Electric Heater Technical Bulletin No. 19

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1 Page 1 of Description The 5.5kW Raypak electric heater is suitable for most Endless Pool installations. In some rare instances, an 11kW heater may be more appropriate. Call the Endless Pools Customer Service Department with any questions regarding heater sizing at (800) or from the UK , from all countries abroad Additional Considerations This heater should only be wired by a licensed electrician. CRITICAL- Read the installation instructions on pages 1 through 5 of this document before installing your heater. The electric heater must be installed downstream from the filter in your water quality system. The heater can be mounted to the same base supplied with the pump and filter, as shown in the Installation Video. However, you may find after reading the installation instructions that another location may be more appropriate. Additionally, access to the heater must be maintained for any future maintenance. Each Raypak electric heater comes factory wired with a pressure switch that senses water pressure created by the circulating pump. Its function is to only allow the heater to come on if the pump is running. However, since this switch senses pressure and not flow, it is important to locate the heater no more than 5 feet above or 5 feet below the water level. If necessary, the heater can be placed on a different grade than the rest of the equipment to meet this requirement (e.g. a small shelf). If the 5' height variance cannot be accommodated, a flow switch may be plumbed in the return line to the pool after the heater. A flow switch can be purchased at a local plumbing supply store. This flow switch would be wired into the electric heater safety circuit Installation Instructions if you have an available circuit breaker (if not follow instructions 19.3A or B) You can use a separate 30 amp electric line, GFCI circuit breaker protected (RCD protected for UK and other countries with the same electrical requirements), to feed the 5.5 kw electric heater. 1) Open the top of the heater by removing the two 5/16 hex/slotted sheet metal screws on the sides of the top. 2) Make sure that the capillary tube does not touch the terminals of the heating ELEMENT or the terminals of the HIGH LIMIT on the top right of the ELEMENT TUBE ASSY. The capillary tube is the thin copper tube that runs from the THERMOSTAT CONTROL on the upper middle of the front panel to the SENSORWELL in the bottom of the ELEMENT TUBE ASSY. 3) Run a set of 3 wires between the 30 amp GFCI circuit breaker (RCD protected MCB for UK and other countries with the same electrical requirements), and the heater (in the US and other countries with the same electrical requirements: two hots L1 & L2, and one ground), (in the UK and other countries with the same electrical requirements: one hot, one neutral and one ground). The wires must be 10 gauge minimum. All appropriate electric codes must be followed. Remove the lower front panel by removing the two 5/16 hex/slotted sheet metal screws. With appropriate wire nuts, connect L1 to the black wire inside the field wiring box labeled L1, and L2 to the red wire inside the field wiring box.

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3 Page 3 of A Installation Instructions for Circuit Saver if you do not have an available circuit breaker (For 5.5kW electric heater only. Not applicable to 11kW electric heaters) For the US and other countries with the same electrical requirements. In the event that you do not have enough circuit breaker space in your breaker panel, or enough current capacity in your breaker panel, the circuit saver feature allows one 220V 30A GFCI protected circuit to be used for both the electric heater and the power unit. This feature only allows one of these pieces of equipment to operate at a time. Pressing the air button for the swim current overrides the heating circuit if the heater is in operation. 1) Open the top of the heater by removing the two 5/16 hex/slotted sheet metal screws on the sides of the top. Remove the lower front panel by removing the two 5/16 hex sheet metal screws. 2) Make sure that the capillary tube does not touch the terminals of the heating ELEMENT or the terminals of the HIGH LIMIT on the top right of the ELEMENT TUBE ASSY. The capillary tube is the thin copper tube that runs from the THERMOSTAT CONTROL on the upper middle of the front panel to the SENSORWELL in the bottom of the ELEMENT TUBE ASSY. 3) With the top open, make sure that there is some slack in the blue safety circuit wire that feeds into the field wiring box. The wire may be wire tied as a bundle with the orange wires. The wire may be simply pulled out of the bundle. If you choose to cut the wire tie, BE CAREFULL NOT TO CUT ANY OF THE WIRES. 4) Run a set of 4 wires between the AS5-TD controller and the heater (two hots, one ground and one relay wire). The relay wire can be as light as 18 gauge. The other wires must be 10 gauge minimum. It will be most helpful to use different color 10 gauge wires. It is imperative that Line 1 remain consistent throughout and the ground wire is not confused. All appropriate electric codes must be followed. 5) Connect the two hot wires to the line side of the contactor in the AS5-TD controller. Note the color of the wire connected to the top line side connection (labeled Line 1 on the attached diagram). This hot wire will be connected to the black wire labeled L1 in the electric heater (see attached diagram). The other hot wire will be connected to the red wire. 6) Connect the ground wire between the AS5-TD controller ground bar and the heater ground lug. 7) With appropriate wire nuts, connect L1 to the black wire inside the field wiring box labeled L1, and L2 to the other red wire. 8) There are two insulated female spade connectors included with the package attached to the heater box. Attach a female spade connection to the relay wire end in the AS5-TD controller. The relay wire gets attached to the spade connection on the circuit board labeled Line Out 1. 9) In the field wiring box, separate the spade connectors that are in the line of the loop of blue safety circuit wire. BE CAREFUL NOT TO BREAK THE MALE SPADE OFF IN THE FEMALE CONNECTOR. Gently sliding the connector side to side along its length should help. Note that bending the connector the short way will fatigue the metal and promote breaking. 10) Attach an insulated female spade connector to the heater end of the relay wire and connect it to the male spade from the loop you just separated. 11) Use electrical tape to tape over the extra female connector so that it does not short out in the field wiring box. 12) Run a set of three 10 gauge wires to connect the power unit to the AS5-TD. Connect the hot wires to the load side of the contactor and the ground wire to the ground bar. Follow the instructions for the motor connection as shown in Technical Bulletin #22.

