Purex Minimax
Contents
1. present and heater doesn t fire replace gas valve Note Before replacing gas valve make sure main burner orifices are clean If no voltage present at red wire replace ICCB Been TROUBLESHOOTING Heater Cycles Rapidly _ Do Not Replace Any Controls Before Reading These Instructions Preliminary checks 1 Make sure pump is primed and you see adequate water flow A If the water level in the pool is low the pump will lose prime and reprime itself causing intermit tent flow to heater causing cycling Ifthe filter is dirty the water flow may fluctu ate causing pressure switch to cycle If wind blows pilot flame away from electrode main burner will cycle on and off D If flow valve is inoperative the heater will cycle Note Turn power off Place jumper wire across the high limit s Turn power on If heater stops cycling problem is the water in header is too hot or high limit s is defective If heater continues to cycle problem is in wiring grounding or another control Check wiring connections to gas valve are they clean and on correct terminals Check ignition wire from ICCB to pilot assembly If ignition wire is loose at ICCB heater will heck all ground connection IID heaters will and operate erratically when not properly unded B To check water related cycling Check for correct heater flow from table 3 page 6 If less than minimum required for model2. Other plumbing connections can be used The instructions on the next page show methods for successfully connecting plumbing to the inlet outlet header with the Quick Flange CAUTION Before operating the heater on a new installation turn on circulation pump and bleed all air from the filter using the air relief valve on top of the filter Water should flow freely through heater Do not operate the heater unless water in pool spa is at proper level Manual By Pass Where the flow rate exceeds the maximum 120 gpm a manual by pass should be installed and adjusted After adjustments are made the valve handle should be removed to avoid tampering 120 120 40 120 Do not exceed the maximum recommended flow rate for the connecting piping Table 3 Below Pool Installation If the heater is below water level the pressure switch must be adjusted This adjustment must be done by a qualified service technician INSTALLATION SECTION PG 7 Quick Flange Installation Instruction Sheet Each MiniMax Quick Flange Kit contains 1 Quick Flange unit 2 2 Rubber gaskets 4 318 Bolts 2 1 1 2 Rubber gaskets 4 3 8 Washers 2 Plastic sleeves FOR 1 1 2 amp 2 SCHEDULE 40 PVC PIPE FOR 1 1 2 amp 2 COPPER PIPE Fig 11 N Gasket Fig 12 1 Insert plastic sleeves into the Quick Flange inlet Ae and outlet openings You DO NOT need the plastic sleeves 2 Slip rubber gaskets over plastic sleeves 1 Inse
3. a qualified Professional Maintenance Instructions It is recommended that you check the following at least appears yellow burners should be inspected and every six months and at the beginning of every swimming cleaned season 4 Keep the heater area clean and free from combustibles and flammable liquids 1 Examine the Flue system Make sure there are no 5 Check wire ends and wire connections They should be obstructions in the flow of combustion and ventilating clean and tight air 6 Check the burner manifold pressure as described in the 2 Inspect the heat exchanger for soot Clean as necessary previous section 3 Visually check the burner and pilot flame When flame Blue Flame 1 2 in L 9 12mm Insulated Electrode Fig 19 Spring and Autumn Operation If the pool is being used occasionally do not turn the heater Relief Valve completely off Set the thermostat down to 65 F This will keep the pool and the surrounding ground warm enough 0 In some installations a relief valve is required on the bring the pool up to a comfortable swimming temperature in MiniMax a shorter period of time Winter Operation Heater Main If the pool won t be used for month or more turn the heater Header of at the main gas valve Where freezing is possible it is necessary to drain the water from the heater This may be done by opening the drain valve located at the inlet out
4. be reversed for left side water connections without removing the heat exchanger 1 Remove the inspection plates 5 Switch the in out header with the return header Replace the heat exchanger tube seals with new seals provided 6 Install the temperature sensing bulb and hi limit wires by passing them through the hole provided on the left side of front panel 2 Disconnect all wires from the high limit switches except short jumper wire Disconnect the pressure switch tube from the in out header Remove the temperature sensing bulb from the in out header 7 Reconnect all high limit wires The order of connec tion is not important Route the wires through the same hole as the thermostat sensor wires Reroute and install the pressure switch tubing behind the control box and into the in out head 8 Reinstall the inspection plates INSTALLATION SECTION PG 9 INSTALLATION INSTRUCTIONS Outdoor The heater should not be installed closer than 6 inches to any fences walls or shrubs at any side or back nor closer than 18 inches at the plumbing side A minimum clearance of 24 inches must be maintained at front of heater Fig 14 Do not install the heater in locations which will permit the accumulation of leaves or other combustible material around the base of the heater Do not install the heater in a location that will allow sprinklers to operate near the heater equipment since th
