Elecro Engineering In-Line + Swimming Pool Heater Parts list manual

PLEASE READ CAREFULLY BEFORE INSTALLING
Do Not Discard, Keep For Future Reference
Incorrect Installation Will Affect Your Warranty
In-Line + Swimming
Pool Heater
Installation Instructions
& Operating Manual

POSITIONING
Your heater must be screw fixed to a firm base or wall. The heater MUST be horizontal and
upright i.e. with the control enclosure located above the flow tube (see diagram below). Under no
circumstances should the heater be operated in any other orientation.
The heater should be installed at a low point in the filtration system. It should be positioned after
(i.e. downstream) of the filter but before (i.e. upstream) of any dosing or other water treatment
plant.
NOTE If the
flow direction
is reversed
(explained
later in this
booklet) the
heater MUST
remain sited
after the filter.
Only clean filtered water
should enter the heater.
It is essential that the pipe work connecting to and from the heater has a minimum bore (internal
diameter) of 1¼’’ (32-mm).
To assist correct air purging and to ensure the heater remains completely full of water during
operation, the return pipe which carries the water back to the pool must incorporate a safety loop
or kick up in the pipe, installed as close as possible to the heater (see diagram on following
page).
Note: When coupling to flexible pipe a safety loop can simply be created by routing the pipe up
and over an obstacle. Remember to use pipe clips to securely fasten all hose connections.
PIPE WORK

WEATHER PROTECTION
The heater should be installed within a dry weatherproof enclosure.
CAUTION
If the heater is not used during winter months it must be drained to prevent frost damage.
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).
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. If required your electrician may replace the
supplied cable entry gland with a larger one to secure the cable powering the heater, this will not
affect your warranty if carried out by a qualified electrician.
Cable section: should be calculated at 5-amp / mm² for distances up to 20 metres (these sections
are indicative and should be checked and adapted if necessary for cable lengths over 20 metres).
POWER REQUIREMENTS
Power Output Volt (V) Amp
2-kW 230 9
3-kW 230 13
4.5-kW 230 20
6-kW 230 27
9-kW 230 40
12-kW 230 53
15-kW 230 66
18-kW 230 79
ELECTRICAL CONNECTION
3 Phase
Power
Output
400V
Star /
230V
Delta
Amp
6-kW 400V / 230V 9 / 15
9-kW 400V / 230V 13 / 23
12-kW 400V / 230V 18 / 31
15-kW 400V / 230V 22 / 38
18-kW 400V / 230V 26 / 46
24-kW 400V 35

The water quality must be within the following limits:
PH 6.8-8.0
TA (Total Alkalinity) 80 - 140ppm (parts per million)
Chloride Content MAX: 150-mg/litre
Free Chlorine: 2.0-mg/litre
Total Bromine MAX: 4.5-mg/litre
TDS (Total Dissolved Solids) / Calcium hardness 200 - 1000ppm (parts per million)
Stainless steel heaters are NOT Suitable for use on saline (salt) water pools.
Only heaters with Pure Titanium Flow Tube And Pure Titanium elements are suitable for use on
saline (salt) water pools.
FLOW REQUIREMENTS
Your heater is factory set to accept input water flow entering on the left and exiting on the right,
this can be reversed by rotating the flow switch 180° (i.e. ½ turn) (see diagram below).
The flow rate of water entering the heater must not exceed 17,000-litres per hour (3,740 UK
gallons per hour). A higher flow rate will require the installation of a by-pass to prevent damage
to the element(s).
The heater will not operate with a flow rate of less than 1,000-litres per hour (220 UK gallons per
hour).
WATER QUALITY
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 in the correct orientation perpendicular (at right
angles) to the flow of water.
Water chemistry is complicated if in doubt seek expert advise.

