Elecro Engineering FLOW-LINE Installation instructions

Flow-Line
Swimming Pool Heater
INSTALLATION & OPERATING MANUAL
Thank you for purchasing the Flow-Line direct electric swimming pool heater manufactured in England to
the highest standards. To ensure your new heater will give years of trouble free service please carefully
read the following instructions.
POSITIONING
The heater should be horizontally sited allowing sufficient space for pipe connections and wiring. It should
be sited downstream (after) the pump & filter but upstream (before) any chemical dosing plant. The heater
can be floor or wall mounted using the brackets fitted to the heater.
To assist correct air purging and to ensure that the heater remains completely full of water during operation
the return pipe that carries water back to the pool must incorporate a safety loop or kick-up in the pipe
work, installed as close as possible to the heater (see diagram above, left).
WEATHER PROTECTION
The heater should be installed within a dry weather proof enclosure.
CAUTION !
If the heater is not used during winter months in must be drained to prevent frost damage.

FLOW REQUIREMENT
The Flow-Line heater is factory set to accept input water from the left and exiting on the right, this can be
reversed by rotating the flow switch 180° (i.e. ½ turn).
Warning! The flow switch paddle can be damaged when reversing the flow direction if it is lifted by
more than 5-mm from its housing and turned with force. If the flow switch has been rotated it is important
to ensure that it is finally locked down in the correct orientation perpendicular (at right angles) to the flow
of water.
The flow rate of water entering the heater must not exceed 13,000-litres per hour (2,860 Imp Gallons per
hour. A higher flow rate will require the installation of a by-pass to prevent damage to the heating elements.
The heater will not operate with a flow rate of less than 1,000-litres per hour (220 Imp Gallons per hour).
ELECTRICAL CONNECTION
The heater must be installed in accordance with the country / regional requirements & regulations. In any
event the work must be carried out by a qualified electrician who will provide a certificate of conformity
upon completion of the work. The power supply must be fitted with a RCD.
The heating element(s) in the Flow-Line heater are pre-wired to the main terminal block and are ready to be
connected via a contactor.
POWER REQUIREMENTS
Power Output Single Phase
Voltage Amp
2-kW 230V 9
3-kW 230V 13
4.5-kW 230V 20
6-kW 230V 27
9-kW 230V 40
12-kW 230V 53
Power Output 3 Phase
Voltage Amp
6-kW 400V 9
9-kW 400V 13
12-kW 400V 18
15-kW 400V 22
18-kW 400V 26
CONTACTOR CONTROL CIRCUIT
The pre-wired control circuit is terminated within the electrical enclosure, all control circuit components
have been factory pre-wired and provide a single volt free switch output (see wiring diagram attached).
Control Components Include:
Quantity Description
1 0˚C to 40˚C Control Thermostat
1 55˚C Pre-Set High Limiting Manual Reset Thermostat
1 Flow Switch Pre-Set 1,000-litres per hour (220 Imp Gallons per hour).
Control Circuit Important Electrical Data:
Limited by the flow switch (reed switch)
Contact Rating - 90.0 W/VA
Switching Current MAX - 1.0 Amp
Switching Voltage MAX - 230V AC
The control circuit includes a transil spike voltage protection

WATER QUALITY
The water quality must be within the following limits:
PH 7.0 - 7.6
Chloride Content MAX: 150-mg/litre
Free Chlorine: 2.0-mg/litre
Total Bromine: 2.0 - 4.0-mg/litre (2 - 4 ppm)
Total Dissolved Solids (TDS): 1,000 - 2,000 ppm
Stainless Steel heaters are NOT suitable for use on saline (salt) water pools.
OPERATING INSTRUCTIONS
Upon completion of the installation, run the water-circulating pump to purge the system & heater of air (i.e.
Remove any trapped air in the system & heater).
When the water circulating pump is operational and delivering in excess of 1,000-litres per hour of flow
(220 UK gallons), and the temperature set point dial is set to a value higher than that of the water tempera-
ture the control circuit will provide the external contact (not supplied) with the signal to switch on, if wired
correctly the red indicator light will illuminate. In this mode the heater is on and heating.
Q = How long will it take to heat my pool?
A = Assuming no heat losses, and a heater sized in the ratio 1.5-kW per 1,000-
UK gallons of water (4,545-litres): it will take 2 days of continuous running to raise the temperature of a
pool from tap temperature to swimming temperature. Heat loss will slow the heating process, particularly
during periods of cold weather, hence the higher the water temperature is to be maintained above average
ambient air temperature, the slower the heating process will become. The only influencing factors are the
level of insulation and the location of the pool with regard to wind shelter.
Useful advice: To reduce running costs and speed up the heating process; Insulate the pool wherever
possible. A floating solar cover is an essential minimum to retain heat.
TROUBLE SHOOTING
Heater will not switch to heater on mode (red light illuminated)
In most cases this will be as a result of one of the following not being met.
Possible Cause 1.) The set point temperature has been achieved.
To confirm if the set point has been achieved increase the set point by rotating the temperature dial to a
higher temperature. If the heater then switches on the pool had reached the previously selected set point
temperature.
Possible Cause 2.) The high limiting thermostat has tripped.
Remedy; Remove the black button cover and press the red button to re-set (See diagram on following
page). If a positive click is felt the cause of the tripping must be investigated and could be caused by a de-
bris / mineral build up or an air pocket trapped inside the flow tube of the heater.
Possible Cause 3.) Insufficient Flow.
A.) Firstly check that the flow switch is located in the correct orientation. An arrow moulded into the top of
the flow switch shows the direction that the water should be passing through the heater. If you are passing
water through in the opposite direction refer to the Flow Requirement section earlier in this manual to ad-
just the flow direction.

[BLANK FOR YOUR NOTES]
TROUBLE SHOOTING CONTINUED
B.) If using a sand filter check the pressure gauge and back wash if necessary.
C.) If using a cartridge filter, remove the cartridge and run the system only as a pump. If the heater then
switches on then a blocked cartridge can be confirmed as the problem & needs to be cleaned or replaced.
Note in some cases the high limit thermostat tripping and a low flow velocity can be linked; When a filter
becomes chocked air can be drawn into the filtration system and become trapped inside the heater so caus-
ing the thermostat to trip.
If you experience any further problems please contact your supplier.