Pentair INTELLIFLO 100 Manuals

Rev. G 1-22-04 P/N 471048 11 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. For additional free copies of this manual; call (800) 831-7133. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances. For Your Safety 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. MiniMax® Plus and PowerMax™ POOL & SPA HEATERS OPERATION & INSTALLATION MANUAL WARNING WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • 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. WARNING U.S. Patent Numbers 6,295,980 5,318,007 - 5,228,618 5,201,307 - 4,595,825 Pentair Pool Products, Inc. 1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151 10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400 1 To Consumer Retain For Future Reference P/N 471048 Rev. G 1-22-04 2 Table of Contents Introduction ............................................................................................................... 3 Important Notices ...................................................................................................................................................................... 3 Warranty Information ................................................................................................................................................................. 4 Operation .................................................................................................................... 4 Safety Rules .............................................................................................................................................................................. 4 Electronic Ignition Lighting/Operation - Natural ......................................................................................................................... 5 Electronic Ignition Lighting/Operation - Propane ....................................................................................................................... 6 Millivolt Lighting/Operation - Natural & Propane ........................................................................................................................ 7 Operating (Controls) .................................................................................................................................................................. 8 Indicator Light Description - Electronic Ignition Model ............................................................................................................... 8 Maintenance ............................................................................................................... 11 Maintenance Instructions........................................................................................................................................................... 11 Relief Valve................................................................................................................................................................................ 11 Energy Saving Tips.................................................................................................................................................................... 11 Spring and Fall Operation.......................................................................................................................................................... 11 Winter Operation ....................................................................................................................................................................... 11 Chemical Balance...................................................................................................................................................................... 12 Installation Instructions ............................................................................................ 13 Specifications .......................................................................................................................... 13 Water Connections.................................................................................................................. 14 Reverse Water Connections ...................................................................................................................................................... 14 Plumbing/Plumbing Connections ............................................................................................................................................... 14 Manual Bypass .......................................................................................................................................................................... 14 Below Pool Installation .............................................................................................................................................................. 14 Quick Flange Installation ........................................................................................................................................................... 15 Gas Connections..................................................................................................................... 16 Gas Line Installation .................................................................................................................................................................. 16 Pipe Sizing Chart/Gas Pressure Requirements ......................................................................................................................... 16 Regulated Manifold Pressure Test ............................................................................................................................................. 16 Ventilation ................................................................................................................................ 17 Outdoor Installation Requirements ............................................................................................................................................ 17 Outdoor Cap Installation ............................................................................................................................................................ 17 Indoor Installation Requirements ............................................................................................................................................... 18 Installation on Floors Constructed of Combustible Materials ..................................................................................................... 19 Indoor Draft Hood Installation .................................................................................................................................................... 20 Electrical .................................................................................................................................. 20 Transformer Wiring Instruction .................................................................................................................................................. 20 Electrical Wiring Diagram .......................................................................................................................................................... 21 Remote Control Wiring .............................................................................................................................................................. 22 Trouble Shooting (General)....................................................................................... 23 MiniMax Plus Parts List & Exploded View ............................................................... 24-26 PowerMax Appendix .................................................................................................. A1-A9 PowerMax Parts List & Exploded View .................................................................... A10-A13 Warranty Information ................................................................................................. Back Cover Rev. G 1-22-04 P/N 471048 3 MiniMax® Plus and PowerMax™* Pool and Spa Heaters Congratulations on your purchase of a MiniMax Plus 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 Plus is a compact, lightweight and efficient gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe and has a built-in top. The MiniMax Plus, also comes equipped with PurexTriton’s nine function indicator lights (electronic ignition only) which show, at a glance, the proper functioning of the heater. All electronic ignition MiniMax Plus heaters are designed with an intermittent ignition device (IID) which eliminates the need for a standing pilot. The electronic ignition MiniMax Plus requires is an external power source (120 VAC or 240 VAC) 50/60 Hz to operate. The millivolt MiniMax Plus has a self sustaining pilot and requires NO external power source. All MiniMax and PowerMax pool and spa heaters are year 2000 compliant. *Unless noted otherwise, any references to the MiniMax Plus include the PowerMax (Induced Draft) models. The wiring and venting of the PowerMax is covered in an appendix to this manual. IMPORTANT NOTICES ...For the installer and operator of the MiniMax Plus pool and spa heater. The manufacturer’s warranty may be void if, for any reason, the heater is improperly installed and/or operated. Be sure to follow the instructions set forth in this manual. If you need any more information, or if you have any questions regarding to this pool heater, please contact Pentair Pool Products, Inc. at (800) 831-7133. These heaters are designed for the heating of swimming pools and spas, and should never be employed for use as space heating boilers, general purpose water heaters, in non-stationary installations, or for the heating of salt water. CAUTION OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 68° F. WILL CAUSE HARMFUL CONDENSATION AND WILL DAMAGE THE HEATER AND WILL VOID THE WARRANTY. Do not use the heater to protect pools or spas from freezing if the final maintenance temperature desired is below 68° F. as this will cause condensation related problems. CODE REQUIREMENTS The installation must conform with local codes or in the absence of local codes with the latest National Fuel Gas Code, ANSI Z223.1, and the latest edition of the National Electrical Code, NFPA 70. Installation in Canada to be made in accordance with the latest CAN/CGA-B149.1 or .2 and CSA C22.1 Canadian Electric Code, part 1. Introduction P/N 471048 Rev. G 1-22-04 4 Operation This instruction manual provides operating instructions, installation and service information for the MiniMax Plus high performance heater. The information in this manual applies to the MiniMax Plus 150, 195, 200, 250, 300, 350, and 400 natural gas and propane (LP) models. It is very important that the owner/installer read and understand the section covering installation instructions, and recognize the local and state codes before installing the MiniMax Plus. History and experience has shown that most heater damage is caused by improper installation practices. SAFETY RULES 1. Spa or hot tub water temperatures should never exceed 104° F (40° C). A temperature of 100° F (38° C) 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 102° F (39° C) 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 100° F (38° C) 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 4° F (2.2° C). 5. Persons with a 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. 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. WARNING WARRANTY INFORMATION The MiniMax Plus 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. Pentair Pool Products’ high standards of excellence include a policy of continuous product improvement resulting in your state-of-the-art heater. We reserve the right to make improvements which change the specifications of the heater without incurring an obligation to update the current heater equipment. Operation (contd.)

