Pentair Swimming Pool Heater MiniMax Plus HP Series User Manual
1  
®
™
MiniMax Plus and PowerMax  
POOL & SPA HEATERS  
OPERATION & INSTALLATION MANUAL  
WARNING  
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.  
To  
Consumer  
Retain For  
Future  
Reference  
U.S. Patent Numbers  
6,295,980  
5,318,007 - 5,228,618  
5,201,307 - 4,595,825  
WARNING  
Warning: Improper installation, adjustment, alteration, service or maintenance can  
cause property damage, personal injury or death. Installation and service must be  
performed by a qualified installer, service agency or the gas supplier.  
WHAT TO DO IF YOU SMELL GAS  
•
•
•
Do not try to light any appliance.  
For Your  
Safety  
Do not touch any electrical switch; do not use any phone in your building.  
Immediately call your gas supplier from a neighbor's phone.  
Follow the gas supplier's instructions.  
•
If you cannot reach your gas supplier, call the fire department.  
Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or other appliances.  
Pentair Pool Products, Inc.  
1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151  
10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400  
Rev. G 1-22-04  
P/N 471048  
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3
Introduction  
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.  
Rev. G 1-22-04  
P/N 471048  
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Operation (contd.)  
4
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.  
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.  
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.  
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  
SAFETY RULES  
4. Before entering the spa or hot tub, the user  
should check the water temperature with an  
accurate thermometer. Spa or hot tub  
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.  
thermostats may err in regulating water  
temperatures by as much as 4° F (2.2° C).  
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.  
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.  
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.  
6. Persons taking medication which induce  
drowsiness, such as tranquilizers, antihistamines  
or anticoagulants should not use spas or hot  
tubs.  
WARNING  
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the  
appliance. Do not use this heater if any part has been under water. Immediately call a qualified service  
technician to inspect the heater and to replace any part of control system and gas control which has been  
under water.  
P/N 471048  
Rev. G 1-22-04  
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Operation (contd.)  
5
MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - NATURAL GAS  
FOR YOUR SAFETY: READ BEFORE LIGHTING  
WARNING  
If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life  
and property damage.  
Do not attempt to light the heater if you suspect a natural gas leak. Lighting the heater can result in a fire or  
explosion which can cause personal injury, death, and property damage.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don't try to repair it.  
Call a qualified service technician. Forced or  
attempted repair may result in a fire or explosion.  
D. 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 the control system and any gas  
control which has been under water.  
A. This heater is equipped with an ignition device  
which automatically lights the pilot. Do not try  
to light the pilot by hand.  
B. BEFORE OPERATING smell all around the  
heater area for gas. Be sure to smell next to  
the floor because some gas is heavier than air  
and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
-
-
Do not try to light any heater.  
Do not touch any electrical switch; do not use  
any phone in your building.  
E. The MiniMax Plus incorporates (9) nine  
indicator lights to aid you in the operation of the  
heater, and to assist in diagnosing a failure in the  
heater’s function.  
-
-
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.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above.  
2. Set the thermostat to the lowest setting.  
3. Turn off electric power to the heater.  
4. This heater is equipped with an ignition device  
which automatically lights the pilot. Do not try  
to light the pilot by hand.  
9. Replace the control access door.  
10. Turn on the electrical power to the heater.  
11. Set the thermostat to the desired setting.  
12. If the heater will not operate, follow the instruc-  
tions "To Turn Off Gas To Heater" and call your  
service technician or gas supplier.  
5. Remove the control access door.  
6. Push in gas control knob slightly and turn clock-  
wise  
to “OFF”.  
Gas  
Inlet  
7. Wait five (5) minutes to clear out any gas. If you  
then smell gas, STOP! Follow "B" in the safety  
information above. If you don't smell gas, go to the  
next step.  
ON  
OFF  
8. Turn knob on gas control counterclockwise  
to “ON”; see Figure 1.  
Figure 1.  
Gas control knob shown in “ON” position.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the heater if  
service is to be performed.  
4. Push in gas control knob slightly and turn  
clockwise to "OFF". Do not force.  
5. Replace control access door.  
3. Remove control access door.  
Rev. G 1-22-04  
P/N 471048  
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Operation (contd.)  
6
MINIMAX PLUS ELECTRONIC IGNITION LIGHTING/OPERATION - PROPANE  
FOR YOUR SAFETY: READ BEFORE LIGHTING  
NOTE  
The MiniMax Plus propane models have special features for additional safety and protection.  
Read the safety instructions for natural gas (page 5) before proceeding.  
WARNING  
If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life  
and property damage.  
Since propane gas is heavier than air, escaping propane will accumulate and remain at ground level. Do not  
attempt to light the heater. If you suspect a propane leak, lighting the heater can result in a fire or explosion  
which can cause personal injury, death, and property damage.  
WHAT TO DO IF YOU SMELL GAS  
-
Immediately call your gas supplier from a  
neighbor's phone. Follow the gas supplier's  
instructions.  
If you cannot reach your gas supplier, call the  
Fire Department.  
-
-
-
Do not try to light matches or lighter.  
Do not try to light any heater.  
Do not touch any electrical switch; do not  
use any phone in your building.  
-
-
-
Shut off gas line at propane tank.  
Do not tamper with the heater because it is  
dangerous and voids all warranties.  
Safety Lockout:  
This MiniMax Plus Propane Heater is equipped with a 100% safety lockout feature. If the pilot does not  
light within a maximum of 90 seconds, lockout will occur.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above.  
2. Set the thermostat to the lowest setting.  
3. Turn off electric power to the heater.  
4. This heater is equipped with an ignition device  
which automatically lights the pilot. Do not try to  
light the pilot by hand.  
9. Replace the control access door.  
10. Turn on the electrical power to the heater.  
11. Set the thermostat to the desired setting.  
12. If the heater will not operate, follow the instruc-  
tions "To Turn Off Gas To Heater" and call your  
service technician or gas supplier.  
5. Remove the control access door.  
6. Push in gas control knob slightly and turn clock-  
wise  
to “OFF”.  
7. Wait five (5) minutes to clear out any gas. If you  
then smell gas, STOP! Follow "B" in the safety  
information on page 5. If you don't smell gas, go to  
the next step.  
Gas  
Inlet  
ON  
8. Turn knob on gas control counterclockwise  
to “ON”; see Figure 2.  
OFF  
Figure 2.  
Gas control knob shown in “ON” position.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the heater if  
service is to be performed.  
4. Push in gas control knob slightly and turn  
clockwise to "OFF". Do not force.  
5. Replace control access door.  
3. Remove control access door.  
P/N 471048  
Rev. G 1-22-04  
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Operation (contd.)  
7
MINIMAX PLUS MILLIVOLT LIGHTING/OPERATION-NATURAL GAS & PROPANE  
FOR YOUR SAFETY: READ BEFORE LIGHTING  
WARNING  
If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life  
and property damage.  
Since propane gas is heavier than air, escaping propane will accumulate and remain at ground level. Do not  
attempt to light the heater. If you suspect a propane leak, lighting the heater can result in a fire or explosion  
which can cause personal injury, death, and property damage.  
-
If you cannot reach your gas supplier, call the Fire  
Department.  
A. This heater is equipped with a pilot which must be  
lighted manually. When lighting the pilot, follow  
these instructions exactly.  
B. BEFORE LIGHTING smell all around the heater  
area for gas. Be sure to smell next to the floor  
because some gas is heavier than air and will settle  
on the floor.  
C. Use only your hand to push in or turn the gas control  
knob. Never use tools. If the knob will not push in or  
turn by hand, don't try to repair it. Call a qualified  
service technician. Forced or attempted repair may  
result in a fire or explosion.  
D. 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 the control system and any gas control which  
has been under water.  
WHAT TO DO IF YOU SMELL GAS  
-
-
Do not try to light any heater.  
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.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above.  
2. Set the thermostat to the lowest setting.  
3. Turn off electric power to the heater.  
7. Push the control knob all the way and hold in.  
Immediately light the pilot with Presslite matchless  
ignition system by pressing the red igniter button  
(located at the panel next to the gas valve). Continue  
to hold the control knob in for about one (1) minute  
after the pilot is lit. Release knob and it will pop  
back up. Pilot should remain lit. If it goes out, repeat  
steps 4 through 7.  
4. Push in gas control knob slightly and turn clock-  
wise  
to “OFF”.  
•
If knob does not pop up when released, stop and  
immediately call your service technician or gas  
supplier.  
Figure 5.  
•
If the pilot will not stay lit  
after several tries, turn the  
gas control knob to “OFF”  
and call your service  
technician or gas supplier.  
Figure 6.  
Robertshaw Millivolt Gas Valve  
Honeywell Millivolt Gas Valve  
Figure 3.  
Figure 4.  
Gas control knobs shown in “OFF” position.  
NOTE  
Knob cannot be turned from “Pilot to “OFF”” unless  
knob is pushed in slightly. DO NOT FORCE.  
8. Turn knob on gas control  
counterclockwise  
“ON”.  
to  
5. Wait five (5) minutes to clear out any gas. If you then  
smell gas, STOP! Follow "B" in the safety informa-  
tion above. If you don't smell gas, go to the next step.  
6. Push in gas control knob slightly and turn counter-  
9. Replace the control access  
door.  
10. Set the thermostat to the  
desired setting.  
Pilot  
clockwise  
to “Pilot”.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the heater if service is  
to be performed.  
4. Push in gas control knob slightly and turn clockwise  
to "OFF". Do not force.  
5. Replace control access door.  
3. Remove control access door.  
Rev. G 1-22-04  
P/N 471048  
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Operation (contd.)  
