Instruction Manual for Swimming Pool Heater ZENITH RANGE 96kW, 120kW, 144kW & 168kW

Transcription

1 Instruction Manual for Swimming Pool Heater ZENITH RANGE 96kW, 120kW, 144kW & 168kW Meddings Thermalec Ltd. Kingsley Close, East Way, Lee Mill Industrial Estate, Ivybridge, Devon, PL21 9LL, United Kingdom Tel: Fax:

2 Contents Preface... ii List of illustrations and drawings... iii Pictograms used in this manual... iv 1. GENERAL... 1 Heater construction... 2 Heater operation... 5 Heater technical details... 5 Standards... 5 Materials of construction... 6 Operating data... 6 Control and indication... 6 Electrical data INSTALLATION... 8 Introduction... 9 Installation... 9 Regulations & Codes of Practice... 9 Location Positioning the heater on the flowsheet Positioning and piping connection of the heater Direction of flow through the heater Electrical Installation OPERATION Commissioning First Start-up Water flowrate through the heater Calculation of the water flowrate Decommissioning Winterisation Operation with salt or sea water Fault finding Diagnostics Status Lamps Controller Drift Contactors frequently switching Heater circuit breaker trips Protective Devices on Supply Trip Noise Pool not reaching desired temperature Warranty Page i

3 Preface Thank you for purchasing this Thermalec Pool Heater. Thermalec electric Pool and Spa heaters are designed for the heating of water for swimming pools and spas. It is manufactured in the United Kingdom by Thermalec Pool & Spa Products and marketed worldwide. Established nearly 50 years ago, Thermalec is renowned in the United Kingdom and overseas as one of the foremost names as manufacturers of high quality products for swimming pools and spas. Thermalec Pool and Spa Products is historically best known for its premium electric pool heaters, but latterly has expanded its range of products for pools and spas to bring novel and high quality equipment to the international pool market. Thermalec Pool & Spa Products is a member of Meddings Thermalec Ltd. We hope that you will be more than satisfied with your Thermalec pool heater. At Thermalec, we always welcome customer feedback. Should you have any comments or suggestions regarding this equipment, please do not hesitate to contact us. Thermalec pool heaters are built to the highest standards using quality components and materials. Should you have any queries or experience any problems, please contact your local reseller or contact us directly. We are here to help. In the following pages you will find information on the installation, operation and maintenance of your Thermalec pool heater. Please read through the whole manual carefully and thoroughly before attempting to install or operate this equipment: it contains information important for a safe, efficient and long service life of the heater. In the event of any questions or queries regarding the installation, operation and maintenance of this heater, please do not hesitate to contact us. Kingsley Close, East Way, Lee Mill Industrial Estate, Ivybridge, Devon, PL21 9LL United Kingdom Telephone: +44 (0) Fax: +44 (0) info@thermalec.co.uk Website: Twitter twitter@thermalec Page ii

4 List of illustrations and drawings Figure 1 External features of the Thermalec Zenith ZHR Pool Heater... 2 Figure 2 Sectional model of a typical Thermalec Pool Heater... 3 Figure 3 Suggested heater position on plant room flowsheet Figure 4 Water connection on a Thermalec pool heater Figure 5 Drg. APH Circuit diagram for 96, 120, 144 & 168 kw heaters Page iii

5 Pictograms used in this manual The following pictograms are used throughout this installation, operating and maintenance manual. Their purpose is to draw your attention to particularly important information. The type of information conveyed by the pictograms is described adjacent to each of them. ATTENTION: Prohibited actions or procedures. WARNING or INSTRUCTION: Warning of danger. General warning that special attention should be paid. Important instruction that must be followed. WARNING: Voltage or high voltage: Risk of electrocution. Safety regulations and accident prevention measures must be strictly adhered to. WARNING: Dangerous situation. Serious injury or death may result. The product or its surroundings can be permanently damaged. INFORMATION: Information that must be understood or instructions that must be followed. IMPORTANT: Recommended actions or measures. Page iv

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7 1. GENERAL Page 1

8 Heater construction Figure 1 External features of the Thermalec Zenith Pool Heater KEY 1 Electrical control gear enclosure 6 Drain valve 2 Circuit breakers on front fascia 7 Support foot 3 Control panel on front fascia 8 Water inlet (default) 4 Water outlet (default) 9 Pressure relief safety valves 5 Heater vessel Page 2