IntelliFlo ® 4 160 and 100 Variable Speed Programmable Pump (Compatible with IntelliTouch™, EasyTouch™ and IntelliComm) Installation and User’s Guide IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS © 2006 Pentair Water Pool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 553-5000 Trademarks and disclaimers: EasyTouch, IntelliChlor, IntelliFlo, QuickTouch and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products. Pentair Water Pool and Spa, Inc. disclaims proprietary interest in marks and names of others. P/N 357269 Rev B - 02/15/2006 Customer Support Sanford, North Carolina (8 A.M. to 5 P.M.) Phone: (800) 831-7133 Moorpark, California (8 A.M. to 5 P.M.) Phone: (800) 831-7133 (Ext. 6312) Fax (800) 284-4151 Web sites: visit www.pentairpool.com and staritepool.com i IntelliFlo 4 Installation and User’s Guide Important Safety Precautions ........................................................................................... ii Section 1: IntelliFlo Overview ........................................................................................... 1 IntelliFlo 4 Variable Speed Pump .......................................................................................... 1 IntelliFlo 4 models ................................................................................................................. 1 External Control.................................................................................................................... 1 Features ............................................................................................................................... 2 IntelliFlo 4 Motor Assembly .................................................................................................. 2 IntelliFlo 4 Drive Assembly and Control Panel...................................................................... 3 IntelliFlo 4 Operator Control Panel ........................................................................................ 4 Controls and LEDs .......................................................................................................... 4 Section 2: Operating IntelliFlo 4........................................................................................ 5 Setting the pump preset speed............................................................................................. 5 Adjusting the pump speed .................................................................................................... 5 Starting the pump ................................................................................................................. 6 Stopping the pump................................................................................................................ 6 Resetting the pump to factory defaults ................................................................................. 6 Assigning a pump address for remote control ...................................................................... 6 Priming the pump for the first time or after service ............................................................... 7 Priming the Pump ............................................................................................................. 8 External Control with IntelliComm Communication Center ................................................... 9 External Control Connection ............................................................................................ 9 Connecting IntelliFlo 4 to an EasyTouch System ................................................................ 10 Section 3: User Maintenance............................................................................................ 13 Pump Strainer Basket ......................................................................................................... 13 Pump Strainer Basket Service ............................................................................................ 13 Motor Service ...................................................................................................................... 14 Winterizing........................................................................................................................... 15 Priming the pump after service............................................................................................ 15 Section 4: Installation and Removal ................................................................................ 17 IntelliFlo 4 Kit Contents ........................................................................................................ 17 Installing IntelliFlo 4 ............................................................................................................. 17 Location ............................................................................................................................... 17 Piping ................................................................................................................................. 17 Check Valve ........................................................................................................................ 17 Wiring the IntelliFlo 4 ........................................................................................................... 18 Pump Disassembly ............................................................................................................. 19 Pump Reassembly/Seal Replacement................................................................................ 20 Shaft Seal Replacement ...................................................................................................... 20 Drive Assembly Removal and Installation........................................................................... 21 Illustrated Parts List............................................................................................................. 22 IntelliFlo Pump Dimensions ................................................................................................. 23 IntelliFlo Flow and Power vs Flow Pump Curve .................................................................. 23 IntelliFlo 4 Electrical Specifications ..................................................................................... 23 Section 5: Troubleshooting .............................................................................................. 25 Warning and Alarm LED conditions ..................................................................................... 25 Alarm and warning LED sequence ...................................................................................... 25 General IntelliFlo 4 Troubleshooting Problems..................................................................... 26 Contents