8
OPERATING (CONTROLS)  
Dual Temperature Control System - (Electronic and Millivolt Models)  
For convenience and economy all MiniMax Plus heaters  
are equipped with two thermostats on the front of the heater  
control panel; see Figure 7.  
THERMOSTAT ADJUSTMENT  
The knob with locking feature eliminates the need for  
constant thermostat adjustments. Set the knob pointer to  
the desired pool or spa temperature.  
If further adjustment is needed, rotate the knob until the  
desired temperature is obtained. This knob position  
corresponding to your desired maximum pool or spa  
temperature may now be preset (locked) by the knob  
stopper which prevents the knob from being turned beyond  
the maximum temperature you set.  
Figure 7.  
THERMOSTAT KNOB STOPPER  
Each thermostat is equipped with a mechanical stop that  
can be locked or unlocked with use of a screwdriver to  
prevent temperatures in excess of that desired by the user;  
see Figure 8.  
Knob Stopper  
Screw A  
Figure 8.  
The maximum setting can be adjusted by loosening the screw  
"A" and turning the stopper dial to desired maximum setting.  
Lock the setting by tightening the screw. The Mechanical  
stop is under the knob. Ensure that the knob is stopping at the  
correct position when the knob is rotated clockwise from a  
lower temperature position. (See Thermostat Adjustment.)  
POWER (THERMOSTAT SELECT) SWITCH  
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 or spa temperature.  
NOTE  
To eliminate error due to piping heat losses,  
measure pool temperature with an accurate  
thermometer directly at the pool or spa.  
3. “Spa” position - This allows separate control of spa  
water temperature.  
INDICATOR LIGHT DESCRIPTION  
The MiniMax Pool Heater provides nine status indicator lights, six can be seen from the front of the control panel which  
help you understand the operation of the heater. If something should go wrong, the lights will aid in troubleshooting the  
problem. Three additional lights can be seen after opening the control panel. These three lights give the service technician  
advanced troubleshooting capability. All the LED lights are green with the exception of the red service LED.  
POWER LIGHT (POWER)  
AUXILIARY (AUX)  
This light is on when it indicates the remote switch contacts  
are closed. This allows you to observe if your remote switch  
is properly closing the heater control circuit. When shipped  
from the factory a jumper is installed to maintain closed  
circuit in the absence of a remote switch.  
The light is on at all times, in any switch position, indicating  
24 VAC power is being supplied to the control circuit. If it  
fails to light, no other light will be on. Possible causes are:  
a) external power to the heater is disconnected, check  
service panel circuit breaker or fuses; b) local circuit  
breaker inside the transformer has tripped -- investigate  
cause before resetting; c) transformer has failed.  
PRESSURE (PRESS)  
This light is on when Spa/Pool Selector switch is on,  
indicates the circulation pump is running properly. If  
pressure light fails to light, the pump may have lost its  
prime or water flow may be restricted by an inadvertently  
closed valve or clogged filter or pump basket. If you have  
determined that there is no water flow restriction to the  
heater, you should call a qualified serviceman.  
THERMOSTAT (TSTAT)  
This light is on when the thermostat contacts close, signaled  
by the water temperature falling below the setpoint, calling  
for the heater to fire to maintain the desired water  
temperature.  
P/N 471048  
Rev. G 1-22-04  
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Operation (contd.)  
9
HEAT (HEAT)  
SERVICE (SERVICE)  
The heat light is on any time the thermostat has  
signaled a call for heat which initializes the ignition  
safety firing circuit -- the light comes on to indicate  
successful firing of the main burners.  
The service light is off during normal operation of  
heater. The light only comes on if a problem with a  
control has occurred or when the heater is first  
firing. The problem must be investigated by the  
serviceman prior to attempts to fire the heater again.  
The diagrams that follow give examples of  
troubleshooting a malfunctioning heater using the  
assistance of the indicator lights.  
TROUBLESHOOTING (CONTROLS)  
Example of troubleshooting with the assistance of the indicator lights.  
SYMBOL TABLE  
SWITCH OR DEVICE  
OPEN CIRCUIT  
(BLOCK CURRENT)  
SWITCH OR DEVICE  
CLOSED CIRCUIT  
(PASS CURRENT)  
LED OFF  
LED LIT  
IGNITION MODULE  
IND  
GND  
VAL  
GAS VALVE  
MV  
TRANSFORMER  
INCOMING  
LINE VOLTAGE  
CIRCUIT  
BREAKER  
HI TEMP  
LIMIT SWITCHES  
REMOTE  
PRESS  
TFUSE  
MV  
THERMOSTAT  
RELAY  
PWR  
TSTAT  
RMT  
PRESS  
HI TEMP  
TFUSE  
MV  
HEAT  
SRVE  
POWER  
THERM  
CLOSE IF  
NO MV  
SERVICE  
AUX  
THERMOSTAT CIRCUIT BOARD  
WATER AT SELECTED TEMPERATURE.... NORMAL OPERATION  
PRESS  
HEAT  
FRONT PANEL LEDS  
OR POOL/OFF/SPA THERMOSTAT SELECT SWITCH OFF.... NORMAL OPERATION  
IGNITION MODULE  
IND  
GND  
VAL  
GAS VALVE  
TRANSFORMER  
INCOMING  
LINE VOLTAGE  
CIRCUIT  
BREAKER  
HI TEMP  
LIMIT SWITCHES  
REMOTE  
PRESS  
TFUSE  
MV  
MV  
THERMOSTAT  
RELAY  
PWR  
TSTAT  
RMT  
PRESS  
HI TEMP  
TFUSE  
MV  
HEAT  
SRVE  
THERM  
AUX  
POWER  
CLOSE IF  
NO MV  
SERVICE  
THERMOSTAT CIRCUIT BOARD  
PRESS  
HEAT  
THERMOSTAT CALLING FOR HEAT - PUMP OFF(NO PRESSURE) BLOCKS FIRING  
NORMAL OPERATION  
FRONT PANEL LEDS  
Rev. G 1-22-04  
P/N 471048  
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Operation (contd.)  
10  
TROUBLESHOOTING (CONTROLS) - Continued  
SYMBOL TABLE  
SWITCH OR DEVICE  
OPEN CIRCUIT  
(BLOCK CURRENT)  
SWITCH OR DEVICE  
CLOSED CIRCUIT  
(PASS CURRENT)  
LED OFF  
LED LIT  
IGNITION MODULE  
IND  
GND  
VAL  
GAS VALVE  
MV  
TRANSFORMER  
INCOMING  
LINE VOLTAGE  
CIRCUIT  
BREAKER  
HI TEMP  
LIMIT SWITCHES  
REMOTE  
PRESS  
TFUSE  
MV  
THERMOSTAT  
RELAY  
RMT  
PRESS  
HEAT  
PWR  
TSTAT  
HI TEMP  
TFUSE  
MV  
SRVE  
POWER  
THERM  
CLOSE IF  
NO MV  
SERVICE  
AUX  
THERMOSTAT CIRCUIT BOARD  
HEATER FIRING - NORMAL OPERATION  
PRESS  
HEAT  
FRONT PANEL LEDS  
IGNITION MODULE  
IND  
GND  
VAL  
GAS VALVE  
TRANSFORMER  
INCOMING  
LINE VOLTAGE  
CIRCUIT  
BREAKER  
HI TEMP  
LIMIT SWITCHES  
REMOTE  
PRESS  
TFUSE  
MV  
MV  
THERMOSTAT  
RELAY  
RMT  
PWR  
TSTAT  
PRESS  
HI TEMP  
TFUSE  
MV  
HEAT  
SRVE  
THERM  
AUX  
POWER  
CLOSE IF  
NO MV  
SERVICE  
PRESS  
HEAT  
THERMOSTAT CIRCUIT BOARD  
THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING  
NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM  
IS IN THERMAL FUSE CIRCUIT  
FRONT PANEL LEDS  
P/N 471048  
Rev. G 1-22-04  
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11  
Maintenance  
MAINTENANCE INSTRUCTIONS  
It is recommended that you check the following items at  
least every six months and at the beginning of every  
swimming season.  
3. Keep the heater area clear and free from  
combustibles and flammable liquids.  
1. Examine the venting system. Make sure there are no  
obstructions in the flow of combustion and ventila-  
tion air.  
2. Visually inspect the main burner and the pilot burner  
flame. The normal color of the flame is blue. When  
flame appears yellow, burners should be inspected  
and cleaned; see Figure 10.  
Relief Valve  
In some installations, a  
relief valve is required  
on the MiniMax Plus.  
Standard  
Test the relief valve at  
least once a year by  
lifting the valve lever.  
(A.S.M.E. version varies  
slightly and has the relief  
valve pre-installed at  
factory.)  
Blue Flame  
3/8 to 1/2 in.  
Insulated  
Electrode  
Figure 11.  
A.S.M.E. Version  
Figure 10.  
Figure 9.  
ENERGY SAVING TIPS  
5. Set time clock to start circulation system no earlier  
than daybreak. The swimming pool loses less heat at  
this time.  
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.  
6. For pools that are only used on the weekends, it is  
not necessary to leave the thermostat set at 78° F.  
Lower the temperature to a range that can be  
2. Reduce the pool thermostat setting to 78° F. or  
lower. This is accepted as being the most healthy  
temperature for swimming by the American Red  
Cross.  
achieved easily in one day. Generally, this would be  
10° F. to 15° F., if pool heater is sized properly.  
7. During the winter or while on vacation, turn the  
heater off.  
3. Use an accurate thermometer.  
8. Set up a regular program of preventative  
maintenance for the heater each new swimming  
season. Check heat exchanger, controls, burners,  
operation, etc.  
4. When the proper maximum thermostat settings have  
been determined, tighten the thermostat knob  
stopper.  