5. or Local Code Nipple 3 4 Flow valve assembly complete BEER N 1 3 A w ol N N N NI NI N N Arala gt gt OQ wo N gt Flow valve gasket Bolt 3 8 16 x 2 1 2 Quick flange Kit fits 1 5 or 2 installation 6 va N 1 Sleeve in out 2 2 2 Bushing in out 2 rubber Bushing 2 to 1 1 2 rubber Safety Shutoff Overheat Thermostat 0 d PN PG 26 MiniMax Parts List Cont Paste nouningbraset J Jeer Screw 8 x 1 4 HH Screw 8 x 1 2 HH Screw 6 x 1 4 re ress eorr lotion cabe weree 75879 Combustion The rapid oxidation of fuel gases accompanied by the Production of heat or heat and light Combustion Chamber The portion of an appliance within which combustion normally occurs Controls Devices designed to regulate the gas air water or electricity supplied to a gas appliance They may be manual semiautomatic or automatic Downdraught Excessive high air pressure existing at the outlet of chimney or stack with tens to make gases flow downward in the stack Flow Valve Installed in the inlet outlet header when the heater fires the sensing mechanism moves towards the inlet forcing more water into the heat exchanger and mixes the water in the header so that the temperature is not too cold or not too hot regulates t
6. the fire box Silicone Rubber Industrial Grade R T V or equivalent The sealant must completely seal the space between the heat exchanger and fire box so that when the heaters is firing heat does not escape to the outer cabinet 4 Place heat exchanger into the box and push down firmly until the heat exchanger sets solidly on the fire box Caution When lifting heat exchanger out of the fire brick use caution so as no to damage the fire brick heater won t fire and you wish to check these gas controls SERVICE SECTION PG 19 MAINTENANCE Burner Tray Removal amp Disassembly At some time during the life of a heater you may need to 9 Remove the bracket the bracket that holds the burner in inspect and repair the parts of the heater that allows the gas place to flow from the gas supply line into the burners If the 1 Turn off gas supply 2 Disconnect the gas union at the heater 3 Remove the gas line installed into the gas valve 4 Remove gas valve holding bracket 5 Remove gas valve wires 6 Disconnect the ignition wire 7 Slide the burner tray out 11 Remove the main burner orifices and check for any blockage 8 You can remove the gas valve if you need to check the Note If heater has been off for the winter or inlet and outlet screens You will have to remove pilot has been installed but not fires for an extended tubing period of time insect will crawl into
7. the water will overheat and cause hi limit to cycle The water temperature will also rise to 150 F inside the header if there is too much restriction in the piping between the heater and the pool This causes the water to slow down as it passes through the heat exchanger The combustion temperature remains constant so if the water speed de creases the temperature increases If water is overheating you can check actual temperature inside the header by installing a heater thermometer where the hose bib is now installed This will tell you if the temperature is above the hi limit will shut the heater off and then when the water temperature the hi limit will allow the heater to re fire This rapid cycle will range from 15 to 45 seconds Note Temperature inside the header is controlled by the flow valve Ifthe water flow is low or close to minimum requirements the flow valve forces most of the water into the heat exchanger keeping the temperature inside the header at an efficient level and below hi limit shut off temperature Ifthe water flow is more than enough or close to maximum gallons per minute the flow valve remains relatively unaffected and allow enough water to by pass so that the temperature inside the header stays at an efficient level Conclusion Ifthe flow valve was inoperative the tem perature inside the heater would reach hi limit shut off temperature and the heater would cycle rapidly So after you have checked the
8. these orifices and the pilot orifice and prevent the heater from firing SERVICE SECTION PG 20 12 Remove the pilot orifice and clean it do not use any sharp object It will destroy the designed orifice size Installation of the high tension ignition wire is very impor tant when reassembling the burner tray into the heater The ignition wire must be pushed onto the ignition controller circuit board tightly and completely to assure proper spark at the pilot electrode during heater start up Main burner orifice Natural large opening Propane small opening Orifice size MM 0 4 000 ft 4 000 6000 ft Natural 3 5mm 29 3 1mm 31 13 After all control devices have been removed clean mani fold 14 Reassemble parts and pieces and reinstall burner tray Note You can use this procedure if you have to change fuel type natural to propane or visa versa The parts needed to convert the MiniMax are Gas valve pilot assembly main burner orifices and module SERVICE SECTION 21 TROUBLESHOOTING HEATER WILL NOT COME ON Automatic ignition system fails Check if eletrical connections are correct and securely fastened If YES call serviceman Check to see if pilot is lit If not refer to Operating Lighting instruction Millivolt Millivolt ignition fails Pump not running Place pump in operation Pump air locked Check for leaks Filter dirty Pump s
