Pentair MiniMax 200 Manuals

Rev. G • Rév. G 5-27-04 P/N • Réf. 472090 11 MiniMax® NT Pool & Spa Heaters OPERATION & INSTALLATION MANUAL 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 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. • 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. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this heater or other appliances. 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. For additional free copies of this manual; call (800) 831-7133. P/N • Réf. 472090 Rev. G • Rév. G 5-27-04 2 Table of Contents Section I. Heater Identification Information ........................................................... 3 Section II. Introduction ............................................................................................ 4 Important Notices ......................................................................................................................................................................... 4 Warranty Information .................................................................................................................................................................... 4 Code Requirements ...................................................................................................................................................................... 5 Consumer Information and Safety................................................................................................................................................ 5 Section III. Installation .............................................................................................. 6 Specifications................................................................................................................................................................................ 6 Plumbing Connections .................................................................................................................................................................. 7 Valves ........................................................................................................................................................................................... 7 Manual By-Pass............................................................................................................................................................................ 7 Below Pool Installation ................................................................................................................................................................. 7 Water Connections ....................................................................................................................................................................... 8 - 9 Gas Connections .......................................................................................................................................................................... 10 Sediment Traps............................................................................................................................................................................. 10 Gas Pipe Sizing ............................................................................................................................................................................ 11 Testing Gas Pressure/Gas Pressure Requirements .................................................................................................................... 12 Indoor Venting—General Requirements ...................................................................................................................................... 13 Indoor (USA) / Outdoor (Canada) Installations ............................................................................................................................ 14 Combustion Air Supply ................................................................................................................................................................. 15 Vent Adaptors ............................................................................................................................................................................... 15 Indoor Installations —Venting Guidelines..................................................................................................................................... 16 Outdoor Installations —Venting Guidelines .................................................................................................................................. 17 Outdoor Vent Kit ........................................................................................................................................................................... 17 Electrical Connections .................................................................................................................................................................. 18 Wiring Schematic for all Dual Voltage Blowers ............................................................................................................................ 19 Wiring Diagram—NT STD & TSI with DDTC................................................................................................................................ 20 Section IV. Operation ................................................................................................ 21 Basic System Operation ............................................................................................................................................................... 21 HSI (Hot-Surface Ignition) Lighting/Operation.............................................................................................................................. 21 Safety Controls ............................................................................................................................................................................. 22 - 23 Digital Display Temperature Controller (DDTC) ........................................................................................................................... 24 - 28 Section V. Troubleshooting ....................................................................................... 28 Troubleshooting (DDTC)............................................................................................................................................................... 28 Troubleshooting (General) ............................................................................................................................................................ 29 Service Checks - Ignition Module ................................................................................................................................................. 29 Section VI. Maintenance ......................................................................................................... 30 Maintenance Instructions.............................................................................................................................................................. 30 Pressure Relief Valve ................................................................................................................................................................... 30 Energy Saving Tips ....................................................................................................................................................................... 30 Spring, Fall and Winter Operation ................................................................................................................................................ 31 Chemical Balance ......................................................................................................................................................................... 32 Replacement Parts — NT STD& TSI w/DDTC............................................................................................................................. 33 - 35 Chauffe-eau pour piscine et spa MiniMax® NT/Guide d'Installation et de Fonctionnement .......................... 