SPRING AND FALL OPERATION  
will keep the pool and the surrounding ground warm  
enough to bring the pool up to a comfortable swimming  
temperature in a shorter period of time.  
If the pool is being used occasionally, do not turn the heater  
completely off. Set the thermostat down to 65° F. This  
WINTER OPERATION  
If the pool won't be used for a month or more, turn the  
heater off at the main gas valve. For areas where there is  
no danger of water freezing, water should circulate  
through the heater all year long, even though you are not  
heating your swimming pool. The MiniMax Plus should  
not be operated out doors at temperatures below 0° F. for  
propane and -20° F. for natural gas. 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/outlet header (see Figure 11.) allow-  
ing all water to drain out of the heater. It would be a  
good practice to use compressed air to blow the water  
out of the heat exchanger. (See additional notes under  
Important Notices in Introduction on page 3.)  
Rev. G 1-22-04  
P/N 471048  
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Maintenance (contd.)  
12  
RULE: 7.4 to 7.6 is a desirable pH range. It is essential  
to maintain correct pH, see Table 2.  
CHEMICAL BALANCE  
POOL AND SPA WATER  
If pH becomes too high (over alkaline), it  
has these effects:  
Your Pentair Pool Products pool heater was designed  
specifically for your spa or pool and will give you many  
years of trouble free service provided you keep your  
water chemistry in proper condition.  
1. Greatly lowers the ability of chlorine to destroy  
bacteria and algae.  
2. Water becomes cloudy.  
Three major items that can cause problems with your  
pool heater are improper pH, disinfectant residual, and  
total alkalinity. These items, if not kept properly bal-  
anced, can shorten the life of the heater and cause  
permanent damage.  
3. There is more danger of scale formation on the  
plaster or in the heat exchanger.  
4. Filter elements may become blocked.  
If pH is too low (over acid) the following  
conditions may occur:  
CAUTION  
Heat exchanger damage resulting from chemical  
imbalance is not covered by the warranty.  
1. Excessive eye burn or skin irritation.  
2. Etching of the plaster.  
3. Corrosion of metal fixtures in the filtration and  
recirculation system, which may create brown, blue,  
green, or sometimes almost black stains on the  
plaster.  
WHAT A DISINFECTANT DOES  
Two pool guests you do not want are algae and bacteria.  
To get rid of them and make pool water sanitary for  
swimming - as well as to improve the water's taste, odor  
and clarity - some sort of disinfectant must be used.  
4. Corrosion of copper in the heater, which may cause  
leaks.  
Chlorine and bromine are universally approved by health  
authorities and are accepted disinfecting agents for  
bacteria control.  
5. If you have a sand and gravel filter, the alum used as  
a filter aid may dissolve and pass through the filter.  
CAUTION: Do not test for pH when the chlorine  
residual is 3.0 ppm or higher, or bromine residual  
is 6.0 ppm or higher. See your local pool supply  
store for help in properly balancing your water  
chemistry.  
WHAT IS A DISINFECTANT  
RESIDUAL?  
When you add chlorine or bromine to the pool water, a  
portion of the disinfectant will be consumed in the  
process of destroying bacteria, algae and other oxidiz-  
able materials. The disinfectant remaining is called  
chlorine residual or bromine residual. You can deter-  
mine the disinfectant residual of your pool water with a  
reliable test kit, available from your local pool supply  
store.  
RULE: Chemicals that are acid lower pH. Chemicals  
that are alkaline raise pH.  
pH Control Chart  
Table 2.  
7.2  
7.4 7.6  
7.8  
8.0 8.2 8.4  
Add Acid  
6.8  
7.0  
Add Soda, Ash or  
Marginal Ideal Marginal  
You must maintain a disinfectant residual level adequate  
enough to assure a continuous kill of bacteria or virus  
introduced into pool water by swimmers, through the air,  
from dust, rain or other sources.  
Sodium Bicarbonate  
ALKALINITY High - Low:  
"Total alkalinity" is a measurement of the total amount  
of alkaline chemicals in the water, and control pH to a  
great degree. (It is not the same as pH which refers  
merely to the relative alkalinity/acidity balance.) Your  
pool water's total alkalinity should be 100 - 140 ppm to  
permit easier pH control.  
It is wise to test pool water regularly. Never allow  
chlorine residual to drop below 0.6 ppm (parts per  
million). The minimum level for effective chlorine or  
bromine residual is 1.4 ppm.  
pH - The term pH refers to the acid/alkaline balance of  
water expressed on a numerical scale from 0 to 14. A test  
kit for measuring pH balance of your pool water is avail-  
able from your local pool supply store; see Table 1.  
A total alkalinity test is simple to perform with a  
reliable test kit. You will need to test about once a  
week and make proper adjustments until alkalinity is  
in the proper range. Then, test only once every month  
or so to be sure it is being maintained. See your local  
pool dealer for help in properly balancing the water  
chemistry.  
Table 1.  
Strongly Acid  
pH Chart  
Neutral  
Strongly Alkaline  
0
1
2
3
4
5
6
7
8
9
10 11 12 13 14  
Muriatic Acid has a pH of about 0. Pure water is 7  
(neutral). Weak Lye solution have a pH of 13-14.  
P/N 471048  
Rev. G 1-22-04  
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13  
Installation Instructions  
SPECIFICATIONS  
IMPORTANT NOTICE: These installation instructions are designed for use by qualified personnel  
only, trained especially for installation of this type of heating equipment and related components. Some  
states require installation and repair by licensed personnel. If this applies in your state, be sure your  
contractor bears the appropriate license.  
Outdoor installation - stackless  
Model  
150  
"A" Dim  
17 7/8 in.  
20 7/8 in.  
23 7/8 in.  
26 7/8 in.  
29 7/8 in.  
"B" Dim  
6½ in.  
TM  
HIGH PERFORMANCE HEATER  
32  
195/200  
250  
9½ in.  
12½ in.  
15½ in.  
18½ in.  
300  
5-1/2  
"B" DIM.  
"A" DIM.  
350  
3
21 12  
400  
33 3/8 in. 22 3/8 in.  
Table 3.  
FRONT VIEW  
SIDE VIEW  
Outdoor installation - with vent kit  
Model  
150  
195/200 20 7/8 in.  
"A" Dim "B" Dim "C" Dim "D" Dim  
"E" DIM.  
"C"  
DIM.  
17 7/8 in.  
6½ in.  
9½ in.  
7¾ in.  
10 in.  
10 in.  
10¼ in.  
13 in.  
17 in.  
39¾ in.  
42¾ in.  
42¾ in.  
43¾ in.  
47¾ in.  
"D"  
DIM  
POWER  
PRESSURE  
HEAT  
HI-LIMIT  
POOL  
TM  
OFF  
HIGH PERFORMANCE HEATER  
HOT  
COLD  
HOT  
COLD  
SPA  
POOL TEMPERATURE  
POWER  
SPA/AUXILIARY TEMPERATURE  
250  
300  
350  
400  
23 7/8 in.  
26 7/8 in.  
29 7/8 in.  
12½ in.  
15½ in.  
18½ in.  
28"  
"B" DIM.  
"A" DIM.  
5-1/2  
33 3/8 in. 22 3/8 in.  
51¾ in.  
Table 4.  
1
21  
2
3
"E" DIM.  
Indoor installation - stack (USA only)  
Outdoor shelter installation (Canada)  
Model "A" Dim "B" Dim "C" Dim "D" Dim "E" Dim  
"C"  
150  
17 7/8 in.  
6½ in.  
9½ in.  
13 in.  
13 in.  
13 in.  
13 in.  
13 in.  
17 in.  
52¾ in.  
53 7/8 in.  
53 7/8 in.  
55 in.  
6 in.  
7 in.  
7 in.  
8 in.  
9 in.  
DIM.  
"D"  
DIM  
195/200 20 7/8 in.  
POWER  
PRESSURE  
HEAT  
HI-LIMIT  
250  
300  
350  
400  
23 7/8 in. 12½ in.  
26 7/8 in. 15½ in.  
29 7/8 in. 18½ in.  
33 3/8 in. 22 3/8 in.  
POOL  
TM  
OFF  
HIGH PERFORMANCE HEATER  
HOT  
COLD  
HOT  
COLD  
SPA  
POOL TEMPERATURE  
POWER  
SPA/AUXILIARY TEMPERATURE  
28  
1
2
14  
56 in.  
7
8
10  
5-1/2  
"B" DIM.  
"A" DIM.  
60¾ in.  
10 in.  
GAS LINE  
OPENING  
1
21  
2
3
Table 5.  
Rev. G 1-22-04  
P/N 471048  
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Installation (contd.)  
14  
WATER CONNECTIONS  
Reversible Inlet/Outlet Connection  
The MiniMax Plus heater 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 exchanger.  
TO  
POOL  
PUMP  
FILTER  
POOL  
HEATER  
MANUAL  
BY-PASS  
ISOLATION  
VALVE  
3
CHECK  
1
VALVE  
Reversing Water Connections  
Disassembly  
Tools needed:  
ISOLATION  
VALVE  
CHECK  
VALVE  
2
1
2
3
Optional.  
FROM  
POOL  
Required when installation is below water level.  
Required when flow rates exceed 120 gpm.  
Figure 12.  
1/4 in Nut Driver  
9/16 in. Socket and Wrench  
1/2 in. & 9/16 in. Open Wrench  
PLUMBING CONNECTIONS  
The MiniMax Plus heater has the unique capability of  
direct schedule 40 PVC plumbing connections. A  
Quick-Flange has been included with the MiniMax  
Plus to insure conformity with PurexTriton’s recom-  
mended PVC plumbing procedure. Other plumbing  
connections can be used. The instructions on page 13  
show methods for successfully connecting plumbing to  
the inlet/outlet header, with the Quick-Flange.  