9 Heater construction (cont d...) Figure 2 Sectional model of a typical Thermalec Pool Heater KEY 1 Electrical control gear enclosure 7 Inlet baffle plate 2 upvc element holding plate 8 Temperature pocket 3 Outlet baffle plate 9 Water inlet overflow weir 4 Water outlet nozzle (default) 10 Water inlet port (default) 5 Water outlet overflow weir 11 Pressure relief valve port 6 Electrical heating elements 12 Heater vessel wall Page 3

10 Heater construction (cont d...) Thermalec electric heaters are specifically designed for use with swimming pools and spas. The base of the heater is a fusion epoxy coated cast iron vessel through which the water from the swimming pool flows. The vessel is fitted with four safety pressure relief valves, a drain valve and the water inlet and outlet nozzles and its base is designed to support the heater on a flat, solid surface. Overflow weirs are cast into the inside of the heater vessel at the inlet and outlet nozzles. These ensure that the vessel is kept filled with water to a constant level at all times. A baffle plate is suspended inside the heater across its width, downstream of the inlet weir. A similar baffle plate is suspended upstream of the outlet weir. The top edges of each of the cast weirs are slightly sloped. This patented combination of weirs and baffles is designed to impart a spiral regime to the flow of water through the heater. It also prevents the direct impingement of cold water directly on to the heating elements. The inlet and outlet pipework are connected to the heater by upvc solvent weld socket stub flanges. These are attached to the inlet and outlet ports on the cast iron vessel by a steel backing flange, ensuring that the upvc socket can be replaced if ever that were necessary. The outer sheath metal of the spiral circular heating elements is in highly corrosion resistant Incoloy 825. The heating elements are suspended inside the vessel from the thick upvc element holding plate that covers the top of the vessel and from which the removable baffles are also suspended. The heating elements are fitted with their smallest profiles facing the direction of flow. The terminal ends of each element pass through glands in the element holding plate and into the heater control enclosure that is fixed to the top of it. Two temperature pockets protrude into the vessel through the element holding plate, one at the inlet end and the other at the outlet end. These contain the probes of the control and safety over-temperature liquid-filled capillary type thermostats, respectively. An additional pocket accommodates the probe for the pool water temperature thermometer. The joint between the upvc element holding plate and the top flange of the cast iron vessel is made tight by a temperature resistant silicone rubber gasket. The powder coated steel heater control enclosure houses the electrical switchgear, the power connection terminals and control components. Mains circuit breakers are provided. They will interrupt the mains power supply should any problems occur during the normal running of the heater. Power is supplied to the elements through heavy duty contactors. An interlock relay is provided to ensure that no mains power can be supplied to the heating elements if the interlock signal from the main pool filter pump is absent. The heating elements on Zenith models are organised in 3/4 banks. A time delay relay engages the contactors in two separate stages to reduce electrical surge and avoid a voltage drop when the heater switches on. Page 4

11 Heater construction (cont d...) The heaters are also equipped with a two stage temperature controller that overrides the time delay in the event of a rapid temperature rise. The supply of power to the heating elements is also conditioned by the two-stage control thermostat and the over-temperature safety thermostat, which must both be set for power to be supplied to the elements. The over-temperature thermostat is provided with a circuit breaker shunt trip that is activated on attainment of the factory set temperature. This trip must be manually reset to permit power to be supplied to the elements. A fuse protects the heater power circuits, and a second fuse protects the heater status indicator lamps. The front face of the enclosure forms the heater control panel and accommodates the mains circuit breakers, the pool temperature setting dial, heater status indicator lamps, the over-temperature thermostat manual reset button, and the indicator dial of the heater outlet water temperature thermometer. Heater operation Before switching any power on, it is ensured that the heater is full of water and that water is flowing through it. The mains power is then switched on, followed by the circuit breakers on the heater. A red indicator shows that the heater is powered. An amber light on the heater indicates that the filter pump is in operation. If the pump does not operate or if the pump interlock has not been fitted, the heater will not heat. The desired pool temperature is now set using the thermostat dial. Two green lights on the heater light in sequence, with a short time delay in between, indicating that the three heating element banks are powered and water is being heated. When the set temperature is reached, the green lights are extinguished. A white light on the heater indicates that the water temperature is below the factory set safety thermostat trip level. If this temperature is reached, the heater has overheated. In this case, the safety thermostat trips and the unit is shut down. This trip must be reset manually. In normal operation, the green lights will only be lit (and heating will occur) if all the other lamps are lit and the pool water temperature is below the set temperature. Heater technical details Standards Thermalec pool and Spa heaters are CE marked and comply with: EU Council Directive 89/336/EEC & 93/068/EEC on Electromagnetic compatibility EU Council Machinery Directive 98/37/EEC EU Council Low Voltage Directive 2006/95/EEC & 72/23EEC Harmonised Standards: EN55014, EN55104, EN5501, EN5502, CEI801-2, CEI801-3 and EN Page 5

