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HeatStar XF EC Product Manual

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XF EC
Product Manual
© Copyright HS Europe Limited 2012
All rights reserved. No part of this document may be stored in a retrieval system, or transmitted in any form or by any means to persons not
employed by Heatstar without written permission of HS Europe Limited.
Although every effort has been taken to ensure the accuracy of this document it may be necessary, without notice, to make amendments or
correct omissions. HS Europe Limited cannot accept responsibility for damage, injury, or expenses resulting there from.
Printed in the UK

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Summary of Contents for HeatStar XF EC

  • Page 1 All rights reserved. No part of this document may be stored in a retrieval system, or transmitted in any form or by any means to persons not employed by Heatstar without written permission of HS Europe Limited. Although every effort has been taken to ensure the accuracy of this document it may be necessary, without notice, to make amendments or correct omissions.
  • Page 2 IMPORTANT This product has been thoroughly tested before leaving the Heatstar factory. However, please check at the earliest opportunity that the product has arrived in good condition and that no transport damage is apparent. If any damage is suspected, please contact the suppliers / carriers immediately.
  • Page 3 The Heatstar product is in any way incorrectly applied for the application in terms of performance capacity or suitability. The Heatstar product is installed in any way that is not in accordance with current procedures as defined by HS EUROPE LIMITED from time to time and documented in the installation manual.

  • Page 4: Table Of Contents

    HOW TO USE THIS MANUAL This manual provides information to support the installation and operation of the Heatstar swimming pool environmental control product. The manual is divided into sections covering the various aspects of the installation and operation procedure. The following index is given to assist in locating and using the information...

  • Page 5: Warranty Registration

    To ensure that the correct warranty is given and to enhance response and efficiency should a service call prove necessary under the manufacturers warranty, the ‘Warranty Registration Form’ should be completed and returned to Heatstar as soon as possible. The information contained will definitely NOT be forwarded to any third party and your statutory rights are not affected.

  • Page 6: Climate Control Requirements

    CLIMATE CONTROL REQUIREMENTS : POOL WATER TEMPERATURE : The pool water requires to be heated to an acceptable temperature. Within a typical indoor pool, the pool water is normally heated to a temperature between 26°C and 31°C. The vast majority of the heat loss from the pool water is through evaporation from the pool surface into the pool room air.
  • Page 7 HOW DOES A 'POOL WATER SURFACE COVER' WORK ? Savings on operating costs are often possible through the use of a pool surface cover. Such a cover primarily acts to 'seal off' the pool water surface when the pool is not in use, reducing evaporation and heat loss to an absolute minimum.

  • Page 8: Product Overview

    PRODUCT OVERVIEW PURPOSE : The Heatstar is a product which is intended to be used, in association with other equipment and services, to facilitate control of the environment within an indoor swimming pool. The term ‘environmental control’, in this instance, relates to temperatures, humidity levels and ventilation provision.

  • Page 10: Principle Of Operation

    However, a small amount of the pool room air sucked into the Heatstar product is blown away to out side using an ‘exhaust air’ fan. At the same time, an equally small amount of fresh air is allowed to be sucked into the Heatstar and then mixed with the air being re-circulated back to the pool room.
  • Page 11 To reduce the amount of heat lost in this way, the Heatstar incorporates a ’plate air-to-air heat exchanger’. This is a simple non-mechanical device which consists only of a series of small channels through which air can pass.

  • Page 12: Installation Requirement Summary

    If a ‘one piece’ plastic ceiling is to be used, then avoid removing the access panels on the Heatstar product while the fan is running, otherwise the ceiling may be damaged. Such ceilings will also be prone to move significantly either up or down due to the ventilation effect of the Heatstar product.

  • Page 13: Off Loading And Manoeuvring The Product

    OFF LOADING & MANOEUVRING THE PRODUCT The Heatstar is heavy and the use of lifting apparatus is advised to safely off load the product from the delivering lorry and to manoeuvre the product into position. Do not drop or jar the product from any height - not even two or three inches. Move it gently and progressively.

  • Page 14: Positioning The Product

    Alternatively, simply circle the floor hole a generous bead of exterior use silicon frame sealant, as well as around the base frame of the Heatstar. It may be necessary to tilt the Heatstar to aid access for this procedure and take all necessary care and assess all risks in doing so.

  • Page 15: Air Distribution Duct System

    The intake duct should increase in size so it is larger than the area of the pool air intake duct spigot on the Heatstar. It is recommended that the air intake spigot on the Heatstar should not be positioned directly through the pool room wall as excessive noise transfer may occur.
  • Page 16 Any electrics located within the plant room are housed within a suitably sealed enclosure. In this instance, part of the casing of the Heatstar may be seen to sweat during cold weather due to the close proximity of cool fresh air within the unit, which is quite normal.
  • Page 17 EXHAUST AIR OUT FRESH AIR IN FLEXIBLE DUCT CONNECTIONS POOL AIR INTAKE SUPPLY AIR AIR FILTER ACCESS DISCHARGE (END DISCHARGE) HEATSTAR XF EC...