1. Remove the inspection plates.  
2. Disconnect all wires from the high-limit  
switches except the short jumper wire. The  
exact order of the disconnection is not impor-  
tant.  
3. Disconnect the pressure switch wiring.  
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 in the Quick-Flange  
Accessory Bag.  
6. Install the temperature sensing bulb by passing  
the wires through the hole provided on the left  
side of the brace panel. Route wires through the  
support bracket.  
CAUTION  
Before operating the heater on a new installation,  
turn on the circulation pump and bleed all the air  
from the filter using the air relief valve on top of the  
filter. Water should flow freely through the heater.  
Do not operate the heater unless water in the pool/  
spa is at the proper level.  
7. Reconnect all the high limit wires. Reconnect  
the pressure switch wiring. Route the wires  
through the same hole as the thermostat sensor  
wires.  
MANUAL BY-PASS  
Where the flow rate exceeds the maximum 120  
GPM, a manual bypass should be installed and  
adjusted. After adjustments are made, the valve  
8. Reinstall the inspection plates.  
handle should be removed to avoid tampering.  
PLUMBING  
Model  
150  
Min.  
20  
Max. *  
120  
VALVES  
195/200  
250  
20  
120  
When any equipment is located below the surface of  
the pool or spa, valves should be placed in the  
circulation piping system to isolate the equipment  
from the pool or spa.  
30  
120  
300  
30  
120  
350  
40  
120  
400  
40  
120  
* Do not exceed the maximum recommended  
flow rate for the connecting piping.  
Check valves are recommended to prevent back  
siphon.  
Table 6.  
CAUTION  
Exercise care when installing chemical feeders so  
as to not allow back siphoning of chemical into the  
heater, filters or pump.  
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.  
P/N 471048  
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Installation (contd.)  
15  
WATER CONNECTIONS  
QUICK-FLANGE INSTALLATION INSTRUCTIONS  
Each MiniMax Plus Quick-Flange Accessory Kit contains the following items:  
One (1) Quick-Flange unit  
Four (4) 3/8 Bolts  
Two (2) Plastic sleeves  
Two (2) 2 in. Rubber gaskets  
Four (4) 3/8 in. Washers  
FOR 1½ & 2 in. SCHEDULE 40 PVC PIPE  
FOR 1½ & 2 in. COPPER PIPE  
Pipe  
Plastic Bushing  
Figure 13.  
Gasket/Sleeve  
Figure 15.  
Gasket  
1. Insert plastic sleeves into the “Quick-Flange”  
inlet/outlet openings.  
2. Slip the 2 in. rubber gaskets over the plastic  
sleeves.  
NOTE  
You “DO NOT” need the plastic bushings.  
*
1. Insert pipe into the inlet/outlet openings of the  
“Quick-Flange”  
3. Bolt the “Quick-Flange” to the header.  
NOTE  
Tighten the bolts evenly! Do not over tighten!  
2. Slip the rubber gaskets over the pipe, using the  
supplied 2 in. rubber gasket for 2 in. copper pipe  
or the 1½ in. rubber gasket (not supplied,  
available from the factory) for the 1½ in. copper  
pipe.  
4. Use plumbers roll or medium grit sand paper and  
clean the inlet/outlet openings of the “Quick-  
Flange”. Use the same method to clean the 2 in.  
PVC pipe. The sand paper will break up any  
grease or contaminant that may not be cleaned  
away with a primer.  
3. Bolt the “Quick-Flange” to the header.  
5. Use 711 PVC glue (or equivalent) and follow the  
manufacturer’s recommendations. Apply to the  
inlet opening of the “Quick-Flange”. Do the  
same to the PVC pipe and quickly insert the  
pipe into the “Quick-Flange” and twist the pipe  
a 1/4 turn. Do the same to the other opening of  
the “Quick-Flange”.  
6. For 1½ in. PVC pipe installations, first glue a 1½  
in. X 2 in. sch 40 PVC bushing (not supplied or  
shown) to the end of the pipe prior to gluing to  
the “Quick-Flange”.  
Figure 14.  
*
Rev. G 1-22-04  
P/N 471048  
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16  
Installation (contd.)  
Table 7.  
GAS CONNECTIONS  
Pipe Sized For Length Of Run In Equivalent Feet  
1/2 in.  
3/4 in.  
1 in.  
1¼ in.  
1½in.  
2 in.  
GAS LINE INSTALLATIONS  
Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP  
Model  
150  
Before installing the gas line, be sure to  
check which gas the heater has been  
designed to burn. This is important  
because different types of gas require  
different gas pipe sizes. The rating plate  
on the heater will indicate which gas the  
heater is designed to burn. Table 7,  
shows which size pipe is required for the  
10' 40' 50' 150' 150' 600'  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
20' 30' 80' 125' 250' 450' 600'  
195/200  
250  
10' 20' 50' 70' 150' 250' 500' 600'  
-
-
-
10' 30' 50' 100' 200' 350' 400' 600'  
300  
10' 20' 30' 70' 125' 250' 250' 500' 500'  
10' 20' 60' 100' 150' 200' 450' 400'  
350  
-
400  
REGULATED MANIFOLD PRESSURE TEST  
1. Attach the manometer to the heater jacket.  
2. Shut off the main gas valve.  
distance from the 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.  
3. Remove 1/8 in. NPT plug on the outlet side of the  
valve and screw in the fitting from the manometer kit.  
4. Connect the manometer hose to the fitting.  
5. Fire the heater.  
6. The manometer must read 4 in. WC for natural gas,  
11 in. WC for propane gas, while the heater is  
operating.  
7. For adjustment, remove the Regulator Adjustment  
Cap and using a screwdriver turn the screw clock-  
wise to increase - counterclockwise to decrease gas  
When sizing gas lines, calculate three (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.  
pressure.  
Regulator Adjustment Cap  
1/8" NPT Plug  
(Inlet Press)  
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 the connecting gas  
pipe will be necessary. Make this reduction as close  
to the heater as possible.  
Figure 16.  
ON  
OFF  
1/8" NPT Plug  
(Manifold Press)  
REGULATOR  
ADJUSTMENT CAP  
The heater and any other gas appliances must be  
disconnected from the gas supply piping system  
during any pressure testing on that system, (greater  
that ½ PSIG).  
Figure 17.  
PILOT  
HONEYWELL  
1/2 P.S.I.  
PRESS  
TAP  
PILOT  
ADJ.  
The heater and its gas connection must be leak  
tested before placing the heater in operation. Do not  
use flame to test the gas line. Use soapy water or  
another nonflammable method.  
CAUTION  
The use of Flexible Connectors (FLEX) is NOT  
recommended as they cause high gas pressure drops.  
A manual main shut-off valve must be installed  
externally to the heater.  
MINIMAX PLUS GAS PRESSURE REQUIREMENTS*  
Propane  
Natural  
Maximum inlet gas pressure 10 in. WC 14 in. WC  
Minimum inlet gas pressure **5 in. WC 12 in. WC  
Normal manifold pressure  
** 6 WC for 400 model  
*All Readings are taken with the heater fired. Any adjustments  
made with heater off will give incorrect readings.  
4 in. WC 11 in. WC  
WARNING  
Do not install the gas line union inside the heater  
cabinet. This will void your warranty.  
Table 8.  
P/N 471048  
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Installation (contd.)  
17  
VENTILATION  
STACK TYPE OUTDOOR VENT KIT  
Model  
150  
Vent Cap Product No. Vent Dia.  
OUTDOOR INSTALLATION ONLY  
OV15  
OV20  
OV25  
OV30  
OV35  
OV40  
460237  
460222  
460223  
460224  
460225  
460226  
6 in.  
7 in.  
7 in.  
8 in.  
9 in.  
10 in.  
(See additional instructions for outdoor Power-  
Max units in PowerMax Appendix)  
195/200  
250  
For outdoor installation with built in vent top, the heater  
must be placed in a suitable area on a level, noncombus-  
tible surface. Do not install the heater under an overhang  
with clearances less than 3 feet from the top of the  
heater. The area under an overhang must be open on  
three sides.  
300  
350  
400  
Table 9.  
Outdoor Stack  
Top Cover  
IMPORTANT!  
In an outdoor installation it is important to protect  
your heater from water damage. Ensure water is  
diverted from overhanging eves with a proper gutter/  
drainage system. The heater must be set on a level  
foundation for proper rain drainage.  
Flue Adaptor  
Inner Panel  
Maintain minimum clearances as indicated below. Install  
a minimum of 4 feet below, and 4 feet horizontally from  
any opening to a building.  
Flue Collector  
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 the front of  
the heater.  
Figure 19.  
Figure 20.  
6"  
6"  
OUTDOOR VENT CAP INSTALLATION  
24"  
The MiniMax Plus heater is shipped standard as an  
outdoor stackless unit. To install the outdoor vent kit:  
1. Take out the louvered outer top after first  
removing all 1/4 in. sheet metal screws attaching  
it along its perimeter to the cabinet. Set it aside.  
18"  
2. Place the flue adaptor over the flue collector  
opening. Temporarily, put the top cover, from the  
kit, on with the label to the front of the heater.  
Center the flue adaptor evenly inside the top cover  
flue stack opening. Remove the top cover and  
secure the centered flue adaptor to the inner panel  
with the provided #8 x 1/2 in. drill qwik screws.  
3. Place the top cover, with the hole for the stack, on  
the heater cabinet.  
4. Install the vent stack through the hole in the top  
cover, over the flue adaptor top ring.  
5. Using a 3/32 in. drill bit, position the “L” bracket  
to hold the top cover and outdoor stack. Drill the  
pilot holes through the “L” bracket holes to accept  
the screws.  