IN-LINE + DIGITAL CONTROLLER KEY
The digital controller fitted to the In-Line + heater has been pre-programmed with all the
necessary parameters to ensure reliable service & operation. Below is a key explaining the
controllers buttons & LED signals however these will all be explained in detail later in this
booklet.
Press and hold for 2 seconds to power the control on / off.
Press to increase required pool temperature.
Press to decrease required pool temperature.
Press and release to activate / deactivate ‘Priority of Heating’.
The actual pool temperature is displayed in the red upper display. The lower green display
‘required temperature’can be selected by the user. This is the temperature you would like your
pool water to be maintained at.
Priority of Heating is a function that ensures your pool water is constantly maintained at your
required temperature. When Priority of heating is activated the Priority of Heating Icon on the
bottom right of the display will illuminate. The control will now monitor the pool temperature,
and start both the pool circulation pump and heating process when necessary - please see pump
interlock section for details on how to connect the pump interlock cable.
When illuminated
unit is heating

PUMP INTERLOCK CABLE
The In-Line + heater is supplied complete with a pump interlock cable that connects into the left
hand side of the heater enclosure, directly below the power in cable entry gland.
To connect simply remove the rubber protection cap from the female connector fitted to the
heater enclosure, insert the male connector supplied on the 5m cable. When fully inserted rotate
the locking nut onto the female connector so that the connector is locked in position.
The end of the cable has 2 wires that need to be connected in order to by-pass the time clock
controlling the swimming pool pump (See suggested wiring diagram below).
NOTE - Do NOT connect the pump interlock cable directly to the swimming pool pump as this
will result in overloading the heaters digital controller.
TIME SWITCHING DELAY
To prevent overheating of the switch components within the heater caused by frequent on and off
switching (cycling), the In Line + digital controller has been pre-programmed with a time delay
function. This prevents rapid fluctuations in temperature or velocity from switching the heater on
and off more than once in a two minute period.
The time delay mode is indicated by the flashing LED next to the word HEAT on the digital
display.
DIFFERENTIAL
When the pool water has reached the required temperature the heater will switch off and will not
switch back on until the water temperature has dropped 0.6˚C. This value is known as the
differential and is also in place to prevent overheating of the switch components caused by
cycling.

Heater will not switch to HEATER ON mode
In most cases this will be the result of one of the following not being met.
Possible Cause 1.) The required temperature has been achieved.
To confirm that the digital controller is requesting the unit to heat check that the window next to
the word HEAT is illuminated. If illuminated go to step 2, if not illuminated increase the required
temperature to a value higher than the current water temperature. Confirm whether the heater
now switches to HEATER ON mode
TROUBLE SHOOTING
Possible Cause 2.) The high limiting thermostat has tripped.
Remedy; remove button cover and press red button to re-set (See diagram below). If a positive
click is felt, the cause of the tripping must be investigated and could be caused by a debris build
up or air pocket trapped inside the flow tube of the heater.
Step 2 - Push the red button
Step 1 - Unscrew the black cover
Possible Cause 3.) Insufficient Flow.
The heater will display a noFL alarm message in the upper (red) display window when the heater
has detected that the flow rate has dropped below 1,000-litres per hour or has stopped
completely.
HEAT = If Continuously Illuminated
Indicates that the water temperature has fallen
below the required temperature.
HEAT = If Flashing
Indicates that the heater is in timed delay mode (see
previous page).
PRIORITY HEATING
REQUIRED
TEMP

