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POOL HEATER with built-in flow switch
EXPORT MODELS: 32212CE-E thru 32272PHS-E 33812CE-E thru 33872PHS-E 34112CE-E thru 34172PHS-E
installation, operation and maintenance
OUTLET
INLET
DO NOT OBSTRUCT
PANEL
SERVICE ACCESS
EITHER TERMINAL COVER
TO UNIT BEFORE REMOVING
DISCONNECT ALL POWER
WARNING
ELEMENTON
OFF
P.S.I.
P.S.I. HYD TEST
MAX. WORKING PRESSURE
kW
kW EACH ELEMENT
PHASE
AMPS
VOLTS, 50/60 CYCLE A.C.
SERIAL NO.
MOD. NO.
SWIMMING POOL AND SPA HEATER
coates
UL
TEMPERATURE
CONTROL
FLOW
Publication 1-2012
INTRODUCTION This manual provides installation procedures, operating and maintenance instructions and a parts list for the Coates Pool Heater. Your Coates Electric Swimming Pool Heater has been designed and engineered to provide you with the most progressive quality heating system possible. Its operation is efficient and pollution-free. Models are available for every size or make of pool. To insure a long life of trouble-free service, your Coates Pool Heater should be carefully installed in accordance with the instructions given in this manual. Failure to do so may damage the pool heater and the pool equipment to which it is connected. Only qualified personnel should install and maintain this unit, and, of course, local plumbing and electrical codes have precedence over these instructions. 1.0 DESCRIPTION The Coates Swimming Pool Heater consists of a heating tank with external enclosure, and the electrical heating and control system. In order to help maintain the heater in a satisfactory manner, a brief description of its components and their operation is included for the customer’s convenience. The pressure vessel and its enclosure comprise the main mechanical portion of the pool heater. The pressure vessel, in conjunction with the flow switch and heating element are the only portions of this equipment in contact with the water. The external enclosure is a sheet steel case totally enclosing the pressure vessel and electrical components. The enclosure is coated with a rust inhibiting, powder coat finish. The electrical system, which is the heart of this unit, can be considered as three separate systems engineered to provide optimum use of energy. They are as follows:
(1) The heating elements; mounted on a four-bolt flange. There are either 2, 3 or 4 elements. (2) The control system; consists of the pilot switch, high limit thermostat, flow switch, temperature control, magnetic contactors and transformer. These controls are wired into a 120V or 220V control circuit designed to control the temperature of the water leaving the heater. The high-limit thermostat is designed to open the control circuit and cut off the power in the event of excessive temperature. A flow switch is built-in to prevent the pool heater from operating without water flow. The flow switch will activate at flow rates of 20 GPM (1.26 L/sec) or greater. (3) The main current-carrying components; are the contactors. These are wired into circuits which carry the full amperage draw of the elements. The contactors function during a high temperature condition to de-energize the elements. The heater has a temperature controller adjustable from 70°F(21°C) to 104°F(40°C) and has one manual reset type high temperature limit thermostat set at 122°F (50°C). 2.0 LOCATION AND PLUMBING A. Installation: Location Coates swimming pool heaters are quiet, do not expel exhaust fumes, and may be conveniently located in shed or basement. Normal positioning of the pool heater should be in close proximity to the pool filtration system. Select a location conveniently close to incoming electrical service and where excessively long piping runs are not required. Minimum clearance:
PHS/CPH CE Front 36 (914)# 36 (914)# Left 18 (457) 4 (102)
Right * 4 (102) Top 18 (457) 20 (508) Back 6 (153) *
* Required clearance is based on plumbing configuration used. # Refer to NEC Table 110.26 (A)(1) - Dimensions: Inches (mm) - Temperature control is located on the front side.
WARNING Only qualified personnel, as defined by National Electric Code Article 100, should install and maintain this equipment. Unauthorized alteration or improper maintenance of this unit may release the manufacturer from any warranty claims. The installation must be in accordance with the instructions in this manual and applicable local plumbing and electrical codes.