6. Secure the vent stack and the inner top with the #8  
x 1/4 in. sheet metal screws through the “L”  
brackets.  
Figure 18.  
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 feet from any wall will  
minimize downdraft.  
Unusually high prevailing wind conditions and  
downdrafts may require the use of a stack type  
outdoor vent kit (available at additional cost).  
NOTE  
This unit shall not be operated outdoors at  
temperatures below 0o F. for propane and -20o F. for  
natural gas.  
Rev. G 1-22-04  
P/N 471048  
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18  
Installation (contd.)  
INDOOR INSTALLATION (USA ONLY)  
OUTDOOR SHELTER INSTALLATION (CANADA)  
(See additional instructions for outdoor  
PowerMax units in PowerMax Appendix)  
All products of combustion and vent gases must  
be completely removed to the outside atmosphere  
through a vent pipe which is connected to the  
draft hood. A vent pipe extension of the same  
size must be connected to the draft hood and  
extended at least 2 feet higher than highest point  
of the roof within a 10 foot horizontal radius, and  
at least 3 ft. higher than the point at which it  
passes through the roof, or as permitted by local  
code; see Figures 21 and 22. The vent should  
terminate with an approved vent cap (weather  
cap) for protection against rain or blockage by  
snow. Double-wall vent pipe and an approved  
roof jack shall be employed through the roof  
penetration. The use of double-walled type B vent  
pipe is recommended.  
Installations in basements, garages, or  
underground structures where flammable liquids  
may be stored must have the heater elevated 18  
inches from the floor using a non-combustible  
base. The following minimum clearances from  
combustible materials must be provided.  
Side  
18 in.  
6 in.  
Front  
Back  
Top  
Water Connection  
Remaining  
24 in.  
6 in.  
Ceiling Clearance  
36 in.*  
*To ceiling or roof.  
Vent terminated at  
least 24 in. above  
any object within 10 ft.  
The draft hood must be installed so as to be in the  
same atmospheric pressure zone as the  
combustion air inlet to the pool heater. The  
certified (factory) draft hood must not be  
modified in any way and must be employed in  
every indoor installation (with the exception of  
the PowerMax units).  
10 ft.  
Vent  
Cap  
Ridge  
2 ft. min.  
3 ft. min.  
Roof  
Jack  
Chimney  
The heater must be located as close as practical to  
a chimney or gas vent. The heater should be  
installed at least 5 feet away from the pool or spa.  
Figure 21.  
Vent Cap and  
Riser Furnished  
by Installer  
The heater must be placed in a suitable room on a  
non-combustible floor or on a non-combustible  
base and in an area where leakage from heat  
exchanger or water connections will not result in  
damage to the area adjacent to the heater or the  
structure. When such locations cannot be  
avoided, it is recommended that a suitable drain  
pan with adequate drainage, be installed under the  
heater. The pan must not restrict air flow.  
* Rise  
Air Supply  
Ventilation  
Air Supply  
Gas Combustion  
* 1” Rise Per Foot  
Recommended  
Figure 22.  
P/N 471048  
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Installation (contd.)  
19  
NOTE  
The heater requires two uninterrupted air supply  
openings; one for ventilation and one to supply  
oxygen for proper gas combustion. The air supply  
openings should be sized according to Tables 10.  
and 11.  
b) Construct a non-combustible base from masonry  
blocks as illustrated, see Figure 23.  
Air supply requirements below apply to all  
MiniMax heaters, including PowerMax versions.  
BASE FOR USE ON  
COMBUSTIBLE FLOORS  
T
O
H
All Air From Inside  
TM  
ER  
AT  
HE  
CE  
AN  
M
OR  
RF  
PE  
GH  
HI  
Air for Combustion  
Sq. In.  
Air Ventilation  
Sq. In.  
Model  
IT  
IM  
-L  
HI  
AT  
HE  
RE  
SU  
ES  
PR  
L
OLD  
RE  
ER  
P
OO  
C
W
PO  
TU  
FF  
RA  
PE  
O
A
H
OT  
LIA  
T
EM  
SP  
RY  
U
XI  
E
R
A
/
A
W
P
PO  
S
6" Min.  
LD  
RE  
CO  
TU  
RA  
PE  
T
HO  
T
EM  
OL  
PO  
150  
195/200  
250  
150  
200  
250  
300  
350  
400  
150  
200  
250  
300  
350  
400  
6" Min.  
SHEET METAL  
BLOCKS  
300  
HOLLOW MASONARY BLOCKS, NOT LESS THAN 4" THICK  
(LAID WITH ENDS UNSEALED AND JOINTS MATCHED  
FOR AIR CIRCULATION). COVER BLOCKS WITH  
24 GA. (MIN.) GALVANIZED SHEET METAL.  
350  
400  
Figure 23.  
Table 10.  
All Air From Outside  
Air for Combustion  
Sq. In.  
Air Ventilation  
Sq. In.  
Model  
150  
195/200  
250  
37  
37  
50  
50  
CAUTION  
63  
63  
Chemicals should not be stored near the heater  
installation. Combustion air can be contaminated by  
corrosive chemical fumes which can void the warranty.  
300  
77  
77  
350  
90  
90  
400  
100  
100  
Table 11.  
INSTALLATION ON FLOORS CONSTRUCTED  
OF COMBUSTIBLE MATERIALS  
The heater may be placed on a “combustible floor”  
using either of the two methods listed below:  
STACK TYPE INDOOR DRAFT HOOD KIT  
The proper draft hood and adapter must be installed on  
the heater as shown below and on page 20:  
a) Use Listed Factory Non-combustible Base Kit  
for use on combustible floors.  
Model Non-Combustible Base Kit  
Model Draft Hood Product No. Vent Dia.  
150  
195/200  
250  
471389  
471390  
471391  
471392  
471393  
471394  
150  
195/200  
250  
DH15  
DH20  
DH25  
DH30  
DH35  
DH40  
460227  
460228  
460230  
460231  
460233  
460234  
6 in.  
7 in.  
7 in.  
8 in.  
9 in.  
10 in.  
300  
300  
350  
350  
400  
400  
Table 13.  
Table 12.  
Rev. G 1-22-04  
P/N 471048  
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Installation (contd.)  
20  
Draft Hood  
Top Cover  
INDOOR DRAFT HOOD INSTALLATION  
1. Take out the louvered outer top piece after first  
removing the sheet metal screws, attaching it to  
the cabinet.  
Adaptor  
Screw  
(2 PLC's)  
2. Install the adaptor (vent kit).  
3. Install the top cover (vent kit).  
4. Install the draft hood (vent kit).  
Use the provided screws to secure the vent assembly.  
HEATER  
Figure 24.  
Transformer Wiring Instruction  
ELECTRICAL, IID ELECTRONIC UNITS  
Electrical Rating  
60 Hz  
115 V.A.C. or 230 V.A.C.  
50/60 Hz 208 V.A.C. or 240 V.A.C.  
NOTE  
If any of the original wiring supplied with this  
heater must be replaced, installer must supply  
(No. 18 AWG 105° C. U.L. approved AWM low  
energy stranded) copper wire or it's equivalent.  
In Canada: wires must be CSA approved.  
WARNING  
The heater must be electrically grounded and  
bonded in accordance with local codes or, in the  
absence of local codes, with the latest national  
electrical codes ANSI/NFPA No. 70.  
In Canada: CSA standard C22.1 Canada Electrical  
Code Part 1 and/or local codes.  
Always use crimp type connectors when connecting  
two wires.  
This heater is equipped with a reversible junction box  
to allow line voltage to be wired from either side.  
Figure 26.  
Figure 25.  
P/N 471048  
Rev. G 1-22-04  
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Installation (contd.)  
21  
MiniMax Plus Electronic Ignition Wiring Diagram  
PLUG  
PLUG  
4
3
2
1
3
2
1
6
T F U S E  
H L M T  
5
4
3
2
1
2
P R E S S  
1
Rev. G 1-22-04  
P/N 471048  
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22  
Installation (contd.)  
PILOT  
GENERATOR  
MINIMAX WIRING DIAGRAM  
(MILLIVOLT) DUAL THERM  
(HONEYWELL ELECTRONIC)  
TH/PP  
WHT  
RED  
TH  
PP  
IF ORIGINAL FACTORY WIRING MUST BE REPLACED,  
INSTALLER MUST SUPPLY UL OR CSA (IF CANADA)  
APPROVED WIRE, 18 GAUGE, 600V, 105 C˚ TEMPERATURE RATING.  
THERMAL FUSE WIRING MUST BE REPLACED WITH  
UL OR CSA (IF CANADA) APPROVED WIRE,  
SAFETY  
PRESS  
SWITCH  
GAS VALVE  
WHT  
HI-LIMIT  
SHUT-OFF  
WHT  
WHT  
WHT  
18 GAUGE, 600V, 125 C˚ TEMPERATURE RATING.  
INTERCONNECTING WIRING TO APPLIANCE MUST  
CONFORM TO THE NATIONAL ELECTRICAL  
THERMAL  
CUT-OFF  
ORN  
CODE OR SUPERCEDING LOCAL (WIRING) CODES.  
WHT  
WHT  
POT 1  
POT 2  
THERMOSTAT BOARD  
POOL  
SPA  
MiniMax Plus Millivolt Wiring Diagram  
After 1-15-01  
OFF  
SENSOR  
Figure 27.  
