Astral Pool HX70 User manual

30/07/2010
INSTALLATION AND
OPERATING INSTRUCTIONS
Melbourne: 03 8796 8600 Gold Coast: 07 5552 2600 Perth: 08 9350 2600
Sydney: 02 9853 2100 Townsville: 07 4750 3100 [email protected]
Brisbane: 07 3308 5400 Adelaide: 08 8152 7600 www.astralpool.com.au
Bolero ND
Cleaner
INSTALLATION AND OPERATING INSTRUCTIONS I INSTALLATION AND OPERATING INSTRUCTIONS
HX Series Pool & Spa Heater
HX70 & HX120
Genus IV

Inst174 HX Series Pool & Spa Heater V07.10
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INDEX
Introduction
Introduction ................................................................................................................................3
Notice to Installers ....................................................................................................................3
Safety Rules...............................................................................................................................3
Operation
Lighting Instructions..................................................................................................................4
Operating Instructions..............................................................................................................4
Turning Gas Off.........................................................................................................................4
Chemical Balance.....................................................................................................................4
Corrosion Prevention in Heaters.............................................................................................5
Digital Thermostat Operation ..................................................................................................6
Fault Indication..........................................................................................................................7
Maintenance
Maintenance Instructions.........................................................................................................8
Energy saving Tips...................................................................................................................8
Winter Operation.......................................................................................................................8
Installation
Installation Instructions.............................................................................................................9
Flow Rates......................................................................................................................9
Water Connections........................................................................................................9
Plumbing Diagram.........................................................................................................9
Heater Dimensions..................................................................................................... 10
Indoor Installation................................................................................................................... 10
Ventilation.................................................................................................................... 10
……………………………………………………………………………………………11
Clearances...............................................................................................................................11
Electrical Connection............................................................................................................. 12
Gas Connection...................................................................................................................... 12
Pressure Switch Adjustment................................................................................................. 12
………………………………………………………………………………………………… 13
Starting the Heater................................................................................................................. 13
Testing Burner Pressure....................................................................................................... 13
Gas Conversion
Burner Conversion................................................................................................................. 14
Troubleshooting
Fault Finding and Remedies................................................................................................. 15
Wiring diagram
HX Series Wiring Diagram.................................................................................................... 16
Warranty
Terms and Conditions........................................................................................................... 17

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INTRODUCTION
Congratulations on your purchase of a Hurlcon Pool and Spa Heater. Proper installation and service of your new
heating system and correct chemical maintenance of the water will ensure years of enjoyment. The HX Series
Heater is a compact lightweight and efficient gas fired pool and spa heater. It is equipped with features that take
advantage of new technology developed exclusively by Hurlcon.
The Hurlcon Pool Heater can safely be connected to PVC pipe and has a built in balanced flue for outdoor
installation. It accepts high flow rates which help the heater run cooler, giving greater performance and long life.
In addition, the Hurlcon Pool Heater is equipped with electronic start up and an accurate electronic thermostat to
ensure ease of use and accurate temperature control. The electronic display tells at a glance the operational
status of the heater.
Note:
The appliance is not intended for use by young children or infirm person without supervision. Please ensure that
young children are supervised to ensure that they do not play with the appliance.
NOTICE TO INSTALLERS
This appliance must be installed by an authorized person.
This appliance must be installed in accordance with the installation instructions, local gas fitting regulations, the
Standards Australia Installation Code AS5601 and any other relevant statutory authorities.
Refer to data plate for details of gas type, gas consumption and burner pressure.
SAFETY RULES
1. Spa or hot tub water temperature should never exceed 40˚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.
3. Pregnant women beware! Soaking in water above 38˚C can cause foetal damage during the first three
months of pregnancy.
4. Before entering the spa or hot tub, the user should check the water temperature with an accurate
thermometer, spa or hot tub thermostats may err in regulating water temperatures by as much as 2˚C.
5. Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure
problems should obtain their physician’s advice before using spas or hot tubs.
6. Persons taking medications which induce drowsiness, such as tranquillisers, 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.

