Consolidated K-STAR K-5 User manual

361 Rowntree Dairy Road, Unit 4
Woodbridge, ON Canada L4L 8H1
Tel: [phone] Fax: [phone]
Email: [e-mail]
INSTRUCTION MANUAL
“K-STAR” ELECTRIC
POOL / SPA HEATERS
APPROVED LR 51670
MODELS:
K-5 / K-10 / K-15
WARRANTY
(For the Original Owner Only)
(For Warranty Information, Please Mail to Manufacturer.)
Customer’s Name :
Address :
Phone :
Unit
Serial # :
Model # :
Date Purchased :
Installer’s Name :
K-Star Pool/Spa Heater is guaranteed for a period of one year from the date
of its purchase to the original owner against any manufacturing defects.
Exception: factory installed heating elements carry a 90 day limited
manufacturer warranty from date of heater installation only.
Any warranty claim must be pre-authorized by Consolidated Pool & Spa
Industries Inc. and claim must include: Model number, Serial number and
Date of purchase. Any defective unit shall be returned freight prepaid only.
Consolidated Pool & Spa Industries Inc. will not be responsible for
disconnection-reconnection charges.
The above warranty shall be considered void if:
i. The installation instructions are not followed.
ii. Unit is powered without any water circulation.
iii. The power is disconnected and unit is not thoroughly drained at time of
winterizing.
iv. The Unit has been mishandled.
v. If corrosion of the unit’s internal parts occurs by unit being exposed to a
salt water system, a system that uses salt to create a sanitizer or improper
water chemistry (applies to all non-titanium heater models only). Warranty
Registration must be done within ten days of purchase of the unit, by
mailing warranty card below to:
361 Rowntree Dairy Road, Unit 4
Woodbridge, ON L4L 8H1 Canada
Tel: [phone] Fax: [phone]
Email:[email protected]

READ AND FOLLOW ALL INSTRUCTIONS
1a) K-Star Heater may be installed indoors or outdoors at least 6”
from any object. Ensure that the installation allows access for electrical
and plumbing connections and that the Thermostat control is
conveniently located.
The installation of current leakage collectors should be done as
per Figure 01 before permanently positioning Heater.
Heater must be installed after the filter and before the Air Injector
or Automatic Chlorinator.
b) A leakage current collector must be installed at the water inlet,
and another at the outlet of the unit, and these shall be electrically
insulated from the unit. The installation of the collectors shall be
such that all water entering and leaving the unit flows through the
two collectors, as shown in Figure 01.The length of the leakage current
collectors shall be made of a corrosion resistant metal and shall be
provided with a copper lug brazed to the collector body.
Hand tighten only. Do not use high force with a pipe wrench.
FIGURE 01. LEAKAGE CURRENT COLLECTOR DIAGRAM
C) The Heater shall be installed as per Figure 02.The water inlet and outlet
are connected to straight connectors of the heater.
FIGURE 02
2 7

MECHANICAL INSTALLATION DIAGRAM
SHOWING BY PASS
Caution:
i) Do not store chlorine near or in the same room as heater.
ii) Valves must not be installed in the piping on the
outlet of heater to the pool/spa.
iii) Use PVC cement for connecting leakage current collectors
into tank body and use teflon tape as sealer in the threads
for drain plug.
d) Water Flow
The water flow in GPM should not exceed the following limits:
Table 01
Important:
Systems with higher GPM ratings will require a bypass around Heater.
This would be necessary if a high velocity pump is employed in the system.
Recommended:
Add water softener for longer heater life.
36
Heater GPM
K-5 08 (Max)
K-10 10
K-15 10
2. Apply electric power to the heater, then rotate the thermostat
control clockwise to the max. position.
The red indication lamp will be lit when the heater is on.
3. After the desired temperature is reached, re-adjust the thermostat
control to suit your requirement.
The scale ranges from 70 to 110F.
4 A high limit manual reset thermostat is provided as a secondary back up
high temperature limit protection. The reset thermostat may trip if the
pump is switched off, or the heater chamber has too much air locked in it.
To reset, switch the heater breaker off. Allow the heater to cool and then
depress the reset, as shown in Figure 05.
Winterizing:
For maximum security, first turn the thermostat to the off position and switch
off the electric power at the circuit breaker.Then completely empty the tank
by removing the drain plug located at the bottom of the heater body. Drain
plug must be left out all winter. Cover the control panel of the heater with
ordinary plastic cover to prevent any penetration of moisture or water into
electrical components. At all times the unit must be properly ventilated
to avoid condensation.
FIGURE 05
WIRING DIAGRAMS (below)

5
2 a) Electrical: Electrical work must be performed by a qualified Electrician
and comply with the Canadian Electrical Code or the American National
Standard Electrical Code lnforce.
Table 02. The wire sizes to be used are as follows:
For installation see Wiring Schematic figure 03.
FIGURE 03. Wiring Schematic
In Accordance with The Electrical Code in effect
b) A green coloured terminal (or a wire connector marked“C”,“GP”. “Ground”
or“Grounding”) is provided within the control box. To reduce the risk
of electric shock, connect this terminal or connector to the grounding
terminal of the electric service or supply panel with a continuous green
insulated copper wire equivalent in size to the circuit conductors
4
Model Amps Fuse
(240V G.F.L. Size)
Wire Size
(90’ Copper Only)
Collector
Ground Wire
(Copper Only)
K-5 21A 30A 10 10
K-10 42A 60A 6 6
K-15 63A 80/100A Use Supply conductor
suitable for 75º C
Use Supply conductor
suitable for 75ºC
supplying this equipment. Addition, bonding lugs are provided and marks
“Bonding Lugs”. To reduce the risk of electric shock connect the bonding lugs
in accordance with the Canadian Electric Code, Part 1.
c) It is mandatory that all Electrical Heaters be installed with
Leakage Collectors at the water outlet of filtration system and at
the outlet of heaters.
SAVE THESE INSTRUCTIONS
Warning:
Ensure that the unit is properly grounded at the provided lug within the unit
and that the leakage collectors are separately grounded at the main entrance.
Improper installation may be a potential cause of fire, electric shock, personal
injury or health hazards and great care should be taken to avoid these. Make
sure that all wiring is secure.
OPERATING INSTRUCTIONS
1. Must be strictly followed for warranty to be valid.
Before energizing the heater, activate the pump and make sure that
the air is out of the heater chamber (no air bubbles will enter the pool/spa
from the heater).Water circulation must be ensured at all times when
unit is energized.