REMOTE SWITCH DUAL THERM IID ONLY  
JUMPER REQUIRED IF NO 2 WIRE REMOTE SWITCH  
24 VAC  
PRESS HILMT TFUSE  
VALVE  
IGNITION MOD  
3 Wire Remote  
OUT  
RETURN  
THERMOSTAT CIRCUIT BOARD  
SPA COM POOL  
TPROBE  
REMOTE POOL/OFF/SPA  
THERMOSTAT SELECT SWITCH  
FRONT PANEL  
POOL/  
OFF/SPA  
THERMOSTAT SELECT SWITCH  
Figure 28.  
JUMPER REQUIRED IF NO 2 WIRE REMOTE SWITCH  
24 VAC PRESS HILMT TFUSE  
RETURN  
VALVE  
IGNITION MOD  
OUT  
2 Wire Remote  
THERMOSTAT CIRCUIT BOARD  
SPA COM POOL  
TPROBE  
FRONT PANEL  
POOL/OFF/SPA  
THERMOSTAT SELECT SWITCH  
Figure 29.  
NOTE: When connecting a remote control to the MiniMax Plus, you must install the low voltage  
thermostat wires in separate conduit from ANY line voltage wires. Failure to follow these  
instructions will cause the thermostat relay to react erratically..  
P/N 471048  
Rev. G 1-22-04  
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23  
Troubleshooting - General  
Possible Cause  
Remedy  
Heater will not come on  
Automatic ignition system fails  
Check if electrical connections are  
correct and securely fastened –  
If YES, call serviceperson.  
Pump not running  
Place pump in operation  
Check for leaks  
Pump air locked  
Filter dirty  
Clean filter  
Pump strainer clogged  
Defective wiring or connection  
Defective pressure switch  
Defective gas controls  
On-Off switch in "OFF" position  
Clean strainer  
Repair or replace wires  
Replace switch  
Call serviceperson  
Turn switch to "ON"  
Heater Short Cycling (Rapid On and Off Operation)  
Insufficient water flow  
Clean filter and pump strainer  
Defective wiring  
Repair or replace wiring  
Call serviceperson  
Call serviceperson  
Defective flow valve or out of adjustment  
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  
Heater exchanger scaled  
Shut off gas supply and call serviceperson  
Shut off gas supply and call serviceperson  
CAUTION  
Please consult the latest edition of the “MiniMax Plus Service Manual” for complete service and repair  
instructions. Repairs should only be attempted by properly trained service personnel.  
Rev. G 1-22-04  
P/N 471048  
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24  
MINIMAX PLUS HEATER - ALL MODELS  
39  
INNER TOPS  
Model No. Part No.  
15  
470024  
470025  
470026  
470027  
470028  
470029  
200  
250  
300  
350  
400  
38  
5
37  
4
3
2
1a  
25  
36  
21  
35  
6
1
33  
7
32  
31  
34  
27  
28  
22  
23  
29  
26  
9
30  
41  
13  
12  
42  
10  
14  
15  
24  
44  
40  
20  
16  
17  
18  
19  
11  
8
P/N 471048  
Rev. G 1-22-04  
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25  
MiniMax Plus (Only) Parts List  
ITEM DESCRIPTION  
Vent kit assy. (indoor)  
QTY  
1
150  
195/200  
250  
300  
350  
400  
1
460227 460228 460230 460231 460233 460234  
460237 460222 460223 460224 460225 460226  
070994 070994 070994 070994 070994 070994  
074216 074216 074216 074216 074216 074216  
073739 073739 073739 073739 073739 073739  
070416 070416 070416 070416 070416 070416  
072180 072180 072180 072180 072180 072180  
070951 070951 070951 070951 070951 070951  
471360 471360 471360 471360 471360 471360  
470179 470179 470179 470179 470179 470179  
073584 073584 073584 073584 073584 073584  
073585 073585 073585 073585 073585 073585  
470122 470122 470122 470122 470122 470122  
470184 470184 470184 470184 470184 470184  
470186 470186 470186 470186 470186 470186  
470295 470296 470297 470298 470299 470187  
470987 470988 470989 470990 470991 470992  
471020 471021 471022 471023 471024 471025  
075468 075604 075488 075605 075606 075490  
070256 075525 070257 075526 075527 070258  
073998 073998 073998 073998 073998 073998  
073999 073999 073999 073999 073999 073999  
075457 075457 075457 075457 075457 075457  
075458 075458 075458 075458 075458 075458  
075191 075191 075192 075192 075193 075193  
076084 076084 076085 076085 076086 076086  
073752 075499 073751 075500 075501 073750  
073906 075508 073905 075509 075510 073904  
075493 075496 075494 075497 075498 075495  
075502 075505 075503 075506 075507 075504  
1a  
2
Vent kit assy. (outdoor)  
1
Return header  
1
3
Bracket washer  
2
4
Bolt HH 3/8" x 2"  
4
5
Bolt 3/8" - 16 x 1 1/2"  
4
6
Washer 3/8" ID 1" OD  
4
7
Tube seal gasket  
18  
1
8
Transformer - w/circuit breaker - dual voltage  
ElectronicThermostat circuit board - IID Models  
Module natural gas  
9
1
1
10  
Module propane gas  
1
11  
12  
13  
Junction Box (IID Units)  
1
Thermostat knob  
2
Switch rocker (single pole & double throw)  
Control panel assy. (complete) - IID Nat  
Control panel assy. (complete) - IID Pro  
Control panel assy. (complete) - Millivolt  
Door - IID or Millivolt  
1
1
14  
1
1
15  
16  
1
Manifold burner  
1
Gas valve natural - IID  
1
Gas valve propane- IID  
1
17  
18  
19  
Gas valve natural - Millivolt  
Gas valve propane - Millivolt  
Pilot tube - IID  
1
1
1
Pilot tube - Millivolt  
Burner tray assy. natural (complete) - IID  
Burner tray assy. propane (complete) - IID  
Burner tray assy. natural (complete) - Millivolt  
Burner tray assy. propane (complete) - Millivolt  
1
1
1
1
2 EA.  
3 EA.  
4 EA.  
5 EA.  
6 EA.  
7 EA.  
20  
20a  
21  
22  
23  
24  
25  
26  
Burner  
070230 070230 070230 070230 070230 070230  
470550 470550 470550 470550 470550 470550  
470190 470190 470190 470190 470190 470190  
073858 075586 073857 075587 075588 073856  
072134 072134 072134 072134 072134 072134  
075459 075459 075459 075459 075459 075459  
072138 072138 072138 072138 072138 072138  
471678 471678 471678 471678 471678 471678  
471424 471424 471424 471424 471424 471424  
073989 073989 073989 073989 073989 073989  
074015 074015 074015 074015 074015 074015  
075492 075492 075492 075492 075492 075492  
075284 075284 075284 075284 075284 075284  
Burner with Pilot Bracket  
Pressure switch  
1
1
1
1
1
1
2
1
1
4
2
1
Combustion chamber assy. (complete)  
Valve drain 3/4"  
Presslite igniter assy. (Millivolt Units only)  
Valve relief 3/4" 50# - ASME or Local Code  
Potentiometer (Millivolt Units only)  
Flow valve assy., Standard (complete)  
Flow valve assy., ASME (complete)  
Flow valve gasket  
27  
28  
29  
30  
Bolt 3/8" - 16 x 2 1/2  
Quick flange Kit  
Rev. G 1-22-04  
P/N 471048  
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26  
MiniMax Plus (Only) Parts List, contd.  
ITEM DESCRIPTION  
QTY  
150  
195/200  
250  
300  
350  
400  
31  
Bushing in/out Lexan  
2
2
2
2
1
1
1
070544 070544 070544 070544 070544 070544  
071895 071895 071895 071895 071895 071895  
070229 070229 070229 070229 070229 070229  
071017 071017 071017 071017 071017 071017  
070985 070985 070985 070985 070985 070985  
074452 075628 074451 075629 075630 074074  
470364 470365 470366 470367 470368 470369  
Sleeve, rubber in/out 2"  
Sleeve, rubber in/out 1½"  
Safety Shutoff  
32  
33  
34  
Main header (in/out)  
Heat exchanger (without heads)  
Heat exchanger (with heads)  
35  
8 ea.  
8 ea.  
8 ea.  
8 ea.  
16 ea.  
16 ea.  
070277 075559 070276 075560 070277 070278  
073810 073810 073810 073810 073810 073810  
073864 075622 073863 075623 075624 073862  
470471 470472 470473 470474 470475 470476  
075783 075784 075785 075786 075787 075788  
471677 471677 471677 471677 471677 471677  
073789 073789 073789 073789 073789 073789  
073790 073790 073790 073790 073790 073790  
470180 470180 470180 470180 470180 470180  
36  
37  
Baffle  
Baffle hold down (2) baffles on 400  
1
1
1
1
1
38  
39  
40  
41  
42  
43  
44  
Flue collector  
Outdoor Top assy.  
Lightback Shield (Propane Gas units only)  
Electronic Thermostat (Millivolt models)  
Panel (return)  
Panel (in/out)  
Thermistor (probe) - (IID models)  
1
* Not Shown  
*
*
*
*
*
*
*
*
*
*
*
*
Plastic mounting bracket  
Wire Kit - Harness IID (complete)  
Clips for wire harness  
Wire Kit - Millivolt  
070715 070715 070715 070715 070715 070715  
470965 470965 470965 470965 470965 470965  
471277 471277 471277 471277 471277 471277  
075511 075511 075511 075511 075511 075511  
071703 071703 071703 071703 071703 071703  
071698 071698 071698 071698 071698 071698  
071716 071716 071716 071716 071716 071716  
071659 071659 071659 071659 071659 071659  
075692 075692 075692 075692 075692 075692  
070551 070551 070551 070551 070551 070551  
470414 470414 470414 470414 470414 470414  
073725 073725 073725 073725 073725 073725  
Screw 8 x 1/4" HH  
Screw 8 x 1/2" HH  
Screw 6 x 1/4"  
Screw 10 -32 x 1/4"  
Screw 10-32 x 3/16  
Bushing 1/2"  
Therm knob stopper  
Bolt 5/16" - 18 x 3/4'  
2
2
3 ea.  