9. D la G20 20 mbar 8 IN WG SUPPLY PRESSURE BURNER PRESSURE mbar 8 9 8 9 8 9 in wg 3 6 3 6 3 6 2 Btu h 150 000 250 000 400 000 Btu h 135 150 225 250 364 400 HEAT OUTPUT kW 35 16 58 64 93 76 Btu h 120 000 200 100 319 900 i FLUE GAS VOLUME l sec 7 16 50 27 5 44 amp 1 0 29 29 29 1 WATER PRESSURE 8 8 8 bar psi 125 125 125 MAXIMUM WATER FLOW 45 45 45 TEMP C ELECTRICAL SUPPLY 240V 50Hz FUSED AT 5A WEIGHT EMPTY kg Ibs 54 62 76 119 NOMINAL FLUE SIZE mm in INDOOR INSTALLATION Table 3 USER SECTION PG 1 Introduction This instruction manual provides operating instructions installation and service information for the MiniMax high perfor mance heater The information in this manual applies to the MiniMax 150 250 and 400 natural and propane LP models Note that the British Gas Certification and the CE Mark apply only to the Natural gas 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 Safety Rules 1 Spa or hot tub water t
10. Flange Installation Water Header Manifold Reversal Outdoor Installation Requirements Indoor Venting Requirements Gas Connections Manifold Gas Pressure Adjustment Electrical Service Section General Maintenance Requirements Heat Exchanger Maintenance Burner Tray Troubleshooting Replacement Parts Glossary MiniMax Pool and Spa Heater Congratulations on your purchase of a MiniMax 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 is a compact lightweight and efficient gas fired high performance pool and spa heater The heater is equipped with features that take advantage of new technology developed exclusively for the MiniMax This is the first pool heater that can be directly connected to schedule 40 PVC pipe and has a built in top IMPORTANT NOTICE 4 Gas Safety Installation and Use Regulations 1994 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 The appliance must be installed by a competent person ie CORGI registered in accordance with the relevant requirements of the Gas Safety Regulations current I E E Regulations Model Water Byelaws L
11. S 6500 table 16 All fuses must be ASTA approved to BS 1362 Connect the main cable to the terminal block on LHS of appliance see wiring diagram and clamp the cable in position using the cable clamp provided This appliance MUST be EARTHED COMMISSIONING THE APPLIANCE Natural Gas Models Only Manifold Gas Pressure Test the installation for gas soundness then light the appliance as described in the User s section and check the burner manifold pressure as follows Turn the power supply OFF Connect a manometer to the burner manifold test point Light the heater and allow it to run for 10 minutes to stabilize the burners Check the pressure and if necessary adjust it to the figure shown in Table 3 for the appropriate heater size The locatio of the manifold pressure setting adjuster on the gas control is shown below Remove the dustcover over the adjust and using a small screwdriver turn the screw beneath clockwise to increase or anti clockwise to decrease the pressure 5 Turn the appliance OFF remove the pressure gauge tighten the test point screw then re light and test for gas sound ness ASNS Pressure adjusting Screw Underneath dust cover Fig 18 Burner Manifold Test Point INSTALLATION SECTION 14 INSTALLATION INSTRUCTIONS Electrical Circuit a aly ANIA SY GIONSIOS NW SERVICE SECTION 15 MAINTENANCE be conducted only
12. Swimming Swimming Pool Systems Systems MiniMax POOL amp SPA HEATER OPERATION INSTALLATION amp SERVICE MANUAL FOR YOUR SAFETY READ BEFORE OPERATING Caution lf 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 and European Patent Pending Wa rn ng Improper installation adjustment alteration service or maintenance can cause property damage loss of life or limb 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 Do not touch any electrical switch do not use any phone in SAFETY your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the Fire Depart ment Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Manufactured by Purex Triton 18400 E Gale Ave City of Industry CA 91748 075882 TABLE OF CONTENTS Introduction lt Important Notice Specifications Specifications Technical Data User Section Introduction Starting Operation Operating Control Installation Section Water Connections Quick
13. ader 4 Remove the temperature sensing bulb from the in out header Note You may cut the wire bundle ties 5 Exchange the in out header with the return header Replace the heat exchanger tube seals with new seals provided 6 Install the temperature sensing bulb by passing the wires through the hole provided on the left side of brace panel Route wires through support bracket 7 Install the pressure switch tubing into the in out header by passing it above the brace panel 8 Reconnect all high limit wires The order of connection is not important Route the wires through the same hole as the thermostat sensor wires 9 Reinstall the inspection plates Plumbing Valves When any equipment is located below the over flow rim of the pool or spa valves should be placed in the circulation piping system to isolate the equipment from the pool or spa Check valves are recommended to prevent back siphon Caution Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater filters or pump Required when installation is below water level Required when flow rates exceed 120 gpm Fig 10 ISOLATION VALVE FROM POOL Plumbing Connections The MiniMax heater has the unique capability of direct schedule 40 PVC plumbing connections A Quick Flange has been included with the MiniMax to insure conformity with Purex Pool Systems recom mended PVC plumbing procedure