2
B. Installation: Plumbing Pipe the heater as shown in Figure 2 to the inlet and outlet openings on the right side. Connect the heater in line between the filter discharge and pool. The water line coming from the filter should be connected to the heater inlet, and the discharge line to the pool should be connected to the outlet. The pool will not heat properly unless it is plumbed correctly. If plastic pipe is used, it should be suitable for at least 122°F (50 °C). A plumbing bypass around the pool heater is not necessary unless flow rates though the heater exceed 80 GPM (5 L/sec). A minimum flow rate of 20 GPM (1.26 L/sec) is required. Lack of sufficient flow will not allow the flow switch to activate the heater. It may be necessary, in larger Olympic-sized or public pools, to use two or more heaters to obtain sufficient KW capacity. If so, the heaters must be placed in parallel, so that each heater takes equal flow. 3.0 ELECTRICAL INSTALLATION First: 1. Check nameplate rating to insure the
heater matches your electrical supply. 2. CHECK ELECTRICAL CONNECTIONS
TO ALL COMPONENTS within the heater for tightness. These can become loose during shipment and handling.
3. Check components for any moisture, rust, or dust which may have accumulated during shipping, and clean or dry where necessary.
All pool heaters covered in this manual have integral thermostats, transformers, contactors and sequencers where required. All other internal connections are completed and tested at the factory. Wiring diagrams on pages 6 through 14 show internal wiring and required field connections for various models. Consult your local electrical code for proper wire and conduit sizes, and other local requirements. Do not connect the pool heater to, or operate at, a voltage other than the voltage rated on the nameplate. Bring wires of adequate size from a fused disconnect switch or circuit breaker with an ampere rating of 125% of the ampere rating shown on heater nameplate. Refer to Table 1 for wire sizes. Connect the power conductors to bus assembly on inside of the heater.
Ground wires must be insulated copper conductor and the same size as supply wiring, but not less than #12 AWG (4 mm2). Table 1
WIRE SIZE: AWG(mm2) KW 220V/3Ø 380V/3Ø 415V/3Ø 12 8(10) 10(6) 10(6) 15 8(10) 10(6) 10(6) 18 6(16) 8(10) 8(10) 24 4(25) 8(10) 8(10) 30 3(35) 6(16) 6(16) 36 2(35) 6(16) 6(16) 45 1(50) 4(25) 4(25) 54 3/0(95) 3(35) 3(35) 57 3/0(95) 3(35) 3(35) 60 3/0(95) 2(35) 3(35) 72 4/0(120) 1(50) 2(35)
Suggested size for insulated copper conductor wires. Based on 125% correction factor for wire with 90°C insulation.
A. To Connect Pool Heater to Power Supply These pool heaters have branch supplemental fusing already installed in the element circuitry; see wiring diagrams. To connect to the power supply, one needs only to protect the main supply lines, either with a circuit breaker or fused disconnect switch (Figure 1). Suggested wire sizes are shown in Table 1.
GroundLine 1 Line 2Ground Line 1 Line 2
o r
GroundGround
o r
ØA ØB ØCØA ØB ØC
Wiring Diagram: Single-Phase Models
Wiring Diagram: Three-Phase Models
Figure 1
3
B. Startup Procedure: 1. Make sure that the pump is on and that there is at
least 20 GPM (1.26 L/sec) flow through the pool heater. The heating elements will fail if allowed to operate dry.
2. Check temperature control setting, also, examine
wiring for loose connections, etc. 3. Set temperature control to the desired
temperature. Note: for each degree the temperature control setting is increased, power usage may increase up to 10%.
4. Turn on power at main disconnect switch. 5. Turn on pilot switch on pool heater. When closing down the pool for any length of time, shut off the power at the main disconnect switch and drain the water from the system. Water must not be allowed to freeze in the heater, as this will cause severe damage.
4.0 MAINTENANCE Element Inspection and Replacement: 1. Turn off power at main disconnect switch and turn
off water at water supply line. 2. Drain pool heater. 3. Remove left end service access panel. 4. Disconnect element leads. 5. Remove the four (4) element flange retaining nuts
and extract element. 6. Installation is the reverse of steps 1 through 5.
