Rev. B 4-16-02 1 P/N 472091
MiniMax NT Heater Single Voltage
6800 Temperature Controller Retrofit Kit (472099)
Installation 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
WARNING
FOR YOUR SAFETY - READ BEFORE OPERATING
Warning: This product must be installed and serviced by a professional service technician qualified in
pool/spa heater installation and maintenance. If you do not follow these instructions exactly, a fire
or explosion may result, causing property damage, personal injury or loss of life. For additional
free copies of these instructions; call (800) 831-7133.
Important Notice
Attention Installer.
This manual contains important information about the installation, operation and safe use of this
product. This information should be given to the owner/operator of this equipment.
Table of Contents
A. INSTALLATION ................................................................................................................ 2
B. WIRES IDENTIFICATION ............................................................................................... 2
C. WIRING .............................................................................................................................. 3
D. OPERATION ...................................................................................................................... 6
E. TROUBLESHOOTING ...................................................................................................... 7
F. RAIN PROTECTION ........................................................................................................ 9
G. PART LIST ........................................................................................................................ 10
P/N 472091 2 Rev. B 4-16-02
P/N 472104
P/N 472105
P/N 472106
P/N 472107
WIRE #1
WIRE #2
WIRE #3
WIRE #4
WIRE #5
P/N 471129
P/N 471763
WIRE #6
ORANGE
ORANGE
BLUE
WHITE
RED
WIRE #P11
P/N 471812
MALE TERMINAL
MALE TERMINAL
FEMALE TERMINAL
FEMALE TERMINAL
18.0"
24.0"
18.0"
FEMALE TERMINAL
18.0"
FEMALE TERMINAL
ORANGE ORANGE
MALE TERMINAL
MALE TERMINAL
FEMALE TERMINAL
18.0"
WHITE
18.0"
WHITE
WHITE
WHITE
FEMALE TERMINAL
ORANGE
24.0"
FEMALE TERMINAL
FEMALE TERMINAL
14"
18"
FEMALE TERMINAL
18"
30.0"
24.0"
FEMALE TERMINAL
18"
WHITE
FEMALE TERMINAL
FEMALE TERMINAL
WHITE
TERMINAL HOUSING
18"
MALE TERMINAL
FEMALE TERMINAL
B. WIRES IDENTIFICATION
The following items are new wire assembly, (provided in the kit).
A. INSTALLATION
1. Turn off the electrical power to the heater.
2. Open the heater’s right door.
3. Disconnect all wires from the 7800 Temperature Controller and the Ignition Module.
4. Remove the left and right doors from the heater if necessary.
5. Remove six screws on the rear cover of the 7800 Temperature Controller.
(NOTE: Please discard the cover, not used.) Then, remove the cover, the PC board, and the front face carrier.
6. Install the 6800 Temperature Controller, (provided in the kit), by using four screws only. See Figure 1.
7. Remove two screws on existing Ignition Module and replace with new Ignition Module using the same two screws,
(provided in the kit).
Figure 1.
Rev. B 4-16-02 3 P/N 472091
C. WIRING
1. Look at the existing wiring diagram on the left door and find out what model of the NT heater you have from top
of wiring diagram.
NOTE
First check the three terminals on your blower. If there are male terminals, please cut them and replace with
female terminals, (provided in the kit).
•If you see “MiniMax NT 400 Low NOx” that means your heater is Single Voltage
Dual Speed (SVDS): Replace the new wiring diagram for SVDS. The label is provided in
the kit, (P/N 472084).
• Please see Figure 2 for SVDS and follow the instructions below exactly.
a. Reconnect existing wire P7 to J7, P9 to J9, and P10 to J10 respectively on the 6800 control board.
b. Reconnect the existing white wire from Low Gas Pressure Switch to “TH” on the Ignition Module.
c. Reconnect the existing 5-pin Mate-N-Lok Plug (with gray, black, white and blue wires) to Ignition Module.
The male terminals of gray and blue wire connect to Hot Surface Igniter (HIS #1).
d. Connect new wire #P11 to J11. Then, connect the common female terminal, orange wire, to “IND” on the
Ignition Module; next, connect the common female terminal, (red/blue) wire, to “VAL” on the Ignition Module.
e. Connect existing wire P4 to J4 but using “splice” to connect new wire #1 (orange). The female terminal connect
to “24VAC” on Ignition Module.
f. Connect new wire #2 (white). The common male terminal connect to white wire of P11; the 1st female terminal
connect to “GND” on the Ignition Module; the 2nd female terminal connect to “RET” on the Fan Board.
g. Connect new wire #3 (white). The common male terminal connect to white wire of the Blower; the female
terminal connect to F1 terminal of Ignition Module; the other female terminal connect to Hot Surface Igniter (HIS #2).
h. Connect new wire #4 (orange). The common female terminal connect to “24 VAC” on the Fan Board; the
female terminal connect to “PC” on the Fan Board; the male terminal connect to orange wire of P11.
i. Connect the new wires #5 (white), from F2 of Ignition Module to Terminal Block #4.
j. Install the In-Line Fuse (provided in the kit) between the Hot Surface Ignitor (HSI #2) and the blower, see Wiring
Diagram (Figure 2).