  • Page 18: Pool Water Pipe Connections

    ‘Installation Services’ document supplied with the product, further copy available on request. PIPE WORK CONNECTIONS : The inlet and outlet to the Heatstar are connected via the return line going back to the pool i.e. after the pump and filter and before the chemical dosing.
  • Page 19 Any existing or independent method of pool water heating must be installed down stream of the Heatstar. In the event that a solar panel heating system is used in conjunction with the Heatstar, care should be taken to ensure that the flow rate of pool water through the filtration circuit is not reduced through the necessity to force water through the solar panel circuit.
  • Page 20 POOL WATER PLUMBING FROM POOL BACK TO POOL 1 : POOL FILTERATION PUMP 4 : MANUAL ISOLATION VALVES 7 : CHEMICAL DOSING 2 : MULTI PORT VALVE 5 : HEATSTAR UNIT 3 : POOL WATER FILTER 6 : INDEPENDANT HEATER (IF APPLICABLE)

  • Page 21: Boiler System Pipe Connections

    The Heatstar simply transfers the heat provided by the boiler into the pool room air / pool water, when necessary. The heat produced by the boiler is taken to the Heatstar using a closed circuit of pipe work filled with water, similar in principle to a standard central heating system.
  • Page 22 The external heating valve should open and allow L.T.H.W. to the air heating coil when electrical power is provided. The electrical supply to the valve from the Heatstar is a switched 230v 1 Amp supply which is either on or off and not proportional.
  • Page 23 The by-pass should be controlled by a pressure pre-set valve which should be adjusted to provide the correct flow through the Heatstar when either one or both of the internal zone valves are in the open position. Alternatively, it is possible to use a dedicated motorised valve as the by-pass. Such a valve would be powered open when both internal air and water heating valves were closed.
  • Page 24 2 : BOILER WATER CIRCULATING PUMP 3 : MANUAL BY-PASS VALVE 4 : MANUAL ISOLATION VALVES 5 : HEATSTAR UNIT- INC. AIR AND WATER HEAT EXCHANGE COILS BOILER PLUMBING HEATSTAR SUPER VERSIONS 5 : HEATSTAR UNIT - INC. AIR HEAT EXCHANGE COIL...

  • Page 25: Electrical Connections

    230v power electricity supply, FROM Heatstar, TO external boiler water by-pass motorised valve. This electricity supply is present when the Heatstar senses that there is no demand for air or pool water heating. Note : a 0v pair of switched contacts are also provided within the Auxiliary Electrical Connection box as an alternative method of switching the boiler demand.
  • Page 26 Heatstar can be damaged. Such damage is not covered under the manufacturers warranty. CIRCUIT BREAKER : In addition to an RCD, the mains supply to the Heatstar must be protected by a Miniature Circuit Breaker (MCB). An MCB is a circuit overload protection device similar to a simple fuse, but re-settable.
  • Page 27 PHASE ROTATION (3 PHASE MODELS ONLY) : If the Heatstar is to be run on a Three Phase electricity supply, the direction of phase rotation must be confirmed to be correct on first connection of the mains supply. This is normally the responsibility of the electrical contractor.
  • Page 28 Auxiliary Electrical Contacts Exhaust Fan Supply Fan Slow Fast Slow Fast...
  • Page 29 6 : BOILER CIRCULATING PUMP 2 : MCB 7 : AIR HEATING MOTORISED VALVE 3 : LOCAL ISOLATOR SWITCH 8 : POOL WATER TEMPERATURE STAT 4 : HEATSTAR UNIT ELECTRICAL CONNECTIONS 9 : POOL WATER HEATING MOTORISED VALVE 5 : FUEL BOILER...
  • Page 30 The boiler supplying heat to the Heatstar should not be governed by any form of time clock control. The Heatstar may call for heat from the boiler at any time, day or night, and, if that heat is not available, then control of the pool room environment will be compromised.
  • Page 31 The electrical link in the Heatstar comprises of a pair of terminals – one terminal has a 12v feed, if this feed is switched via a remote relay so that it connects to the second terminal, then ‘cover open’ mode is selected. The relay requires to maintain a ‘closed circuit’...

  • Page 32: Condensate Water Drainage

    It is necessary that a U-BEND TRAP be included in the pipe to prevent the suction effect of the fans in the Heatstar from sucking up the condensate water back into the unit. The trap should have a drop of at least 130mm.

  • Page 33: Principle Of Control

    The control setting simply tells the Heatstar what temperature you consider to be ‘warm enough’. The heat output available from the Heatstar is a fixed quantity and increasing the control setting will not serve to increase the amount of heat coming from the Heatstar at all.

  • Page 35: About The Controls

    Note that the temperature and humidity readings displayed by the controls relate to the conditions at the location of the Heatstar and may differ slightly from those measured within the actual pool room. Normally the stats will display the actual temperature or humidity, as measured at the time.