14. as being the most healthy temperature for swimming by the American Red Cross 3 Use an accurate thermometer 4 When the proper maximum thermostat settings have been determined tighten the thermostat knob stopper 5 Set timeclock to start circulation system no earlier than daybreak The swimming pool loses less heat at this time 6 For pools that are only used on the weekends it is not necessary to leave the thermostat set at 78 F Lower it to a range that can be achieved easily in one day Generally 10 F to 15 F if pool heater is sized properly 7 During a long period of non use turn heater off 8 Set up a regular program of preventive maintenance for the heater each new swimming season Check heat ex changer controls burners operation etc USER SECTION 2 Preventive Maintenance Service Maintenance work must only be conducted a qualified professional Purex Pool Products MiniMax heaters are especially designed for swimming pool and spa use Most homeowners enjoy many years of trouble free service For continued trouble free service each swimming season a qualified professional service engineer should be called to 1 Remove and clean burner tray and pilot assembly 2 Clean and retighten_all wiring terminals 3 Remove heater top and inspect heat exchanger for soot deposit 4 Remove inspection plate and return head to check for scale 5 Clean and adjust pressure switch 6 With burner t
15. cise extreme caution so as OK no to etch or damage the copper tubing To remove a light soot formation with the heat exchanger still in the heater use the following procedures Inspecting The Heat Exchanger Tubes Heat Exchanger in place Under normal operating conditions the MiniMax heater will operate for years without scale deposits forming in the tubes i Remove he bumers and the orifices to protect In some pools however the mineral content of the water is against dirt or other material such that completely scale free operation is next to impos sible For this reason the MiniMax pool heater has been 2 Remove flue collector and baffles designed so that the heat exchanger can be easily inspected without disassembling the entire unit Inspection of the tubes at regular intervals is good assurance of longer life and less maintenance To inspect the tubes for scale deposits use the following procedure 1 Remove inspection plate 2 Remove the four 4 bolts holding the return head in place 3 Remove the return head and visually inspect the tubes 4 Replace tube gaskets 3 Using brush with a long handle you may brush off the bottom of the tubes which will generally remove any soot present You may choose to use a vacuum cleaner Note Do Not use Wire Brush or compressed air to remove soot 4 Brush off and clean all burner heads using caution not to damage burner ports To
16. e water may cause damage to the controls and or electronics Do not install directly under any roof mounted gutter Do not install the heater under an overhang of less than three 3 feet from the top of the heater The area under the overhang must be open on three sides Overhangs must be such that flue products are not diverted into living spaces Heaters installed under overhangs must be protected from direct roof water drainage by gutters and the like From the point where the flue products leave the heater that point MUST be a minimum of four 4 feet below four 4 feet hori zontally from or one 1 foot above any door window or gravity inlet to a building Fig 15 IMPORTANT When locating the heater consider that high winds can roll over or deflect off adjacent buildings and walls Normally placing the heater at least three 3 feet from any wall will prevent adverse conditions If it must be installed next to a wall consult your Purex Triton dealer for advice INSTALLATION SECTION PG 10 INSTALLATION INSTRUCTIONS Indoor Flue Requirements Air Supply Requirements A flue extension of the same size must be connected to the When a heater is installed indoors two air openings must be draft divertor and extended two feet above any obstacle provided One opening should be placed at the bottom and within a 1 0 foot radius of the flue The flue should then be at the top of the room to allow for a free flow of a
17. eader If the appliance will not light before contact ing a service engineer press the re set button Fig 5 once If the overheat condition persists or is repeated contact your service engineer or gas supplier Press To Reset Overheat Thermostat MANUAL By pass iA F CHECK ae VALVE ya Fig 5 INSTALLATION SECTION 5 INSTALLATION INSTRUCTIONS Water Connections HEATER Fig 6 Accessibility To assure easy access plumbing should not be installed over the top of the heater The water lines should come directly into the heater from the side or up from the ground Below Pool Level Installations Where a pool heater is to be installed below the water level of the pool it is necessary to readjust the pressure switch to allow for the constant water pressure in the system Gate valves should NOT be installed on the return line from the heater When the heater is installed below pool level install a check valve after the heater and a gate valve between Caution Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into heater filters or pump Non Combustible flooring Note Heater must be installed on a non combustible floor and at least six inches from any combustible material or wall Before installing water pipe check local building codes related to pool heaters Heaters installed below water
