Sta-Rite 472099 Installation Manual

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 [phone].

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 • [phone]
10951 W. Los Angeles Ave., Moorpark, CA 93021

Rev. B 4-16-02 1 P/N 472091

• [phone]

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