4 Page 4 of 15 Helpful hints 1) In the unlikely event that the male connector breaks off, clip off the remaining connector remnants, strip the wire, and use a wire nut to connect the relay wire from the AS5-TD to the blue safety circuit wire. 2) If there is a problem with crimping the female spade connector on the relay wire inside the AS5-TD, use the blue safety circuit wire with the taped female end from the heater. To do this reach into the top of the heater and pull off the female connector from the L1 spade lug on the contactor. Wiggling the taped blue wire inside the field wiring box will help indicate which is the proper wire. Cut the wire in half and strip one end. In the AS5-TD attach the wire to the relay wire with a wire nut and attach the other end to the spade connection on the circuit board labeled Line Out 1. The following is a MODIFIED WIRING DIAGRAM showing the Circuit Saver option. If you choose not to use the circuit saver option refer to the schematic diagram on page 8 for wiring instructions of electric heater and refer to Technical Bulletin 23 for wiring instructions for the AS-5TD. There are 4 wires (3 #10 &1 control #18) that need to be run between the AS-5TD controller and the 5.5kW Raypak Electric Heater. Please note that the ground wire is not shown between the controller and heater.

5 Page 5 of B Installation Instructions for Circuit Saver if you do not have an available circuit breaker (For 5.5kW electric heater only. Not applicable to 11kW electric heaters) For the UK and other countries with the same electrical requirements. 1) Feed 220V 30A RCD protected power supply into the AS5TD controller and connect to the line side of the contactor. The contactor will act as a junction box between the incoming power and the heater. 2) Run a set of 4 wires between the AS5TD controller and the heater(one live, one neutral, one ground and one relay wire). The relay wire can be as light as 18 gauge. The other wires must be 10 gauge minimum. It will be most helpful to use different color 10 gauge wires to assure that Line 1 remains consistent throughout. 3) Connect the ground wire between the AS5TD controller ground bar and the heater ground lug. 4) Connect the hot wire to the top connection on the line side of the contactor in the AS5TD controller. This hot wire must be connected to the black wire labeled L1 in the electric heater (see attached diagram). Connect the neutral wire to the red wire in the electric heater. 5) Attach a female spade connection to the relay wire located in the AS5TD controller. The relay wire gets attached to the spade connection on the circuit board labeled Line Out 1. 6) Separate the spade connectors inside the heater junction box in the loop of blue safety circuit wire. Attach an insulated female spade connector to the heater end of the relay wire and connect it to the male spade from the loop you just separated. Use electrical tape to cover the loose female spade connector to be sure that a short does not occur. 7) Run a set of three 10 gauge wires to connect to the power unit. Connect the hot and neutral wires to the load side of the contactor and the ground wire to the ground bar. Follow the instructions for the motor connection as shown in Technical Bulletin #22. The following is a MODIFIED WIRING DIAGRAM showing the Circuit Saver option for UK and other countries with the same electrical requirements. There are 4 wires (3 10 gauge &1 control 18 gauge) that need to be run between the AS-5TD controller and the 5.5kW Raypak Electric Heater. Please note that the ground wire is not shown between the controller and heater.

6 Page 6 of 15 The following is the STANDARD WIRING DIAGRAM for use when not using the circuit saver feature just described. This diagram is for UK and other countries with the same electrical requirements.

7 Page 7 of 15 The following booklet is a copy of the Raypak 5.5kW electric heater Installation and Operating Instructions which can also be found inside the heater box. Please carefully review the installation instructions.

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