18. electrical controls for bad ground or wiring check the flow valve Note The flow valve is located in the inlet outlet header To check flow valve Remove flow valve from header A 33 4 eam B Check factory measurement 3 3 4 from mounting plate to the 2nd disc onside excluding gasket Element Note Discs must be parallel with mounting plate C Check flow valve for any physical damage D Hold power element under hot water and see if power element moves the discs towards the mounting plate 3 8 1 2 Turn cold water on power element should retract to original factory setting If flow valve expands retracts and returns to original measurement flow valve is OK The power element is the part of the flow valve that when heated moves the 2 discs over toward the inlet forcing more water into the heat exchanger and retracts when the water is cold allowing water to bypass or return to the pool without going into the exchanger Here is a list of things that will cause the power element to fail and cause the heater to cycle on the hi limit A Ifthe pH of the water is too low the power element will be eaten away and will not move B Ifthe calcium hardness is too high the power element will become coated with calcium deposits that will disable the flow valve If power element has been installed incorrectly D If any debris in the circulation system were to pass by or throu
19. emperature and minimizes condensation Flue Gases Flue Products Products of combustion and excess air in appliance flues or heat exchang ers before the draft hood Gas Valve A device that allows gas to flow from the gas supply line into the pilot assembly and into the main burners after receiving voltage from the module Heat Exchanger Any device from transferring heat High Limits or Safety Cutoffs Switches installed on the outlet side of the in out header to prevent the water temperature inside the header from exceeding 150 degrees ICCB Ignition Wire board ICCB and the pilot ignitor that carries voltage to the pilot ignitor and back to the ICCB to signal the gas valve to open when the pilot flame is established 29 Glossary con t 3 Input Rating The gas burning capacity of an appliance in BTU per hour as specified by the manufac turer Appliance input ratings are based on seal level operation and need not be changes for operation up to 2 000 feet elevation For operation at elevations above 2 000 feet input ratings should be reduced at the rate of 4 percent for each 1 000 feet above sea level Liquefied Petroleum Gases The terms Liquefied Petroleum Gases LPG and LP Gas mean and include any fuel gas which is composed predominantly of any of the following hydrocarbons or mix tures of them propane propylene normal butane or isobutane and butylenes Manifold The conduit of an applia
20. emperatures should never exceed 104 F 40 C A temperature of 100 F 38 C is consid ered 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 heater thermostats may err in regulating water temperatures as much as 4 F 2 2 C 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 medications which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tub ej lll Energy Saving Tips 1 If possible keep pool or spa covered when not in use This will not only cut heating costs but also keep dirt and debris from settling in the pool and conserve chemicals 2 In swimming pool applications the pool heater thermo stat setting should be 78 F or lower This is accepted
21. f 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 2 Immediately call your gas supplier from a neighbour s 6 Do not try to light any appliance phone 7 Do not touch any electrical switch Do not use any 3 Follow the gas supplier s instruction phone in your building 4 Ifyou cannot reach your gas supplier call the fire 8 Open all doors and windows Indoors department STOP Have you read the safety information TO LIGHT THE APPLIANCE 1 Set the thermostat to lowest setting refer to next 7 pilot should spark and the pilot should ignite them page heater will fire 2 Push power switch off 8 In new installations where the gas line hasn t been bled 3 Wait five 5 minutes to clear out any gas If you then the pilot and main burner combustion sequence may be smell gas STOP Follow the safety information If slower than normal you don t smell gas go to next step 9 Ifthe heater does not operate as it should a reason 4 sure pump is running and primed able amount of time read the Troubleshooting Guide 5 Push power switch on Either pool or spa mode portion of this manual 6 Set thermostat to desired setting ees TO TURN THE APPLIANCE OFF 1 Set the thermostat to lowest setting and turn off power 2 Turn off all electric power to the appliance if service is sw
22. gh the filter and become lodged in the flow valve mechanism If water temperature inside IS NOT 150 F and all above tests have been completed and heater still cycles the hi limits should be replaced SERVICE SECTION PG 24 TROUBLESHOOTING Heater Cycles Rapidly con t 25 MINIMAX HEATER ALL MODELS Fig 23 MiniMax Parts List t kii assembly indoor 1 d Return header 70994 70994 70994 74216 74216 73739 73739 70416 70416 72180 72180 70951 70951 75865 75865 71134 71134 1949 71949 75936 75938 73869 73867 70256 70258 75864 75864 75931 75932 75925 75926 75927 70230 70230 71580 71580 73858 73856 72134 72134 71983 71983 72138 72138 71388 71388 73841 73841 74015 74015 75492 75492 75284 75284 71895 71895 70544 70544 70229 70229 71017 71017 75875 75875 75979 75980 Bracket washer Bolt HH 3 8 x 2 Bolt 3 8 16 x 1 1 2 Washer 3 8 ID 1 OD Tube seal gasket 3 zx A 8 Ignition Controller complete ID Thermostat knob 0 1 1 Switch rocker double pole double throw Control panel assembly complete IID Door Manifold burner Gas valve natural IID Pilot tube IID Burner tray assy natural complete IID 5 gt 1 Pressure switch 9 Combustion chamber assembly complete 1 Valve drain 3 4 T 3 4 brass ASME or local code Valve relief 3 4 50 ASME