12 Materials of construction Heater vessel: Element holding plate: Gasket: Water connections: Heater elements: Electrical enclosure: Fusion epoxy coated cast iron upvc Silicone rubber upvc socket (metric or imperial) Incoloy 825 sheath Powder coated steel or leather grain coated steel Operating data Water inlet/outlet: Socket for 63 mm or 3 NB pipe Max. water temperature: 52 C heater outlet Operating pressure: 2.0 bar max. Ambient temperature: 40 C max. Pool temperature control range: 15 C to 45 C Thermostat operating differential: 0.5 C Heater technical details (cont d...) Permissible water flowrate ranges Zenith Heater Installed power 96 kw 120 kw 144 kw 168 kw Maximum (hard water) l/min Maximum (soft water) l/min Minimum l/min Control and indication Power supply isolation: Water temperature cut-out: Thermostats: Pool temperature indicator: Pool temperature control: Mains indicator lamps: 2 x 3 pole 100A heavy duty circuit breakers (96 & 120 kw heaters) and 3 x 3 pole 100A heavy duty circuit breakers (144 & 168kW heaters) on front fascia. Factory set to trip at water outlet temperature of 52 C. Manual reset on front fascia. Pressurised liquid filled capillary type. Pressurised liquid filled capillary thermometer with analogue indicator dial. Analogue dial - calibrated 15 C to 45 C and graduated at 1 C intervals. Red (mains power on), Amber (filter pump running) Page 6

13 Control and indication(cont d ) Status indicator lamps: Red (heater circuit breaker armed and powered), White (safety thermostat trip armed), Amber (pump interlock relay OK), 4 x Green (heating elements powered). X 1 Red EHOT. Electrical data Protection level: IP 21 Fuses: 2 x 2 Amp Pump interlock voltage: 230 V AC Element heat flux: 11.5 W/cm 2 max. Standard Power Supply: 400V/3ph/50Hz Model Ref. Load kw Current Amps Per phase Elements (no. x nominal kw) ZHR kw x 8 kw ZHR kw x 8 kw ZHR kw x 8 kw ZHR kw x 8 kw Weights and dimensions Packed dimensions: 81 x 58 x 83 cm Packed weight: 145 kg Page 7

14 2. INSTALLATION Page 8

15 Introduction The Thermalec Zenith heater is designed for use with swimming pools, spas and other similar installations. To prevent damage to the heater it must not be operated unless it is fully flooded with a sufficient flow of pool water. An interlock is fitted, ensuring that the heater cannot be operated unless the filter pump is running. A temperature controller is fitted to allow control of the water temperature in the range 15 to 45 C. The maximum water temperature is limited to 52 C by a safety thermostat. A thermometer displays the heater outlet water temperature when the heater is OFF. When the heater is ON the reading may be slightly higher, depending on the flow rate through the heater. The heater is designed to operate at a maximum pressure of 2 bar (30 psi). Exceeding this limit will operate the pressure relief valves located on the heater vessel. The pool temperature will rise gradually if the heater has been sized according to our published sizing methods. These are designed such that in May of an average year, in North-western Europe, an outdoor pool that is heated during the off-peak power supply period of seven hours a day, will take about five nights to reach the required temperature. It is assumed that the pool would be equipped with a solar cover. The actual time taken to reach temperature is determined by the ambient air and water temperatures and by the overall heat losses from the pool. Installation Regulations & Codes of Practice. This heater must be installed by a competent and certified person, strictly in accordance with the relevant standards and regulations in the country of use for the installation of mains powered electrical equipment in the vicinity swimming. In the UK these standards are BS 7671 (lee Regulations, 16 th Edition) and the SPATA standards. Electrical installations for swimming pools in the UK are classified as Notifiable under Part P of the Building Regulations This means that a qualified electrician, registered with a self-certification scheme, must carry out the work. Alternatively, another person may carry out the work, but it must be notified to the local authority who will arrange for inspection & testing to be carried out. Page 9