•If you see “MiniMax NT 250 Low NOx” that means your heater is Single Voltage
Single Speed (SVSS): Replace the new wiring diagram for SVSS. The label is provided in
the kit, (P/N 472088).
• Please see Figure 3 for SVSS and follow the instructions below exactly.
a. Reconnect existing wire P7 to J7, P9 to J9, and P10 to J10 respectively on the 6800 control board.
b. Reconnect the existing white wire from Low Gas Pressure Switch to “TH” on the Ignition Module.
c Reconnect the existing 5-pin Mate-N-Lok Plug (with gray, black, white and blue wires) to Ignition Module.
The male terminals of gray and blue wire connect to Hot Surface Igniter.
d. Connect new wire #P11 to J11. Then, connect the common female terminal (orange) wire to the Air Pressure
Switch; then connect the female terminal (orange) wire to the “IND” on the Ignition Module; next, connect the
common female terminal (red/blue) wire to “VAL” on the Ignition Module; last, connect the female terminal
(white) wire to “GND” on the Ignition Module.
e. Connect existing wire P4 to J4 but using “splice” to connect new wire #1 (orange). The female terminal connect
to “24VAC” on Ignition Module.
f. Connect the new wires #5 (white) from F2 of Ignition Module to Terminal Block #4.
g. Connect the new wire #6 (white) from F1 of Ignition Module to the white wire of the Blower.
P/N 472091 4 Rev. B 4-16-02
GRN
IGN MODULE
HOT SURFACE IGNITER
BURNER
GND
VAL
IND
S2
L2
L1
MiniMax NT Low NOx Single Voltage Dual Speed (SVDS) W/6800 Control Board Wiring Diagram
ORG
WHT
GRN
ORG
RED
THERMAL FUSE
WHT
BLU
RED
SWITCH
WATER PRESSURE
SPST EXTERNAL SWITCH
GAS VALVE
RED
WHT
BLU
RED
HIGH LIMIT
115˚F
1
2
3
4
5
3
2
1
GRN
AIR PRESS. SW(LO)
BLOCK
TERM BLOCK
TERM
WHT
WHT
BLK
WHT
BLK
WHT
ORG
ORG
WHT
WHT
WHT WHT
BLOWER
BLK/WHT
BLK
BLK
S1
TH
WHT
BLK
120 VAC
ONLY
BLK
WHT
RED
LOW GAS
24VAC
WHT
POOL
JUMPER REQUIRED
J6
PROBE
TEMP.
VLV
TPROBE
J5J8
24V
J4 J7
IGN MODULE
J10 J11
PRESSURE SW.
IF ORIGINAL FACTORY WIRING MUST BE REPLACED,
INSTALLER MUST SUPPLY UL/CSA APPROVED WIRE
WITH 18 AWG, 600V, 105˚ C TEMP. RATING.
ORG
SW/HL/TFUSE
J9
POOLSPA COM
WHT
WHT
ORG
WHT
WHT
GRN
GRN OFF SPA
J2 J3
THERMAL FUSE WIRING MUST BE REPLACED WITH
INTERCONNECTING WIRING TO APPLIANCE MUST
CONFORM TO THE NATIONAL ELECTRICAL CODE OR
SUPERSEDE LOCAL (WIRING) CODES.
WHTWHTWHT
WHT
IF NO REMOTE SWITCH
RED
RED/WHT
BLK
BLK/WHT
ORG
BLU
WHT
BLK
GRY
ORG
HIGH LIMIT
150˚F
18 AWG, 600V, 150˚ C TEMP. RATING.
ATTACH
GROUND
WIRE
HERE
GRN
(ON THE SIDE JACKET)
GREEN SCREW
FROM
TRANSFORMER
WHT
BLK
WHT
AIR PRESS. SW(HI)
ORG
HOT SURFACE IGNITER
WHT
WHT
ORG
FAN BOARD
PH
FL
PL
PC
FH
FC
RET
24VAC
BLK
ORGRED
WHT
BLU
WHT
WHT
472084
WHT
RED
RED/WHT
WHT
ORG
WHT
SPLICE
P9
MV
MV
P4 P7 P10 P11
(HSI #2)
(HSI #1)
F1
F2
FC2/FC1
WHT
WHT
RED
BLK FUSE BLK
ORG 400˚F ORG
EXHAUST HIGH LIMIT
THERMOSTAT
CIRCUIT BOARD
(6800)
Figure 2.