  • Page 36: About The Heatstar Control Panel

    ABOUT THE HEATSTAR CONTROL PANEL ‘POWER’ Neon - This neon, when lit, indicates that mains electricity is being supplied to the Heatstar. ‘POOL WATER FLOW CUT-OUT’ Neon - This neon, when lit, indicates insufficient pool water flow through the Heatstar.
  • Page 37 SWITCHING OF POOL COVER MODES : A 12v switched link is provided within the Heatstar unit to govern switching between the two modes. A simple manual switch is provided with the unit, which can be positioned within the pool room and wired back to this link, to control the air temperature mode.
  • Page 38 INTERNAL LIGHT : The Heatstar unit is fitted with an internal light which can be used to illuminate the special supply air fan. The light is switched on and off by a manual switch on the end of the unit.

  • Page 39: Initial Control Settings

    INITIAL CONTROL SETTINGS The controls should initially be set as follows : CONTROL SETTING DEHUMIDIFICATION - 65 : Full Ventilation Rate switch on point. ‘In use’ period heating switch off point. AIR TEMPERATURE - 30 : ‘Set back’ period heating switch off point. 22 : POOL TEMPERATURE - 29 :...

  • Page 40: Starting The Heatstar

    SWITCH ON FUEL BOILER Ensure that the fuel boiler and associated circulating pump is ready to function. If the fuel boiler is controlled via the Heatstar, the boiler may not come on until the Heatstar is switched on and demanding heat.

  • Page 41: Commissioning The Installation

    On the Heatstar control panel, the 'POOL WATER FLOW CUT-OUT' red neon should now be lit. If there is a head of water above the Heatstar, the flow sensor may require adjustment. Should this be the case, please contact Heatstar for details.
  • Page 42 Such a temperature is obviously very hot and is not far short of boiling. Therefore the copper pipe entering the Heatstar should be far too hot to hold for any length of time. If this is not the case, then the boiler is not supplying enough heat to the Heatstar.

  • Page 43: About The Warming Up Period

    Seasoning of wood & plaster : With a new pool room construction, when the Heatstar is first switched on and the pool room air heated, the humidity levels could become very dry until the pool water reaches normal temperature.

  • Page 44: Adjustments To The Controls

    The boiler supplying heat to the Heatstar should not be governed by any form of time clock control. This also applies to the boiler water circulating pump. The Heatstar may call for heat from the boiler at any time, day or night, and, if that heat is not available, then control of the pool room environment will be compromised.

  • Page 45: Basic Maintenance Requirement

    The pool room air filter is positioned within the air duct spigot connection sucking air from the pool room. The purpose of the pool room air filter is to prevent the finned air heat exchange coils within the Heatstar from becoming blocked.

  • Page 46: Frost Damage Prevention

    Disconnect and drain the pool water circulation pipe work circuit. Consider where such a large quantity of water will go! Flush out, using a hose, the pool water inlet and outlet connections on the Heatstar with FRESH water and drain again.

  • Page 47: Corrosion Damage Prevention

    However, the metal alloys used within the Heatstar are selected due to their high durability and, if a correct and appropriate chemical balance is maintained within the pool water, and the method of chemical introduction is appropriate, then the Heatstar will be protected from such corrosion damage.
  • Page 48 INCORRECT WINTERISATION : If the Heatstar and filtration system are not required to be in operation for a period of time and are not flushed with fresh water, then the conditions of the stagnant pool water retained within the system may prove damaging as the water evaporates to leave increased concentration of corrosive chemicals.

  • Page 49: Fault Finding

    If the ‘POWER’ amber neon is off and other neons on the Heatstar are lit, this indicates that the ‘POWER’ neon bulb is faulty.
  • Page 50 Please note that, during cold weather, some condensation on double glazing may be anticipated and is normal. POOL WATER FLOW CUT-OUT : If this red neon is lit then there is insufficient flow of pool water through the Heatstar. If this is lit, check that : The pool water filtration pump is running.
  • Page 51 The heating of the pool room air is a very simple process : The heated boiler water is circulated through a ‘car radiator’ type coil within the Heatstar. The pool room air is blown through this coil, picking up heat as it does so.
  • Page 52 If the FRESH AIR VENTILATION green neon is lit due to excess pool room air temperature, then the Heatstar is attempting to reduce the pool room air temperature (see ‘ABOUT THE CONTROLS’). The green neon under the AIR TEMPERATURE control is lit.
  • Page 53 Each heating coil has a safety over-heat cut-out. In the event that a cut-out has occurred, the cut-out is re-set simply by switching the mains electricity to the Heatstar off and then back on again. If the cut-out re-occurs, the cause of the cut-out requires to be investigated and resolved. Failure to do so...

  • Page 54: Extended Warrantees

    HEATSTAR EXTENDED WARRANTEES In the UK the Heatstar is supported by a full parts and labour warranty which initially runs for one year from the original supply date. When this initial period expires, continuing extended warranty cover is then available at an additional premium.

  • Page 55: Disposal Of Redundent Product

    DISPOSAL OF REDUNDENT PRODUCT The refrigeration circuit within the Heatstar incorporates refrigerant and oil. When the time comes to renew the Heatstar, a refrigeration company should be employed to recover any remaining refrigerant and to safely dispose of the oil.

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