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LIGHTING INSTRUCTIONS
For your safety –read before lighting
This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the
burner by hand.
BEFORE OPERATING smell all around the appliance 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 appliance. Do not touch any electrical switch. Do not
use any telephone in your building. Immediately call your gas supplier from a neighbour’s house.
DO NOT PLACE ARTICLES ON OR AGAINST THIS APPLIANCE
DO NOT USE OR STORE FLAMMABLE MATERIALS NEAR THIS APPLIANCE
DO NO SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Turn off electric power to appliance.
3. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light
the burner by hand.
4. Wait five minutes to clear out any gas. If you then smell gas, STOP! Refer to instructions above.
5. Turn filtration pump on.
6. Turn on power to the heater and press the pool/spa button to select pool or spa mode.
7. Set thermostat to desired setting and the ON/OFF switch to turn the heater ON.
8. The heater will ignite in around 10 seconds.
9. If the appliance will not operate, follow instructions 5 to 7 above. If the appliance still does not ignite, call
your service technician.
TO TURN GAS OFF TO APPLIANCE
1. Turn off all electrical power to the appliance.
2. Turn off gas tap in gas line prior to heater.
CHEMICAL BALANCE
It is imperative that correct chemical balance be maintained in your pool and spa water, otherwise corrosion of
your heater may occur. Corrosion of the heat exchanger voids warranty. Your local pool shop specialist or
spa retailer can advise correct chemical balance. Your water should be checked and maintained regularly by a
pool water professional. As a guide the following parameters may be used.
pH 7.6 to 7.8
Total Alkalinity 80 to 120 ppm
Calcium Hardness 150 to 250 ppm
Salinity 4000ppm max. Excessive salt can damage your heater.
You should test your water chemical balance at least on a weekly basis.
Excessive sanitiser can damage your heater. Chlorine should not exceed 3 ppm and bromine should not exceed 5
ppm. Salt chlorinators, especially when used on spa pools or indoor or covered pools, can easily produce
excessive chlorine levels which will damage the heater internals.

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CORROSION PREVENTION IN HEATERS
All pool and spa heaters use copper or copper nickel to make their heat exchangers as it is the most efficient
material in transferring heat from the combustion chamber into the water. The typical life expectancy of a well
maintained pool/spa heater is between 8 and 15 years.
Often the same heat exchanger used in residential and commercial boilers and hot water systems will have a life
expectancy of 20 years.
The addition of sanitisers (Chlorine, Bromine etc) and other water balancing and conditioning chemicals can
increase the rate of wear and tear on the heat exchanger and associated parts in your heater.
There are three most common reasons for heat exchanger corrosion which can be avoided with a little care and
attention.
1. Excessive Sanitiser. This means too much Chlorine or Bromine in the water. Be careful, if the level of
Chlorine or Bromine is excessively high your test kit (and the pool shops) may not read accurately or indeed may
show a nil reading. Any time a salt chlorinator is operating for extended periods, (when heating the swimming pool
from cold), particularly if the weather is overcast or the pool enclosed or covered, the Chlorine level may exceed
normal levels. When heating a Spa Pool, turn the chlorinator down or off for the duration of the heating period.
2. Out of balance water. The water balance is a combination of pH, total alkalinity, Calcium hardness and
temperature. These measurements must be at the correct levels to maintain balanced water and effective
sanitation of your pool. Balanced water will help prevent corrosion of your heater. Balanced water should be
between 7.2 - 7.8 pH.
3. The addition of acid to lower pH. Acid must always be added in small quantities and spread over the
pool surface evenly, not added in to the skimmer. Do not add a litre at a time, add a cupful each day to lower your
pH.
4. Never add chemicals to skimmer - dilute and circulate as far away as possible from skimmer.
If you have a salt chlorinated INDOOR pool or COVERED pool be very careful of the level of Chlorine being
produced. If you use a salt chlorinated spa be very careful of the level of Chlorine as the Chlorinator is usually
sized for the pool and therefore should be switched off when heating the spa. Leaving the chlorinator on can
raise the chlorine level very rapidly in a small volume of water.
These comments are intended as a guide only and are not definitive answers or recommendations on pool water
chemistry. Hurlcon’s intention is to provide a little understanding of the potential problems of water chemistry and
the dangers of corrosion to heaters (and other pool equipment and fittings).
You should always seek the advice of your local pool shop professional and provide him with as much information
and feedback as possible when analysing your pool and spa water and obviously be sure to tell him you have a
heater connected to the system even though it may not be in constant use.
YOUR WATER SHOULD BE ADJUSTED & BALANCED PRIOR TO ANY CORRODED PARTS BEING
REPLACED.

