lockout requires a manual reset by resetting the thermostat or turning off the ON/OFF switch for a minimum period of 5 seconds.

IMPORTANT!

IT IS RECOMMENDED THAT NO MORE THAN TWO IGNITION ATTEMPTS IN SUCCESSION BE PERFORMED FOR NATURAL GAS SYSTEMS . BEFORE FURTHER IGNITION ATTEMPTS, WAIT AT LEAST FIVE MINUTES FOR GAS TO CLEAR.

FOR PROPANE (LPG) SYSTEMS ALLOW AT LEAST FIVE (5) MINUTES BETWEEN IGNITION ATTEMPTS FOR THIS HEAVIER-THAN-AIR GAS TO SAFELY DISSIPATE. AFTER TWO UNSUCCESSFUL IGNITION ATTEMPTS WITH PROPANE, OPEN THE BURNER ACCESS DOOR AND WAIT AT LEAST THIRTY (30) MINUTES BEFORE REPLACING DOOR TO ATTEMPT FURTHER IGNITION ATTEMPTS.

Control Fault -Diagnostic LED Conditions

Error Mode LED Indication

Internal Control Failure Steady on Flame Sense Fault 2 flashes Ignition Lockout 3 flashes

The DBI Ignition Control can be accessed after removing the heater’s front control panel. The diagnostic LED located on the top of the DBI control will flash on for 1/4 second, then off for 1/4 second during a fault condition. The pause between fault codes is 3 seconds.

NOTE

Normally the heater will light in the first or second attempt. And with the exception of a new installation or one that has been shut down for an extended period, where there is considerable air trapped in the gas supply line, unsuccessful ignition indicates other problems with the ignition system such as an unclean ignition electrode impeding flame sensing.

3. If the thermostat is still calling for heat one hour after a lockout the control will automatically reset and attempt to ignite the burner again.

Flame Failure-Re-Ignition

1. If the established flame signal is lost while the burner is operating, the control will respond within

0.8 seconds. The H.V. spark will be energized for a trial for ignition period in an attempt to relight the burner.

a.If the burner does not light, the control will

de-energize the gas valve, shutting off the gas flow , and the control will go into lockout as described above in “Failure to Light-Lockout." If flame is re-established, normal operation resumes.

P/N 471438 Rev. A 2-4-2000

+ 22 hidden pages