N or P  
4 ea.  
N or P  
5 ea.  
N or P  
6 ea.  
N or P  
7 ea.  
N or P  
8 ea.  
N or P  
Orifice main burner natural  
Orifice main burner propane  
Pilot - natural - IID  
073727 073727 073727 073727 073727 073727  
073728 073728 073728 073728 073728 073728  
471204 471204 471204 471204 471204 471204  
471205 471205 471205 471205 471205 471205  
471292 471292 471292 471292 471292 471292  
471291 471291 471291 471291 471291 471291  
071515 071515 071515 071515 071515 071515  
075173 075173 075173 075173 075173 075173  
471740 471740 471740 471740 471740 471740  
470178 470178 470178 470178 470178 470178  
471293 471293 471293 471293 471293 471293  
471328 471328 471328 471328 471328 471328  
470181 470181 470181 470181 470181 470181  
070715 070715 070715 070715 070715 070715  
074540 074540 074540 074540 074540 074540  
471271 471271 471271 471271 471271 471271  
072253 072253 072253 072253 072253 072253  
071240 071240 071240 071240 071240 071240  
*
*
*
*
*
*
*
*
*
*
*
*
*
1
1
1
1
1
1
1
1
1
1
2
Pilot - propane - IID  
Pilot - natural - millivolt  
Pilot - propane - millivolt  
Pilot - generator  
Thermal cutoff - fusible link  
Thermistor (probe) complete (Millivolt models)  
Power element (flow-valve)  
Pilot rainshield  
Pilot electrode (only)  
Stem, thermostat control (IID models)  
Clips for transformer  
*
*
*
*
*
"L" brackets  
3
Bracket adapter Q379 pilot, MV  
Jumper  
Door latch  
P/N 471048  
Rev. G 1-22-04  
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PowerMax™ Pool & Spa Heater  
OPERATION & INSTALLATION MANUAL  
(APPENDIX)  
INSTALLER: AFFIX THESE INSTRUCTIONS  
TO OR ADJACENT TO POOL & SPA HEATER  
Pentair Pool Products, Inc.  
1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151  
10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400  
A-1  
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Rev. G 1-22-04  
P/N 471048  
PowerMax™  
Pool and Spa Heater  
INTRODUCTION  
This manual provides information for the proper installation, operation and  
maintenance of the PowerMax pool and spa heater. Please read these installation and  
operation instructions thoroughly before attempting installation or operation of your  
pool and spa heater.  
GENERAL SPECIFICATION  
...For the installer and operator of the PowerMax 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.  
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.  
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.  
The PowerMax Induced Draft Pool and Spa Heater is a fan assisted balanced flue gas  
combination, the field installation kit is designed for application to the PurexTriton  
Pool and Spa Heater Electronic Ignition Models 150 to 400. The PowerMax is  
approved for both indoor and outdoor installation using either natural gas or propane.  
The unit operates in both vertical and horizontal reduced vent pipe locations, in both  
the new and existing installations, and for applications such as through the (side) wall  
venting.  
MODEL NO.  
INPUT  
MBH  
MINIMUM  
DISCHARGE DIA  
(Inches)  
150  
200  
250  
300  
350  
400  
150  
200  
250  
300  
350  
400  
3
3
4
4
4
4
Table 1.  
A-2  
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P/N 471048  
Rev. G 1-22-04  
MOUNTING ASSEMBLY  
Follow these instructions if the PowerMax  
venting system was purchased as an assembly  
kit.  
1. Remove the vent kit assembly (indoor).  
2. Mount the plenum assembly on the flue collector  
top using the screw provided.  
3. Connect the wire harness to the heater control box.  
Follow the instructions on page 5.  
4. Mount the new top on the top of the heater. Using  
a #28 drill bit to drill the four holes on the right  
side of the heater for the mounting screws. The  
front and back side of the top will snap into the  
heater with no screws.  
Figure 1.  
DESCRIPTION OF SYSTEM OPERATION  
SYSTEM OPERATION:  
1. Set the thermostat to the lowest setting.  
2. Push the power switch off. The electric power supply requirement is:  
• 115 volts 60 Hz, 1 Ph, 1.5 Amp  
3. Remove the door.  
4. Push in the gas control knob slightly and turn clockwise  
to “OFF”.  
5. Wait (5) minutes to clear out any gas. If you then smell gas STOP. Follow the safety information.  
If you don’t smell gas, go to the next step.  
6. Turn the knob on the gas control counterclockwise  
7. Replace the door.  
to “ON”.  
8. Make sure the pump is running and is primed.  
9. Push the power switch on.  
10. Set the thermostat to the desired setting.  
• a. Fan motor starts, draft proving switch closes.  
• b. Ignition module energized.  
• c. Check for spark at the gas pilot.  
11. The pilot should spark and then ignite, then the main burners will ignite.  
12. Heater will operate until the desired temperature is reached.  
AIR PRESSURE SWITCH  
PRESSURE SWITCH  
OPERATION  
The air pressure switch is a safety device to insure that  
the blower is operating and has been designed to monitor  
the vacuum (negative) pressure within the fan housing.  
The air pressure switch is in the ignition module circuit  
and the ignition module does not operate unless the  
switch is closed.  
Figure 2.  
A-3  
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Rev. G 1-22-04  
P/N 471048  
VENTING  
The vent pipe must be the same size or larger than what is indicated in Table 1. The PowerMax heaters are  
capable of a 360-degree discharge rotation and operate with a positive vent static pressure and with a vent gas  
temperature less than 400 F. The total length of the horizontal run must not exceed an equivalent of 45 feet. For  
all cases, each 90-degree elbow reduces the maximum horizontal vent run by 8 feet and each 45-degree elbow in  
the vent run reduces the maximum vent run by 4 feet. See Table 2 for the maximum vent lengths using a 90  
degree and 45 degree elbows. The PowerMax induced-draft pool and spa heater uses positive pressure to push  
flue gases through the vent pipe to the outside. This requires a completely sealed vent system--single wall vent  
pipe with sealed-seams and joints may be used. Flue gases under positive pressure may escape into the dwell-  
ing with any cracks or loose joints in the vent pipe, or improper vent installation. The vent pipe must be of a  
sealed-seam construction such as those listed for use with category III appliances. Alternately, single wall or  
double-wall type B duct which has had duct seams and joints permanently sealed using cements or other suitable  
means which are rated for use at the flue gas temperatures of 325° F. and are permanent are acceptable. The use  
of listed thimbles, roof jacks and/or side vent terminals are required; and the proper clearances to combustible  
materials must be maintained in accordance with type of vent pipe employed- in the absence of a clearance  
recommendation by the vent pipe manufacturer, the requirements of the Uniform Mechanical Code should be  
met. The ventilation air and combustion air requirements for the PowerMax heaters are identical to the  
requirements for the Standard MiniMax heaters of the same output capacities and can be found in the main  
section of the Operation/Installation Manual, page 18. It is recommended that vent runs over 18 feet be insu-  
lated to reduce condensation related problems and/or the use of a condensate trap in the vent run close to the  
heater may be necessary in certain installations such as cold climates. The PowerMax is suitable for through-the-  
wall venting. (Refer to page A-5, diagram 1.).  
Recommended sources for Side-wall vent hood terminals include: The Field Controls Co. (2308 Airport Road,  
Kingston, NC 28501, (800) 742-8368) and Tjernlund Products Inc. (1601 Ninth Street, White Bear Lake, MN  
55110, (800) 255-4208)--consult manufacturer for model information and availability.  
CAUTION  
Do NOT combine exhaust vent pipes to a common exhaust vent in multiple unit installations. Run separate vent pipes.  
Reduced Maximum Equivalent Vent Run (feet)  
Additional 90° elbows  
after first elbow  
Additional 45° elbows  
after first elbow  
Quantity  
Maximum Length  
Quantity  
Maximum Length  
1 (2 total)  
2 (3 total)  
3 (4 total)  
37  
29  
21  
1 (2 total)  
2 (3 total)  
3 (4 total)  
41  
37  
33  
Table 2.  
Figure 3.  
A-4  
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P/N 471048  
Rev. G 1-22-04  
31  
A-5  
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Rev. G 1-22-04  
P/N 471048  
A-6  
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P/N 471048  
Rev. G 1-22-04  
PowerMax Electronic Ignition Wiring Diagram  
PLUG  
PLUG  
4
3
2
1
3
2
1
6
T F U S E  
H L M T  
5
4
3
2
1
2
P R E S S  
1
A-7  
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Rev. G 1-22-04  
P/N 471048  
INSTRUCTION FOR WIRING A POWERMAX INDUCED DRAFT  
ASSEMBLY TO A POOL HEATER WITH IID IGNITION.  
WARNING  
Make sure all power is off before wiring the heater. The Power vent assembly only operates on a 120 VAC.  
The following instructions configure the power vent assembly to operate with the PowerMax on a single 120  
VAC circuit. Take care as wiring errors may burn-out the transformer and blower motor.  
If the Field installation is supported and the installed heater operates from 230 VAC, there must be a  
separate 120 VAC service ran for the Power vent assembly.  
1. Route the PowerMax wiring through a corner opening into the lower compartment area.  
2. Disconnect the orange wire from the ignition module pin 6 (24V) and connect it to the orange wire from  
the air pressure switch.  
3. Connect the blue wire from the air pressure switch to the ignition module pin 6 (24V).  
4. The green wire that comes from the relay connect to the same place ignition module is grounded in the  
main control box.  