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DIGITAL THERMOSTAT OPERATION
DESCRIPTION
The sophisticated digital thermostat provides temperature read out, set point temperature and operating status of
the heater. The electronic display indicates the operational status of the heater and any fault conditions.
TEMPERATURE DISPLAY
The temperature display indicates water temperature in the inlet of the heater. Therefore the pump must be
operating for an accurate pool or spa water temperature to be displayed.
Comfortable pool temperature is between 26˚C and 30˚C. Normal spa temperature is between 36˚C and 38˚C. To
select your desired temperature press the up or down button repeatedly until the desired temperature is reached.
To prevent rapid cycling of the heater, the thermostat has an inbuilt time delay which prevents the heater from
turning on for two minutes after the set point has been reached. If the time delay is activated, the symbol “L” will
be displayed. This is part of normal operation.
The thermostat can be set to temperatures between 10˚C and 40˚C. It also incorporates several safety features
including a 45˚C high limit function to prevent overheating of the pool or spa. On simultaneous shut down of the
circulating pump and heater, the water within the heater may exceed 45˚C for a short period. If the pump and
heater are restarted during this period, the thermostat will go into a standby mode and prevent the heater from
relighting until the temperature within the heater has dropped below the set temperature.
Should the thermostat fail to stop the heater at the set point or at 40˚C, there are three temperature limiting safety
devices designed to lock the heater out and prevent further heating. A lock out condition is indicated by the
symbols F1 or F2. To reset a lock out condition, turn the power off for five seconds.
>
<
HURLCON
HURLCON
○
I
ON/OFF POOL/SPA WARM COOL

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FAULT INDICATION
Under fault conditions the thermostat will display a set of alpha numeric symbols to indicate the status of the
heater. The meaning of each symbol and action to be taken are listed as follows:
SYMBOL MEANING ACTION
Temp Display Unit has power. No action.
F0 Heater locked off, thermistor If water temperature reads
wire disconnected or water greater than 0C, phone for
at 0C (freeze conditions). service.
F1 Thermostat reads greater Allow water to cool,
than 45C. turn heater off then on again.
F2 Mechanical Hi Limit greater Allow water to cool,
than 45C. turn heater off then
on again.
F3 Thermistor fault Phone for Service
LHeater locked out on time No action. Heater will
delay for 2 minutes. Automatically reset after
time delay.
Or switch off then on again
for immediate ignition.
Pump operating & sufficient No action.
water pressure to operate heater
Thermostat calling for heat. No action.
Electronic Flame Supervision
operating.