16 Location The protection rating of the heater is lp21 and it should be installed in a weatherproof enclosure with good drainage. A suitable anti-condensation heater should be provided in high ambient humidity conditions, since moisture can damage electrical components. The heater must be installed in a cool, dry location. Regulations that stipulate minimum distances for electrical equipment from water sources must be observed. Positioning the heater on the flowsheet The following diagram illustrates a suggested plant flowsheet showing the positioning of the heater with respect to the other plant room process units. Figure 3 Suggested heater position on plant room flowsheet Chemical dosing systems should not be installed adjacent to the heater. lf installed upstream of the heater it must be before the filter. lf installed downstream, a check valve must be fitted to prevent backflow of chemicals when the filter pump is not operating. There should be a drop in level between the pipe leaving the heater and entering the dosing system. The pipe system should have valves to isolate the heater. A shut off valve should be included in the bypass to stop the flow around the heater when not required. Page 10

17 Positioning and piping connection of the heater To enable the power supply cable to be inserted through the back panel, allow space behind the heater equal to at least the depth of the heater casing. The minimum clearance above the heater should be 400mm. The default water flow direction through the heater is left to right, allowing the temperature controller to sense the temperature coming from the pool. This direction can, however, be modified by following the instructions below. The heater must never be installed at the highest point of a pipework system. Water may drain from the heater causing damage to it. The pipework must be designed such that the heater is always full of water. The heater must always be installed horizontally and properly levelled; NEVER install vertically. Pipe connections are stub flanges to suit 120 mm (3") nominal bore pipe (upvc or ABS). lf using ABS the solvent jointing compound must be suitable for both materials. Reducers may be fitted to suit smaller pipes. It is not necessary to fit unions either side of the heater as the stub flanges are easily disconnected from the heater, by removing the nuts securing the aluminium backing flanges to the heater. In very tight installations, the studs themselves may be unscrewed. Figure 3 Water connection on a Thermalec pool heater Page 11

18 Positioning and piping connection of the heater(cont d ) Zenith Range Instruction Manual If required levelling screws can be used in the four holes in the base of the heater. These are used to level the heater. More importantly, they will stop the heater rocking on its base. If the heater is installed on a shelf, the holes may be used to screw the heater down. This can be achieved by bolting the heater down, or by using wood screws from the top. If the heater is connected to rigid pipework and is floor mounted, the levelling screws, together with the pipes and cable will usually keep the heater stable. Direction of flow through the heater The default direction of flow of pool water through the heater is left to right. This allows the temperature controller to sense the temperature of the water coming from the pool. If required, the flow direction may be reversed by exchanging the positions of the probes of the control thermostat and the safety thermostat. This is carried out as follows: a) Switch heater circuit breakers to OFF; b) Switch main power supply and pump interlock supply to OFF; c) Remove main cover; d) Reverse the two probes. The controller probe is situated at the left-hand end of the element plate. The safety thermostat probe is situated at the right-hand end of the element plate and is marked with a short length of white sheathing; e) Move the thermometer probe to the empty pocket on the left-hand side; f) Replace and fix the top cover before reconnecting connecting electrical supplies. Electrical Installation All electrical work must be carried out by a competent and experienced electrician, certified according to the regulations in the country of installation. Earth leakage protection must be provided by fitting a Residual Current Device (RCD) to installations involving swimming pools or spas. The RCD must be rated to carry the current drawn by the heater (see table below) and the current drawn by other items of equipment on the same supply. Overcurrent protection must also be provided in the form of a Circuit Breaker. Due to the continuous high load that will be drawn, the circuit breaker should be rated at least 20% higher than of the current shown in the following table. Page 12