If using a cartridge filter: Confirm this by running the system with the cartridge removed from
your pump & filter unit, this will supply the heater with the maximum flow rate your unit is ca-
pable of. If the heater then switches on (i.e. red light on) a blocked cartridge can be confirmed to
be the cause. The cartridge should be cleaned or replaced.
If using a sand filter: Check the pressure indicator on your sand filter and back wash if necessary
Note; In some cases the high limit thermostat tripping and a low flow rate can be linked; When a
filter becomes choked air can be drawn into the filtration system and become trapped inside the
heater so causing the thermostat to trip.
TROUBLE SHOOTING CONTINUED
The water entering my pool doesn’t feel much warmer
The temperature gain of the water after it has passed through the heater will be directly
proportional to the volume of water being pumped in relationship to the power output of the
heater.
For example: A 6-kW heater, when connected to a 4000-litre per hour pump, will produce a lift in
temperature of approximately 1.2˚C (almost undetectable to the human hand). However, as the
water being heated is re-circulated from a single body of water, the time required to heat it
remains unaffected by the volume of flow. A popular misconception is that slowing down the
flow rate will speed up the heating process.
A large domestic pool pump of 1-horsepower will draw less than 1-kW in a one hour period. The
conclusion of the test should prove that for example a 6-kW heater and a ½ horsepower pump
will draw between 6.3-kW to 6.5-kW in one hour. It is impossible for an electric heater to waste
energy, if it is drawing power then that power will be turned into heat that will be transferred to
the water.
Quick Function Test
Observe the property’s main electricity meter when the heater is on (i.e. Red Heating indicator is
illuminated) and then observe it again when the heater is in standby mode. The test should show
that the meter is recording more electricity being used by the heater when the Heating indicator is
illuminated.
It is impossible for an electric heater to waste energy, if it is drawing power then that power will
be turned into heat that will be transferred to the water.
Accurate Function Test
If a more accurate test is required to confirm that your heater is delivering the specified heat out-
put, two electricity meter readings will need to be taken from the property’s main electricity
meter, with an exact one hour interval (i.e. take one meter reading and then a second reading
exactly one hour later). Then by subtracting the first reading from the second reading the number
of units (kilo watts kW) consumed can be calculated. Note that your heater is also rated in kW
hours. The pool pump and heater will need to be running continuously during the test (i.e. with
the Heating indicator illuminated).
To avoid inaccurate results when performing this test, it is important to refrain from using other
high current drawing appliances in the property (such as tumble dryer, showers, cooker etc).

The flow tube does not feel warm
Due to the high efficiency of your electric heater no warmth should be detectable from the flow
tube of the heater.
The most likely causes of the flow tube feeling warm are
Possible Cause 1.) The heater has been positioned in direct sunlight.
Possible Cause 2.) An air pocket is trapped inside the heater, particularly if the tank feels warmer
at the highest point of the tank (as air rises).
No lights appear on the heater when it is switched on
Possible cause: Power Failure external to the heater - Remedy:
Check any fuses, RCD or other switch components installed in the supply cable.
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-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 sighting 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.
ROHS COMPLIANCE STATEMENT
WASTE OFELECTRICAL / ELECTRONIC EQUIPMENT
This product complies with EU directive 2002/96/EC
Do Not dispose of this product as unsorted municipal waste.
This symbol on the product or on it’s packaging indicates that this product should not be treated
as household waste. Instead it should be handed over to the applicable collection point for the
recycling of electrical and electronic equipment.
By ensuring this product is disposed of correctly you will help prevent potential negative conse-
quences for the environment and human health, which could otherwise be caused by
inappropriate waste handling of this product. The recycling of materials will help to conserve
natural resources. For more information please contact your local Civic office, your household
waste disposal service or the retailer where you purchased the product.
Elecro Engineering Limited certify that our Electric Swimming Pool Heater Range complies in
accordance with RoHS Directive 2002/95/EC on the restriction of hazardous substances.

CE Declaration Of Conformity
The manufacturer declares that the herewith products or ranges
ELECTRIC SWIMMING POOL HEATER RANGE
Are in conformity with the provisions:
of the ELECTROMAGNETIC COMPATIBILITY directive 89/336/EEC, as
amended 93/068/EEC. Controlled by AEMC Measures laboratory—technical report
no P96045T
The harmonised standards have been applied: EN 55014—EN 55104
EN 55011
EN 55022
CEI 801-4
CEI 801-2
CEI 801-3
of the LOW VOLTAGE directive 73/23/EEC.
The harmonised standards have been applied
EN 60335-2-35
Elecro Engineering Limited
Unit 11 Gunnels Wood Park
Stevenage
Hertfordshire
SG1 2BH
UK
Tel: [phone] Fax : [phone]
Website: www.elecro.co.uk Email: [email protected]
Copyright 2010
GUARANTEE
Your heater is guaranteed for 2 years from the date of purchase against faulty
workmanship and materials.
The manufacturer will replace or repair, at it’s discretion, any faulty units or compo-
nents returned to the company for inspection. Proof of purchase may be required.
The manufacturer will not be liable in cases of incorrect installation of the heater, or
inappropriate use, or neglect of the heater.