5. Twist the red and white/red tracer wires from the transformer with the white wire from the fan motor.  
Using a wire nut, connect the common wire from the 120 VAC line circuit with these wires.  
6. Twist the black and white/black tracer wires from the transformer with the black wire from the fan motor.  
Using a wire nut, connect the hot wire from the 120 VAC line circuit with these wires.  
7. Connect the branch circuit’s safety ground wire (green) to the heater ground lug.  
(Refer to Figure 4.)  
CAUTION  
The heater must be electrically grounded and bonded in accordance with the local codes or, in absence of  
local codes, with the latest national codes ANSI/NFPA No. 70.  
A-8  
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P/N 471048  
Rev. G 1-22-04  
WIRING DIAGRAM FOR POWERMAX KIT  
AIR PRESSURE  
SWITCH  
BLACK  
BLACK  
GREEN  
24 VAC RELAY  
GRD  
FAN  
MOTOR  
HEATER  
GROUND  
LUG  
BLACK  
HOT  
120 VAC ONLY  
WHITE  
COMMON  
ORANGE  
BLUE  
GREEN  
SAFETY  
GROUND  
MALE  
TAB  
FEMALE  
TAB  
FEMALE  
TAB  
TO GROUND  
MAIN CONTROL BOX.  
ORANGE  
TO IGNITION  
TO THERMOSTAT  
CIRCUIT BOAD  
MODULE PIN 6  
24V  
Figure 4.  
A-9  
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Rev. G 1-22-04  
P/N 471048  
POWERMAX HEATER - ALL MODELS  
1
38  
37  
5
4
3
2
OPTIONAL OUTDOOR VENT  
25  
21  
36  
Models 150 - 200  
Models 250 - 400  
471395  
471396  
35  
6
33  
32  
7
31  
34  
27  
22  
28  
23  
29  
30  
9
13  
12  
10  
14  
15  
40  
20  
16  
17  
19  
11  
8
18  
A-10  
P/N 471048  
Rev. G 1-22-04  
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PowerMax Heater (Only) Parts List  
ITEM DESCRIPTION  
QTY  
150  
195/200  
250  
300  
350  
400  
1
PowerMax Vent Kit (complete)*  
1
460048 460049 460050 460051 460052 460221  
(Power Max Vent replacement parts  
detailed in PowerMax Appendix, A-13)  
2
3
4
5
6
7
8
9
Return header  
1
2
4
4
4
18  
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
070994 070994 070994 070994 070994 070994  
074216 074216 074216 074216 074216 074216  
073739 073739 073739 073739 073739 073739  
070416 070416 070416 070416 070416 070416  
072180 072180 072180 072180 072180 072180  
070951 070951 070951 070951 070951 070951  
471360 471360 471360 471360 471360 471360  
470179 470179 470179 470179 470179 470179  
073584 073584 073584 073584 073584 073584  
073585 073585 073585 073585 073585 073585  
470122 470122 470122 470122 470122 470122  
470184 470184 470184 470184 470184 470184  
470186 470186 470186 470186 470186 470186  
470388 470389 470390 470391 470392 470393  
471039 471040 471041 471042 471043 471044  
075468 075604 075488 075605 075606 075490  
070256 075525 070257 075526 075527 070258  
073998 073998 073998 073998 073998 073998  
073999 073999 073999 073999 073999 073999  
075191 075191 075192 075192 075193 075193  
073752 075499 073751 075500 075501 073750  
073906 075508 073905 075509 075510 073904  
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  
Transformer - w/circuit breaker - dual voltage  
Thermostat circuit board - IID  
Module natural gas  
10  
Module propane gas  
11  
12  
13  
Junction Box  
Thermostat knob  
Switch rocker (S.P.D.T.)  
Control panel assy. (complete) - IID Nat  
Control panel assy. (complete) - IID Pro  
Door - assy.  
14  
15  
16  
Manifold burner  
Gas valve natural - IID  
Gas valve propane- IID  
Pilot tube - IID  
17  
18  
19  
Burner tray assy. natural (complete) - IID  
Burner tray assy. propane (complete) - IID  
2 EA.  
3 EA.  
4EA.  
5 EA.  
6 EA.  
7 EA.  
20  
20a  
21  
22  
23  
25  
Burner  
070230 070230 070230 070230 070230 070230  
470550 470550 470550 470550 470550 470550  
470190 470190 470190 470190 470190 470190  
073858 075586 073857 075587 075588 073856  
072134 072134 072134 072134 072134 072134  
072138 072138 072138 072138 072138 072138  
471424 471424 471424 471424 471424 471424  
073989 073989 073989 073989 073989 073989  
074015 074015 074015 074015 074015 074015  
075492 075492 075492 075492 075492 075492  
075284 075284 075284 075284 075284 075284  
Burner with Pilot bracket  
Pressure switch  
1
1
1
1
1
1
1
4
2
1
Combustion chamber assy. (complete)  
Valve drain 3/4"  
Valve relief 3/4" 50# - ASME or Local Code  
Flow valve assy., Standard (complete)  
Flow valve assy., ASME (complete)  
Flow valve gasket  
27  
28  
29  
30  
Bolt 3/8" - 16 x 2 1/2  
Quick flange Kit  
A-11  
Rev. G 1-22-04  
P/N 471048  
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PowerMax Heater (Only) Parts List, contd.  
ITEM DESCRIPTION  
QTY  
150  
195/200  
250  
300  
350  
400  
31  
Bushing in/out Lexan  
2
2
2
2
1
1
1
070544 070544 070544 070544 070544 070544  
071895 071895 071895 071895 071895 071895  
070229 070229 070229 070229 070229 070229  
071017 071017 071017 071017 071017 071017  
070985 070985 070985 070985 070985 070985  
074452 075628 074451 075629 075630 074074  
470364 470365 470366 470367 470368 470369  
Sleeve, rubber in/out 2"  
Sleeve, rubber in/out 1½"  
Safety Shutoff  
32  
33  
34  
Main header (in/out)  
Heat exchanger (without heads)  
Heat exchanger (with heads)  
35  
8 ea.  
8 ea.  
8 ea.  
8 ea.  
16 ea.  
16 ea.  
36  
37  
38  
40  
Baffle  
070277 075559 070276 075560 070277 070278  
073810 073810 073810 073810 073810 073810  
073864 075622 073863 075623 075624 073862  
075783 075784 075785 075786 075787 075788  
Baffle hold down (2) baffles on 350, 400  
Flue collector  
1
1
1
Lightback Shield (Propane Gas units only)  
* Not Shown  
*
*
*
*
*
*
*
*
*
*
*
Plastic mounting bracket  
Wire Kit - Harness (gas valve) IID  
Screw 8 x 1/4" HH  
070715 070715 070715 070715 070715 070715  
470965 470965 470965 470965 470965 470965  
071703 071703 071703 071703 071703 071703  
071698 071698 071698 071698 071698 071698  
071716 071716 071716 071716 071716 071716  
071659 071659 071659 071659 071659 071659  
075692 075692 075692 075692 075692 075692  
070551 070551 070551 070551 070551 070551  
470414 470414 470414 470414 470414 470414  
470178 470178 470178 470178 470178 470178  
073725 073725 073725 073725 073725 073725  
Screw 8 x 1/2" HH  
Screw 6 x 1/4"  
Screw 10 - 32 x 1/4"  
Screw 10 - 32 x 3/16"  
Bushing 1/2"  
Therm knob stopper  
Power element (flow valve)  
Bolt 5/16" - 18 x 3/4"  
2
1
2
3 ea.  
4 ea.  
5 ea.  
6 ea.  
7 ea.  
8 ea.  
N or P  
N or P  
N or P  
N or P  
N or P  
N or P  
*
*
*
*
*
*
*
Orifice main burner natural  
Orifice main burner propane  
Pilot - natural - IID  
073727 073727 073727 073727 073727 073727  
073728 073728 073728 073728 073728 073728  
471204 471204 471204 471204 471204 471204  
471205 471205 471205 471205 471205 471205  
075173 075173 075173 075173 075173 075173  
470180 470180 470180 470180 470180 470180  
470181 470181 470181 470181 470181 470181  
1
1
1
1
2
Pilot - propane - IID  
Thermal cutoff  
Thermistor (probe) complete (IID models)  
Stem, thermistat control (IID Models)  
A-12  
P/N 471048  
Rev. G 1-22-04  
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PowerMax Assembly  
PowerMax Assembly Parts List  
ITEM DESCRIPTION  
QTY  
1
150  
200  
250  
300  
350  
400  
1
2
3
4
5
6
7
8
Plenum  
470139 470140 470141 470142 470143 470144  
470008 470008 470007 470007 470007 470007  
470331 470331 470331 470331 470331 470331  
470337 470337 470337 470337 470337 470337  
470336 470336 470326 470326 470326 470326  
470334 470334 470325 470325 470325 470325  
470328 470328 470328 470328 470328 470328  
470010 470010 470010 470010 470010 470010  
Blower combustion  
Control box side & base  
Control box top  
Adapter ring  
1
1
1
1
Adapter base  
Silicone rubber tube  
Relay  
1
1
1
Pressure Switch  
9
9
1
1
470009 470009 470009 470009 470009 470009  
471428 471428 471428 471428 471428 471428  
Sea Level to 4000 ft.  
Pressure Switch  
High Altitude  
Sea Level 4000 - 8000 ft.  
A-13  
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Rev. G 1-22-04  
P/N 471048  
SAVE THESE INSTRUCTIONS.  
Pentair Pool Products, Inc.  
1620 Hawkins Ave., Sanford, NC 27330 • (919) 774-4151  
10951 W. Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400  
P/N 471048  
Rev. G 1-22-04  
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