36-72 Rev. G • Rév. G 5-27-04 P/N • Réf. 472090 3 To identify the heater, see rating plate on the inner front panel of the heater. There are two designators for each heater, one is the Model Number and the other is the Heater Identification Number (HIN). a. Heater Identification Number (HIN) The following example simplifies the identification system: 1) HTR : Heater 2) (200, 250, 300 or 400) : Input rating (Btu/hr) X 1000 3) NT : MiniMax NT Series 4) STD or TSI : Series Character 5) NH : Gas type (Natural gas) and ignition system (Hot Surface Ignition) 6) Options : Blank: Standard Model ASME: ASME Certified (Bronze Headers) ASHI: ASME Certified Bronze Header and High Altitude Rating HALT: High Altitude Rating Section I.Heater Identification Information Heater Identification Information HEATER IDENTIFICATION INFORMATION — (HIN) P/N • Réf. 472090 Rev. G • Rév. G 5-27-04 4 MiniMax® NT Pool and Spa Heaters Congratulations on your purchase of a MiniMax NT 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 NT is a compact, lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe. The MiniMax NT also comes equipped with the Pentair multifunction temperature controller which shows, at a glance, the proper functioning of the heater. All MiniMax NT heaters are designed with a direct ignition device, HSI (hot-surface ignition), which eliminates the need for a standing pilot. The MiniMax NT requires an external power source (120/240 VAC 60 Hz) to operate. This instruction manual provides operating instructions, installation and service information for the MiniMax NT high performance heater. The information in this manual applies to all MiniMax NT 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 NT. History and experience has shown that most heater damage is caused by improper installation practices. IMPORTANT NOTICES ...For the installer and operator of the MiniMax NT 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. WARRANTY INFORMATION The MiniMax NT pool heater is sold with a limited factory warranty. Specific details are described on the warranty registration card which is 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. These heaters are designed for the heating of swimming pools and spas, and should never be used as space heating boilers, general purpose water heaters, in non-stationary installations, or for the heating of salt water. 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. CAUTION OPERATING THIS HEATER CONTINUOUSLY AT WATER TEMPERATURE BELOW 68° F. WILL CAUSE HARMFUL CONDENSATION AND WILL DAMAGE THE HEATER AND 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. Introduction Section II. Introduction

Rev. B 1-22-04 P/N 472235 11 MiniMax® NT/TSI Low NOx Series POOL & SPA HEATERS OPERATION & INSTALLATION MANUAL — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or other appliances. — 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. — Installation and service must be performed by a licensed qualified installer, service agency or the gas supplier. WARNING If the information in these instructions are not followed exactly, a fire or explosion may result, causing property damage, personal injury or death. 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 Model TSI Natural Gas Only For additional free copies of this manual; call (800) 831-7133. P/N 472235 Rev. B 1-22-04 2 Table of Contents Introduction ...................................................................................3 General Description..........................................................................3 Code Requirements ........................................................................3 Warranty Information ......................................................................4 Product Identification.......................................................................4 Consumer Information and Safety .................................................5 Installation Instructions...............................................................6 Specifications ..................................................................................6 Installation — Electrical ..................................................................7 Installation — Wiring Schematic for all Dual Voltage Blowers .....8 Installation — Wiring Diagram........................................................9 Installation — Remote Hook-Ups (2 and 3 Wire) ..................... 10 Installation — Operating Controls ...................................... 11 - 12 Installation — Troubleshooting (Controls) ......................... 12 - 13 Installation — Plumbing ................................................................14 Installation — Water Connections................................................15 Installation — Reversing Heads...................................................15 Installation — Gas Connections....................................................16 Installation — Sediment Traps .....................................................16 Pipe Sizing Chart/Gas Pressure Requirements ..........................17 Regulated Manifold Pressure Test ...............................................17 Venting — Indoor Installations ............................................. 18 - 21 Venting — Outdoor Installations ..................................................22 Basic Operation — General Description......................................23 Basic Operation — HSI Lighting/Operation .................................24 Basic Operation — Safety Controls ..................................... 25 - 26 Basic Operation — HSI Ignition Module ......................................26 Maintenance Instructions ..........................................................27 Pressure Relief Valve ...................................................................27 Chemical Balance (Water Treatment) ..........................................28 Troubleshooting (General) ........................................................29 Troubleshooting (Service Checks - Ignition Module) ..................29 Exploded View & Parts List ................................................. 30-31 Warranty ...................................................................... Back Cover Rev. B 1-22-04 P/N 472235 3 Congratulations on your purchase of a MiniMax NT/TSI Low NOx 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 NT/TSI Low NOx is a compact, lightweight, efficient, induced-draft, gas fired high performance pool and spa heater that can be directly connected to schedule 40 PVC pipe. The MiniMax NT/TSI Low NOx, also comes equipped with the Pentair multifunction temperature controller which shows, at a glance, the proper functioning of the heater. All MiniMax NT/TSI Low NOx heaters are designed with a hot-surface ignition (HSI) which eliminates the need for a standing pilot. The MiniMax NT/TSI Low NOx requires an external power source (120/240 VAC 60 Hz) to operate. This instruction manual provides operating instructions, installation and service information for the MiniMax NT/TSI Low NOx high performance heater. The information in this manual applies to the MiniMax NT/TSI Low NOx 200, 250, 300, and 400 natural gas 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 NT/TSI Low NOx. History and experience has shown that most heater damage is caused by improper installation practices. GENERAL DESCRIPTION The MiniMax NT/TSI Low NOx Pool and Spa Heater incorporates a special burner with an induced draft combustion system. The heater series is available in 200,000/250,000/300,000 and 400,000 Btu/hr. The MiniMax NT/TSI Low NOx heaters are design certified by CSA (Canadian Standards Association) as complying with the latest edition of ANSI (American National Standard Institute) Z21.56 · CSA 4.7-M98 in the USA and Canada for both indoor and outdoor installations. The MiniMax NT/TSI series complies with the Low Nitrogen Oxides emission requirements of California, South Coast Air Quality Management District (SCAQMD) Rule 1146.2, Ventura County Air Pollution Control District (APCD) Rule 74.11.1 and Title 30 Texas Administrative Code (TAC), Chapter 177.465. The MiniMax NT/TSI Low NOx is designed to operate both in stackless outdoor installations and indoors with stack vent installations—the indoor installation may be made using Kit 460506 or 460507; see pages 6 and 20, vertical vent pipe or with an approved side-wall vent. 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 472235 Rev. B 1-22-04 4 WARRANTY INFORMATION …For the installer and operator of the MiniMax NT/TSI Low NOx 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 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 used 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 no use the heater to protect pools and spas from freezing if the final maintenance temperature desired is below 68° F, as this will cause condensation related problems. The MiniMax NT/TSI Low NOx 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. PRODUCT IDENTIFICATION To identify the heater, see rating plate on the inner front panel of the heater. There are two designators for each heater, one is the Model Number and the other is the Heater Identification Number (HIN). a. Model Number: Example: 400 TSI 1st through 3rd character: Input rating (Btu/hr) X 1000 4th through 6th character: Series character, Two-Stage Ignition b. Heater Identification Number (HIN): The following example simplifies the identification system. 1 2 3 4 5 6 R T H 0 0 4 T N I S T H N T L A H 1) HTR : Heater 2) (200, 250, 300 or 400) : Input rating (Btu/hr) X 1000 3) NT : MiniMax NT Series 4) TSI : Series Character, Two-Stage Ignition 5) N H : Gas type (Natural gas) and ignition system (Hot Surface Ignition) 6) Options : Blank: Standard Model ASME: ASME Certified (Bronze Headers) ASHI: ASME Certified Bronze Header and High Altitude Rating HALT: High Altitude Rating CAN: Canadian Compliance CANH: Canadian Compliance and High Altitude Introduction