23. he connecting gas pipe will be necessary Make this reduction as close to the heater as possible The heater and any other gas appliances must be discon nected from the gas supply piping system during any pressure testing on that system greater that 1 2 PSIG The heater and its gas connection must be leak tested before placing the appliance in operation Do not use flame to test gas line Use soapy water or other nonflammable method A manual main shut off valve must be installed external to the heater It is essential that the natural gas appliance is supplied with a governed gas supply Do not install gas line union inside heater cabinet This will void your warranty INSTALLATION SECTION PG 13 INSTALLATION INSTRUCTIONS Electrical Electrical Electrical Rating 230 V AC 50 Hz fused at 5A Note If any of the original wiring supplied with Caution The heater must be electrically is appliance must be replaced installer must grounded and bonded in accordance with local supply No 18 AWG 105 C approved low codes or in absence of local codes with the energy stranded copper wire or it s equivalent latest national electrical codes This appliance must be connected to the main supply via a fused double pole switch having a 3mm 1 8 in contact separa tion in both poles serving only the heater pump and any external controls Wiring should be a minimum of PVC insulated cable not less than 24 0 2 mm to B
24. ir If fitted with a suitable terminal NOTE Do not alter the other gas appliances are installed in the same room you must heater draught divertor in any way it has been designed by check to see that they have been provided with the proper the manufacturer and approved by British Gas plc To size openings otherwise they may use the air intended for ensure efficient flueing use 45 Elbow for horizontal your pool heater installation when attaching flue pipe to draught divertor Vent Cap And Ventilation Requirements Area y Installer All air from outside Air Supply High Level Low Level SCH in 59 270 42 540 84 150 270 42 540 84 Combustion 250 300 46 600 92 400 400 62 800 124 Table 4 1 Rise Per Foot Recommended Fig 16 A quick check of your flue installation Allow heater to operate for 15 minutes Then strike a wooden match and blow out the flame With the match smoking hold next to the draught divertor If the smoke is pulled up into the flue E and out of the room the flue is correct If it does not you d must make flueing corrections It is essential that the ventilation is direct from outside The appliance must not be installed in a room directly or indirectly connected to a living space Fig 17 INSTALLATION SECTION PG 11 INSTALLATION INSTRUCTIONS Assembling Draught Divertor Secure with screws Place d
25. ire If the spark is weak or there is no spark replace the ICCB 1 If there is a good spark between ICCB and wire terminal turn power OFF and push ignition wire back on to the ICCB Pull ignition wire and electrode assembly from pilot Check condition of wire if it is damaged replace ignition wire electrode If ignition wire electrode is OK hold close to pilot assembly and turn power on If a good spark is present between electrode and pilot assembly wire is OK if no spark replace wire electrode assembly If you have a good spark between pilot assembly and electrode push electrode back on pilot and turn power on If you have good spark at pilot electrode pilot is OK Ifno spark or weak spar A Make sure pilot assembly is attached to the burner clean and tight to create a good ground Make sure ceramic insulator is not cracked Make sure electrode is clean If still no spark replace pilot assembly Make sure spark gap is set properly Fig 22 SERVICE SECTION 23 TROUBLESHOOTING Heater Won t Fire Pilot emm Check all wire connection to control and ground They should be clean and tight Check voltage at both terminals of thermal cutoff pressure switch and hi limit If voltage is present on both terminals these controls are OK Check voltage at ignition controller circuit board ICCB 4 Check voltage at gas valves red wire If voltage is
26. itch to be performed 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 USER SECTION PG 4 USSR A OPERATING CONTROL For convenience and economy all MiniMax heaters are equipped with two thermostats on the front of the heater control panel Fig 3 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 temperature 3 Spa position This allows separate control of spa water temperature SELECTOR DIALS The selector dials eliminate constant thermostat adjust ments Set the spa dial at the desired spa temperature and the pool dial at the desired pool temperature This provides convenient preset operating temperatures ee THERMOSTAT KNOB STOPPER Each thermostat is equipped with a mechanical stop Fig 4 that can be locked with use of a screwdriver to prevent temperatures in excess of that desired by the user 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 Knob Stopper Screw A Fig 4 OVERHEAT THERMOSTAT A manual re set overheat thermostat is fitted adjacent to the flow h