19 Electrical installation (cont d...) Standard Power Supply: 400V/3ph/50Hz Model Ref. Load kw Current Amps Per phase Elements (no. x nominal kw) ZHR kw x 8 kw ZHR kw x 8 kw ZHR kw x 8 kw ZHR kw x 8 kw The size and specification of the cable to the heater should be decided by consulting the electrical regulations applicable in the country of installation. To minimise the effects of voltage drop, the plant room should be located as close as possible to the main electrical supply. The supply cable enters the heater via the removable plate at the back of the heater. The plate should be drilled out to suit the size of cable gland used. Under no circumstances should cable be installed through the metal plate without the use of a gland. To access the terminals, remove the heater cover and terminal cover. The wires of the incoming power supply (L1, L2, L3, N and E) must be connected to the appropriate terminals. It is vital that all wires are firmly terminated into each terminal. A 6mm spanner should be used to ensure that the clamps are pulled firmly down onto the incoming cable ends. Make sure that the cable is of sufficient diameter to ensure a good clamp is made and if required, wind a length of copper strand around the other strands to increase the diameter. After termination, check all the cables for tightness and replace both sets of covers. The heater will not operate without a pump interlock supply that switches 230V ON when the filter pump is running. The live of this supply should be connected to terminal A and the neutral to terminal B of the heater. The supply must be taken from the last device switching the filter pump, to ensure that the heater will switch off at the same time as the filter pump. This pump interlock supply can also be used to control the operation of the heater further. A time switch can (for example) be fitted to interrupt the supply to terminal A, ensuring that it can only come on during specific periods of cheap electricity. This is detailed on drawing APH 1319, together with arrangements for an override switch allowing the filter pump to be run continuously. Thermalec also produce a range of Pool Control Panels, which enable pumps, heating and all other pool items to be controlled from a single control box. All panels are made to order, to match the specific equipment. Please contact the Sales office for more details. Page 13

20 Figure 4 Drg. APH Heater filter pump interlock Page 14

21 3. OPERATION Page 15

22 Commissioning First Start-up When using the heater for the first time (or after it has been isolated for the winter) it is vital that the heater is commissioned using the correct procedure. Failure to do so will result in serious damage to the heater. a) Check heater circuit breakers are all OFF. b) Check main power supply is OFF. c) Check filter pump is OFF. d) Check heater drain valve is closed. e) Set pool temperature controller to less than 15'C f) Check heater isolation valves are OPEN and water is flowing through the heater g) Check that the heater is full of water before proceeding h) Check that time switch (if fitted) is on and heater control supply is enabled. i) Switch on the Filter Pump - Check positive flow of water into pool: Amber pump supply lamp 9ON j) Switch main power supply to ON. Red mains power supply light 3 is ON. k) Remove seal from heater circuit breakers and switch ON Red 6, 7 and Amber 8heater status lamps ON l) Set pool temperature controller to desired temperature First Green heater status lamp 4 ON (closing of contactor can be heard); After a delay of several minutes the second bank of contactors will close. Second Green heater status lamp 5 ON (closing of contactor can be heard). After a delay of several minutes the third bank of contactors will close. Third Green heater status lamp 5 ON (closing of contactor can be heard); After a delay of several minutes the forth bank of contactors will close. Fourth Green heater status lamp 5 ON (closing of contactor can be heard). All lamps are now ON m) Turn filter pump OFF. Amber pump supply lamp 9 switches OFF. Green 4, 5 and Amber 8 heater status lamps switch OFF n) Turn filter pump ON o) Reset the time switch. Page 16

23 Water flowrate through the heater The flow rate of water through the heater should be set within the ranges given in the following table: Flow Rate 96 kw 120 kw 144 kw 168 kw Hard water maximum - use bypass above this rate 9000 gal/hr 9000 gal/hr 9000 gal/hr 9000 gal/hr - minimise scale formation 700 l/min 700 l/min 700 l/min 700 l/min Soft water maximum - use bypass above this rate 4500 gal/hr 4500 gal/hr 4500 gal/hr 4500 gal/hr - improves element life 350 l/min 350 l/min 350 l/min 350 l/min 1920 gal/hr 2400 gal/hr 2880 gal/hr 3360 gal/hr Minimum 160 l/min 200 l/min 240 l/min 280 l/min Calculation of the water flowrate To calculate the exact flowrate of water flowing through the heater, apply the following method: Allow the pump to run with the heater off for a few minutes; Take a reading on the outlet water temperature indicator; Then switch the heater on and allow about five minutes for the temperature to stabilise before taking a second temperature reading. The difference between the two readings gives the exact temperature rise for that particular flow rate; Use the following formula to establish the rate: Flowrate (litres/min.) = Heater kw rating x 14.4 Temperature rise in C Page 17