Rev. B 4-16-02 5 P/N 472091
Figure 3.
GRN
MiniMax NT Low NOx Single Voltage Single Speed (SVSS) W/6800 Control Board Wiring Diagram
ORG
WHT
GRN
ORG
RED
THERMAL FUSE
WHT
BLU
RED
SWITCH
WATER PRESSURE
SPST EXTERNAL SWITCH
GAS VALVE
RED
WHT
BLU
RED
HIGH LIMIT
115˚F
3
2
1
GRN
AIR PRESS. SW.
BLOCK
TERM
WHT
BLK
WHT
ORG
ORG
WHT
WHT
WHT WHT
BLOWER
WHT
BLK
120 VAC
ONLY
BLK
LOW GAS
POOL
JUMPER REQUIRED
J6
THERMOSTAT
CIRCUIT BOARD
PROBE
TEMP.
VLV
TPROBE
J5
J8
24V
J4 J7
IGN MODULE
J10 J11
PRESSURE SW.
(6800)
IF ORIGINAL FACTORY WIRING MUST BE REPLACED,
INSTALLER MUST SUPPLY UL/CSA APPROVED WIRE
WITH 18 AWG, 600V, 105˚ C TEMP. RATING
ORG
ORG
SW/HL/TFUSE
J9
POOL
SPA COM
WHT
WHT
ORG
GRN
GRN
OFF SPA
J2 J3
THERMAL FUSE WIRING MUST BE REPLACED WITH
INTERCONNECTING WIRING TO APPLIANCE MUST
CONFORM TO THE NATIONAL ELECTRICAL CODE OR
SUPERSEDE LOCAL(WIRING) CODES.
WHTWHTWHT
WHT
IF NO REMOTE SWITCH
RED
RED/WHT
BLK
BLK/WHT
ORG
HIGH LIMIT
150˚F
18 AWG, 600V, 150˚ C TEMP. RATING
ATTACH
GROUND
WIRE
HERE
GRN
(ON THE SIDE JACKET)
GREEN SCREW
FROM
TRANSFORMER
472088
WHT
BLK
5
4
3
2
WHT
WHT
BLK
BLK
WHT
TERM
BLOCK
1
RED
RED/WHT
BLK
BLK/WHT
P9
SPLICE
MV
MV
P4 P7 P10 P11
WHT
BLU
RED ORG
IGN MODULE
IND
GND
VAL
WHT
L1
S2
L2
TH
BLU
WHT
WHT
S1
FC2/FC1
GRY
BLK
BURNER
F2
24VAC ORG
F1 WHT
WHT
HOT SURFACE IGNITER
WHT
WHT
WHT
ORG 400˚F ORG
EXHAUST HIGH LIMIT
P/N 472091 6 Rev. B 4-16-02
Knob Stopper
Screw A
D. OPERATION
Dual Temperature Control System
For convenience and economy all MiniMax NT heaters are
equipped with two thermostats on the front of the heater
control panel; see Figure 1.
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 4.
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.)
NOTE
To eliminate error due to piping heat losses,
measure pool temperature with an accurate
thermometer directly at the pool or spa.
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 4.
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)
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.
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.
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.
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.
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.
3. “Spa” position - This allows separate control of spa
water temperature.
Rev. B 4-16-02 7 P/N 472091
HEAT (HEAT)
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.
SERVICE (SERVICE)
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.
E. TROUBLESHOOTING
Example of troubleshooting with the assistance of the indicator lights.
INDICATOR LIGHT DESCRIPTION, (cont’d.)