27. let header allowing all water to drain out of the heater Use compressed air to blow the water out of the heat exchanger Also disconnect the pressure switch from its 1 4 copper line This will prevent freeze damage to the switch May be required for Note Uncirculated water trapped in the heater can ASME or result in freeze damage to the heat exchanger or local code headers Freeze damage is specifically not covered by the warranty To winterize open drei Caution If the heater has been drained for freezing ranvalye condition do NOT turn until the system is circulation water SERVICE SECTION 16 MAINTENANCE Soot Formation on the Heat Exchanger z 5 t eater Usual Causes of Sooting burners and 1 Low gas pressure in the gas supply line 2 Excessive water flow can create condensation which can cause a soot formation 3 Foreign material in burners and orifices Remove foreign material such a8 dirt spider webs etc 4 Inadequate air supply for the heater when installed 1 Powdered detergent and scrub brush accompanied by indoors can cause a soot formation high water pressure to spray the heat exchanger thor oughly Note After de sooting a heater the flame should be SE blue in color NOT YELLOW Dust in the air can turn 2 very mild acid and water solution and high water the flame yellow A slight yellow tip on a blue flame is pressure When using acid ex
28. level require adjustment of the pressure switch 1 Backwash filter and clean the pump hair and lint basket before making any adjustment to the pressure switch 2 Turn on the circulation pump switch the heater power switch and set the thermostat s to the hottest setting 3 Turn the pressure switch adjustment knob clockwise until the heater turns off 4 Turn the adjust knob 1 4 turn counter clockwise The heater should come back on 5 Turn the pump off The heater should shut off with the circulation pump If no repeat steps 2 3 and 4 6 Use the circulation pump switch to turn the heater on and off several times to insure proper adjustments Note If pool is more than 1 ft above heater or vice versa the pressure switch may have to be replaced with a flow switch INSTALLATION SECTION PG 6 INSTALLATION INSTRUCTIONS Water Connections Reversible Inlet Outlet Connection The MiniMax is factory assembled with right side inlet outlet water connections The inlet outlet header can be reversed for left side water connections without removing the heat ex changer Reversing Water Connections Disassembly Tools needed 1 4 Nut Driver 9 16 Socket and Wrench 1 2 amp 9 16 Open Wrench Remove the inspection plates 2 Disconnect all wires from the high limit switches except short jumper wire The exact order of disconnection is not important 3 Disconnect the pressure switch tube from the in out he
29. nce which supplies gas to the individual burners Natural Gas Any gas found in the earth as opposed to gases which are manufactured Orifice An opening in an orifice cap hood orifice spud or other device through which gas is dis charged and whereby the flow of gas is limited and or controlled Pilot A small flame which is used to ignite the gas at the main burner Pilot Ignitor or Pilot Assembly Establishes a pilot flame just prior to ignition of main burners Pressure Switch A control that responds to water pressure When the heater senses adequate water pressure the heater will fires and when the pressure drops below 1 1 2 PSI at the switch the heater stops firing Primary Air The combustion sir introduced into a burner which mixes with the gas before it reaches the port Usually expressed as a percentage of air required for complete combustion of gas Propane A hydrocarbon gas heavier than methane but light than butane It is used as a fuel gas alone mixed with air or as a major constituent of liquefied petroleum Soot A black substance mostly consisting of small particles of carbon which can result from incom plete combustion and appear as smoke Therm A unit of heat energy equal to 1000 000 BTU Thermal Cutoff A heat sensitive fuse that breaks the power to the controls if the temperature is too high in the gas valve area causing the heater to switch off Transformer A coil device that changes high v
30. ocal 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 Typical documents include BS 6891 Installation of low pressure pipework BS 6644 Installation of Gas Fired Hot Water Boilers 60kW to 2MW CP341 Water Supply British Gas Publications IM2 Purging Procedures of Non domestic Gas Installations 5 Soundness Testing Procedures for Industrial and Commercial Gas Installations IM11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters Model Water Bylaws SPECIFICATIONS Dimensions Outdoor Installation Flueless 400 A Dim 17 7 8 SE 23 7 8 Ss 33 3 8 H Table 1 rs 4 Ge 2 FRONT VIEW SIDE VIEW Fig 1 Indoor Installation with draught divertor Model Dim Dim Dim Dim 150 1727 8 6 1 2 7 3 4 39 3 4 S 250 23 7 8 12 1 2 10 42 3 4 p 400 33 3 8 22 3 8 IO 51 3 4 Ss 1 F s Table 2 287 L su Dim Fig 2 SPECIFICATIONS Technical Data Natural Gas Models Only GAS CATEGORY TYPE AN
31. oltage into low voltage Flue A Device such as a pipe to transfer flue products from an appliance to the outdoors This term also is used to designate a small hole or opening for the escape of a fluid such as in a gas control Water Column Abbreviated as W C A unit used for expressing pressure
32. protect eyes from soot or cleaning solution use safety eye wear SERVICE SECTION PG 17 MAINTENANCE Removing The Heat Exchanger For heavy soot accumulation which cannot be successfully removed by merely brushing or use of a vacuum cleaner the heat exchanger must be removed from the heater 1 Turn off main gas to heater 7 Remove the heat exchanger mount screws on the side of 2 Turn pump off Be sure that the stops on the clock will the heater not allow the pump to come on during inspection or while the heat exchanger is removed 3 Remove the top from the heater 4 Remove inner lid flue collector and inspection panels Se d 8 Lift heat exchanger out of heater 5 Disconnect the plumbing at the break away flanges and the pressure switch line Remove the thermostat bulb and hi limit wires from the inlet outlet header Caution When lifting heat exchanger out of the fire brick use caution so as not to damage the fire brick K 3 SERVICE SECTION 18 MAINTENANCE Reinstalling Heat Exchanger 1 Inspect fire box for damage or cracks that would allow 5 Reconnect the inlet and outlet flange to the headers use heat to leak out into the outer cabinet and controls new flange gaskets careful not to move the heat exchanger and break the seal 2 Remove any old sealant from fire box 6 Reinstall flue collector inner panel and top 3 Apply new sealant to