24 Decommissioning Winterisation If the pool is to be closed over the winter, damage may be caused by chemically treated water and debris left standing in the heater vessel. The following procedure should be followed to preserve the integrity of the heater: a) Switch heater circuit breakers to OFF; b) Switch main power supply and pump interlock supply to OFF; c) Remove main cover and check main terminals for tightness; d) Apply WD40 (or similar to) all electrical components, particularly the contactors; e) Close heater isolation valves; f) Empty vessel using drain valve; g) Remove drain valve locking screw and check for debris at the bottom of vessel with 6mm dowel rod. If the rod cannot be fully inserted then consideration should be given to opening the vessel to remove debris. If the pool is to be kept in a semi-operational condition during the winter then the heater may only be left full of water if the filter pump is fitted with a frost-stat. Operation with salt or sea water If the heater is to be used on sea water pools or salt water pools, it is recommended that the heater vessel be flushed through with fresh water at frequent intervals (approximately after every 3 weeks of use). This is particularly important when the heater is used with very high salinity sea water or in salt spas. Fault finding Safety Warning: The electrical supplies to the heater are potentially lethal. All maintenance and repair operations should be carried out by trained personnel, supported by appropriate safe systems of work. Before removing the top cover ensure that, both the three phase main supply and, the single phase pump interlock supply, are both isolated. Page 18

25 Diagnostics Status Lamps The lamps will light in sequence in steps 1 to 7. The green lamps will only light (and the pool water be heated) when the other lamps are all lit. The following actions should be taken if any of these lamps are not lit: Controller Drift If, over time, the calibration of the temperature controller drifts such that the value set on the dial has to be gradually increased to maintain the same actual pool water temperature, then the thermostat should be replaced. Contactors frequently switching Switching of the contactors every few minutes indicates that the direction of water flow is incorrect. Heater circuit breaker trips Check if red reset button from Safety Thermostat has popped out. lf so reset and wait, if thermostat trips again check for sufficient water flow and air in system. lf trip is not associated with this check individual heating elements for insulation resistance. Protective Devices on Supply Trip If RCD has tripped, first check that other equipment in the installation has not caused the trip, then check heating elements for insulation resistance. lf MCB has tripped, check that it is correctly rated. Noise Excessive "buzzing" when heating indicates t h a t t h e re a r e small amounts of rust on the pole faces of the contactor. WD40 should be applied to the affected area. Pool not reaching desired temperature lf the status lamps are lit as described above and the contactors can be heard engaging, then the heater can be assumed to be operating correctly. lf the pool does not reach the required temperature after an appropriate number of hours then the current drawn by the heater should be checked using a clip-on ammeter. Page 19

26 Diagnostics (cont d ) An alternative method is to set the temperature control several degrees above normal and use the main supply meter to check how many Units (kwh) the heater consumes in an hour. This figure should be slightly above the kw rating of the heater, allowing for the filter pump and other domestic equipment on the same supply. If the power consumption is less than the rating of the heater then the issue is elsewhere in the system, for example: Low voltage supplied to the heater, indicating that cable diameter is too small or run is too long; Inadequate mixing of the warm water from the heater with the cooler water in the pool, leading to a layer of warmer water forming at the height of the inlets. To cure this, aim the direction of the pool inlet jet downwards; Incorrect setting of any time witches fitted to heater or filter pump; The time switches are not synchronised with the main off=peak electrical supply meter; Lack of water flow caused by insufficient pump head, or blockages in the pipework. Warranty The heater is guaranteed for two years against faulty workmanship or materials. This does not cover damage caused by incorrect commissioning & maintenance or by other neglect of the heater. In the event of a claim, Thermalec will at it sole discretion replace the heater, provide replacement parts or effect a repair at its factory or its local distributor. Page 20