PWR TSTAT RMT PRESS
SRVE
HI TEMP TFUSE
GAS VALVE
MV
MV
IGNITION MODULE
IND GND VAL
MV HEAT
CLOSE IF
NO MV
THERMOSTAT
RELAY
REMOTE PRESS TFUSE
HI TEMP
LIMIT SWITCHESBREAKER
CIRCUIT
TRANSFORMER
INCOMING
LINE VOLTAGE
THERMOSTAT CIRCUIT BOARD
LIMIT SWITCHES
HI TEMP
NO MV
CLOSE IF
THERMOSTAT CIRCUIT BOARD
TRANSFORMER
LINE VOLTAGE
INCOMING
PWR
CIRCUIT
BREAKER
TSTAT RMT
RELAY
THERMOSTAT
REMOTE
PRESS
SRVE
PRESS HI TEMP
MVTFUSE
TFUSE
HEAT
IGNITION MODULE
IND GND VAL GAS VALVE
MV
MV
WATER AT SELECTED TEMPERATURE.... NORMAL OPERATION
THERMOSTAT CALLING FOR HEAT - PUMP OFF(NO PRESSURE) BLOCKS FIRING
NORMAL OPERATION
SYMBOL TABLE
LED LIT LED OFF
SWITCH OR DEVICE
OPEN CIRCUIT
(BLOCK CURRENT)
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
THERM
AUX
PRESS
HEAT
POWER
SERVICE
FRONT PANEL LEDS
FRONT PANEL LEDS
HEAT
PRESS
AUX
THERM
SERVICE
POWER
OR POOL/OFF/SPA THERMOSTAT SELECT SWITCH OFF.... NORMAL OPERATION
P/N 472091 8 Rev. B 4-16-02
PRESS
PRESS
HEATER FIRING - NORMAL OPERATION
NOTE: SERVICE LED LIT FLAGS PROBLEM, TFUSE LED OFF SHOWS PROBLEM
PRESS
PRESS
THERMOSTAT CALLING FOR HEAT - BLOWN THERMAL FUSE BLOCKS FIRING
FRONT PANEL LEDS
HEAT
PRESS
AUX SERVICE
TRANSFORMER
THERM POWER
INCOMING
LINE VOLTAGE
FRONT PANEL LEDS
PRESS
HEAT
AUX
THERMOSTAT
PWR
CIRCUIT
BREAKER
TSTAT
RELAY
RMT
REMOTE
TRANSFORMER
THERM
INCOMING
LINE VOLTAGE
THERMOSTAT
PWR
BREAKER
CIRCUIT
TSTAT
RELAY RMT
REMOTE
THERMOSTAT CIRCUIT BOARD
NO MV
CLOSE IF
IGNITION MODULE
SRVE
HI TEMP
LIMIT SWITCHES
HI TEMP
TFUSE MV
IND
TFUSE
GND
THERMOSTAT CIRCUIT BOARD
GAS VALVE
HEAT
VAL
MV
MV
IGNITION MODULE
SRVE
CLOSE IF
NO MV
HI TEMP
LIMIT SWITCHES
HI TEMP
TFUSE MV
IND
TFUSE
GND GAS VALVE
HEAT
VAL
MV
MV
POWER
SERVICE
IS IN THERMAL FUSE CIRCUIT
SYMBOL TABLE
LED LIT LED OFF
SWITCH OR DEVICE
OPEN CIRCUIT
(BLOCK CURRENT)
SWITCH OR DEVICE
CLOSED CIRCUIT
(PASS CURRENT)
E. TROUBLESHOOTING, (cont’d.)
Rev. B 4-16-02 9 P/N 472091
F. RAIN PROTECTION
NOTE
Please ignore the following steps in Section F if the heater has been installed with a rain protection shield.
1. Using the silicon tube (provided in the kit) to seal the 3 sides of the edge. See Figure 5.
WARNING
The edges of the heater door can be sharp. Handle heater door with care when trimming the plastic studs. Failure
to do so could result in lacerations from the heater door.
2. Using a knife, slightly trim the plastic stud, (if required), and push it through the plastic barrier. Then insert the
pushnuts, included in the kit, onto the plastic stud in order to hold the plastic barrier, (see Figure 5).
SEAL THESE 3 SIDES WITH SILICON
TRIM THE STUD FIRST, THEN HOLD THE SHIELD
BY PUSHING THE NUT THROUGH THE STUD.
Figure 5.
P/N 472091 10 Rev. B 4-16-02
Save These Instructions Together With Your Existing
Operation & Installation Manual
For Future Reference.
G. PARTS LIST
P/N Description Quantity
071925 Quick Connector, 1/4 in. Female 3
471129 Wire #5, White, Female x Female 1
471706 Pushnut 2
471763 Wire #6, White, Female x Male 1
471812 Wire #P11, White/Red/Blue/Orange, with Terminal Housing 1
472059 Barrier (Rain Shield) 1
472060 Silicon Tube 1
472084 Label, Wiring Diagram, NT LN SVDS, Model 400 Only 1
472086 Temperature Controller Assembly, 6800 1
472088 Label, Wiring Diagram, NT LN SVSS, Models 200/250/300 1
472091 Instruction Sheet, 6800 Retrofit Kit 1
472094 Splice (Self-Stripping Electrical Tap Connector) 1
472096 In-Line Fuse, 5 Amp. 1
472103 Ignition Module, 2466H-676-223 1
472104 Wire #1, Orange, Female 1
472105 Wire #2, White, Female x Female x Male 1
472106 Wire #3, White, Female x Male x Male 1
472107 Wire #4, Orange, Female x Female x Male 1
/