33. rafthood adaptor over flue collector iit aa S Parts Draught Divertor Adaptor Top Cover 2 Install cover Lg Place draught divertor over adaptor secure with screws E A Remove stackless top lt INSTALLATION SECTION PG 12 INSTALLATION INSTRUCTIONS Gas Connections Pipe Sized For Length Of Run In Equivalent Feet Before installing the gas line be sure to check what gas the heater has been designed to burn LP This is important because different types of gas require different gas pipe 250 500 600 sizes The rating plate om the heater will indicate 100 150 200 450 which gas the heater is designed to burn Table 5 shows what size pipe is Table 5 required for the distance from gas meter to the heater The table is for natural gas at a specific gravity of 65 and propane at specific gravity of 1 5 When sizing gas lines calculate 3 additional feet of straight pipe for every elbow used When installing the gas line avoid getting dirt grease or other foreign material in the pipe as this may cause damage to the gas valve which may result in heater failure The gas meter should be checked to make sure that it will supply enough gas to the heater and any other appliances that may be used on the same meter The gas line from the meter will usually be of a larger size than the gas valve supplied with the heater Therefore a reduction of t
34. ray removed check fire box for cracks Whether or not scale is a problem a yearly inspection is good preventive maintenance If a minor problem should exist it is much better to catch it in the early stages rather than to incur extensive repair charges later on WARNING Should overheating occur or the gas supply fall 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 USER SECTION PG 3 LIGHTING OPERATION Natural Propane Ms FOR YOUR SAFETY READ BEFORE LIGHTING MINIMAX 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 C Do not use this appliance if any part has been under which automatically lights the pilot Do not try to light water Immediately call a qualified service technician to the pilot by hand inspect the appliance and to replace any part of the control system and any gas control which has been B BEFORE OPERATING smell all around the appliance under water area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Never store any materials within the vicinity o
35. rt pipe into inlet outlet opening of the Quick 3 Bolt the Quick Flange to the header mange NOTE Tighten the bolts evenly 2 Slip the rubber gasket over the pipe using the 2 Do not over tighten rubber gasket for 2 copper pipe or the 1 1 2 i rubber gasket for 1 1 2 copper pipe 4 Use plumbers roll or medium grit sand paper and 3 clean the inlet outlet openings of the Quick Flange Use the same method to clean the PVC pipe The sand paper open will break up any grease or contaminant that may not be cleaned away with a primer Bolt the Quick Flange to the header 5 Use711 PVC or comparable glue and follow manufacturer s recommendations Apply to the b inlet opening of the Quick Flange Do the same to the PVC pipe and quickly insert pipe into Quick Flange and twist pipe 1 4 turn Do the same to the other opening of the Quick Flange 6 For 11 2 PVC pipe installations first glue a 1 1 2 x 2 sch 40 PVC bushing not supplied or shown to end of pipe prior to gluing to the Quick Flange noig Aln intr Fig 13 HEATER 2 QUICK 2 2 PVC PIPE HEADER RUBBER FIANGE SLEEVE BUSHING INSTALLATION SECTION PG 8 INSTALLATION INSTRUCTIONS Water 4 Remove return header Reversible Inlet Outlet Connections The MiniMax is factory assembled with right side inlet outlet water connections The inlet outlet header can
36. trainer clogged Clean filter Clean strainer Defective wiring or connection Repair or replace wires Overheat thermostat open Manually reset button on thermostat Defective pressure switch Replace switch Defective gas controls Call serviceman On Off switch in Off position Turn switch to Pool or Spa HEATER SHORT CYCLING RAPID ON AND OFF OPERATION Insufficient water flow Clean filter and pump strainer Defective wiring Repair or replace wiring Defective flow valve or out of adjustment Call serviceman Call serviceman Defective hi limit and or thermostat HEATER MAKES KNOCKING NOISES MAKE SURE ALL VALVES ON SYSTEM ARE OPEN Heater operating after pump has shut off Shut off gas supply and call service man Heater exchanger scaled Shut off gas supply and call serviceman SS SERVICE SECTION PG 22 TROUBLESHOOTING Heater Won t Spark With the other voltmeter lead touch each terminal or connection on the thermal overload pressure switch and high limits If voltage is present on both sides of these switches they are operating properly Ignition Controller SparkTes If there is still no pilot spark turn power OFF and remove ignition wire from ignition controller circuit board ICCB Hold wire terminal close to ICCB terminal and turn power ON If ICCB is good there will be a strong 1 8 spark between ICCB and ignition w
Download Pdf Manuals
Related Search