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MAINTENANCE
It is recommended that you check the following at least every six months and at the beginning of every swimming
season.
1. Examine the balanced flue or indoor draught diverter. Make sure there are no obstructions to the flow of
air to, or flue products from, the appliance.
2. Visually check the burner flames. If the flame appears yellow, the burner should be cleaned by a qualified
service technician.
3. Keep the heater area clear and free of combustibles and flammable liquids. Chlorine should not be stored
in the vicinity of the heater. Chlorine vapours, when drawn through a heater, can rapidly cause corrosion
of the heat exchanger.
4. Keep the heater area free from garden refuse and debris. This will help prevent insects nesting in the unit
and ensure extended life and reliability of your heater.
ENERGY SAVING TIPS
1. If possible, keep pool or spa covered when not in use. This will not only cut heating costs, but will also
keep dirt and debris from settling in the pool and conserve chemicals.
2. Reduce pool thermostat setting to 28˚C or lower. This is accepted as a comfortable and healthy swimming
temperature.
3. Use an accurate thermometer.
4. Set timeclock to start filtration and circulation system no earlier than daybreak. The pool loses less heat at
this time.
5. For pools that are only used on weekends, it is not necessary to leave the thermostat set at 28˚C. During
the week, lower it by an amount that can easily be achieved in one day (generally 5˚C to 8˚C).
6. During the winter or while on vacation, turn the heater off.
7. Set up a regular program of preventative maintenance for the heater each new swimming season. Check
heat exchanger, controls, burner operation etc.
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 freezing, water should circulate through your heater all year long even though you are not heating
your pool.
Where freezing is possible, it is necessary to drain the water from the heater. This may be done by loosening the
inlet or outlet barrel union. If the heater is below water level, isolate it from the pool first by closing shut off valves
before and after the heater.
CAUTION: If the heater has been drained for freezing conditions, do not turn on until the system is circulating
water.

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INSTALLATION
THIS APPLIANCE MUST BE INSTALLED BY AN AUTHORISED PERSON. Refer to heater data plate for
specifications of gas type, gas consumption, burner pressure and water pressure.
This appliance must be installed in accordance with local regulations and Standards Australia Installation Code
AS5601.
FLOW RATES
The Hurlcon Pool Heater requires a minimum of 150 litres per minute flow and the maximum permissible flow rate
is 450 litres per minute. For flow rates in excess of 450 litres per minute, an external by-pass valve must be fitted.
WATER CONNECTIONS
The heater should always be installed after the pump and filter. The water connections are located on the right
hand side of the heater. Left hand connection models are available by special order. The inlet and outlet are
clearly marked. Water connections require 40 mm PVC glue in plumbing.
All automatic sanitising devices must be installed after the heater and in such a way that the sanitiser cannot enter
the heater without first mixing with the water in the pool or spa. Sanitisers that are connected prior to the heater
will void heater warranty.
The Hurlcon Pool Heater incorporates a balanced flue terminal and is suitable for outdoor installation.
PLUMBING DIAGRAM
To Solar
From Solar
From Pool
Pump
Filter
Heater
Chlorinator
Return to Pool
Heater Diagram
1. Plumbing in high pressure 40mm or 50mm PVC pipe
2. Connection to heater in Class 12 or higher
3. All automatic Chlorinators or Sanitisers Must be installed after heater
PVC Piping

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HEATER DIMENSIONS
INDOOR INSTALLATION
If the HX Heater is to be installed indoors, an indoor draught hood kit must be purchased from Hurlcon and
installed on the HX Heater to convert it to an indoor model.
Product code numbers for draught hood kits are:
Heater model
Indoor top model
Flue size
Part number
HX 70
DH 07
125 mm
10133
HX 120
DH 12
125 mm
10134
A flue no smaller than the draught diverter diameter must be installed and terminated with an approved gas flue
cowl (not a Chinaman’s hat) 600mm above any roofline that is within 1.5 metres horizontally from the flue.
VENTILATION
When installing the heater indoors, it is imperative that an adequate supply of fresh air is provided for combustion.
Failure to provide adequate ventilation voids all warranties and may be a danger to persons or property.
Two permanent openings shall be provided directly to outside. The openings shall be located to ensure the
distance between the top of the upper opening and the ceiling of the room or enclosure, and the distance between
the bottom of the lower opening and the floor of the room or enclosure does not exceed 5% of the height of the
room or enclosure.
The minimum vertical dimension of any free ventilation opening shall be 6 mm.
The minimum free ventilation area provided by each opening shall be:
MODEL
AREA
HX 70
23,000 mm2
HX 120
39,000 mm2
Model
Dimension A
Dimension B
Dimension C
Dimension D
HX 70
420mm
320mm
700mm
370mm
HX 120
515mm
390mm
800mm
400mm