(Reinstall element with new gasket) Semi-Annual Cleaning: Accumulated sludge in the tank is the greatest cause of element failure. Twice yearly (before summer start-up and before winter), the pool heater should be drained and cleaned to remove any scale or sludge. More frequent cleaning may be required if pool water contains sediment or any amount of foreign matter. 1. Turn off system at main disconnect switch. 2. Open drain valve. 3. Permit water to run until it is clear. 4. Close valve and restart normally. If high temperature causes manual reset high limit switch to shut off the heater, disconnect power at disconnect switch and determine the cause before resetting.
** NOTICE **
NO PRESSURE RELIEF VALVE IS SHIPPED WITH THIS HEATER AND NONE
IS REQUIRED PER UL STD 1261. DO NOT INSTALL SHUT OFF
VALVE BETWEEN THE HEATER AND POOL OR
SPA. A CHECK VALVE IS ACCEPTABLE AND IN
ACCORDANCE TO UL STD 1261 REVISED JULY 1983.
COATES POOL HEATER
FILTER
POOL or
SPA
CHECK VALVE
DRAIN VALVE BALL OR GATE
VALVE
PUMP BALL OR GATE VALVE
CAUTIONDO NOT INSTALL ANY SHUT-OFF VALVE ON DISCHARGE SIDE OF HEATER. A SWING CHECK VALVE IS PERMITTED.
Exception: If a 30 psi (2.1 Kg/cm2 ) pressure relief valve is installed between the heater and valve, the valve may be of the shut-off (ball or gate) type.
Proper water balance is important to extending the life of your Coates Heater. While pH control is critical, the control of alkalinity and calcium hardness will protect against scaling and also help to prevent corrosion.
ACID ALKALINE
HEATER CAN BE
DAMAGED
CORROSIVE WATER
IDEAL RANGE
ALKALINE WATER
0 1 2 3 4 5 6 7 7.2-7.8 8 9 10 11 12 13 14
HEATER CAN BE
DAMAGED
The correct level of sanitizer, pH, total alkalinity and calcium hardness will very, depending on the type of pool (plaster, fiberglass or vinyl) and the chemical content of the fill water.
Water that is out of balance can damage your pool heater and void the warranty. This heater is not for use in salt water pools.
PROTECTING YOUR COATES HEATER W ITH PROPER WATER CHEMISTRY
4
HEA
TIN
G E
LEM
ENT,
6kW
@ 2
08V
2000
6036
12H
EATI
NG
ELE
MEN
T, 9
kW @
208
V20
0060
2912
22
22
22
2
44
1 12
1 4211 11 4211 1
32
2 172 100 4
2 160 83 4
44
21
1 4211 11 4211 1
32
2 172 109 4
2 160 91 4
4
21
1 41 1 334157
60
HEA
TIN
G E
LEM
ENT,
18k
W @
380
V20
0060
6512
HEA
TIN
G E
LEM
ENT,
6kW
@ 2
40V
2000
6046
12
11
11
XFM
R, T
4 38
0*41
5/12
0V-7
5VA
2201
0904
7
3226
0PHS4
3387
2PHS4
3386
0PHS4
3417
2PHS4
3416
0PHS4
4 7 17 10 11 8 9 6 13 12 12 12 12 1220
0060
04H
EATI
NG
ELE
MEN
T, 1
5kW
@ 2
08V
ILLUSTRATION ITEM
FNM
1/2
EXPL
IST-
Q
11
11
11
11
11
11
11
11
11
44
7987
5757
3415
7PHS4
3385
4PHS4
Part
No.
TOTA
L kW
PER
HEA
TER
AMPE
RAG
E AT
FU
LL L
OAD
ELEM
ENTS
PER
HEA
TER
FUSE
, F6,
1/2
A @
250
VAC
XFM
R, T
3 38
0*60
0/12
0V-5
0VA
CO
NTA
CTO
R, C
R7
3P 2
20V
CO
ILPI
LOT
SWIT
CH
, PS2
TEM
P LI
MIT
SW
ITC
H, T
S1
TEM
P C
ON
TRO
L, T
S2PI
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LIG
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AM
BER
, PL1
, 2 &
4
FLO
W S
WIT
CH
HEA
TIN
G E
LEM
ENT
GAS
KET
HEA
TIN
G E
LEM
ENT,
12k
W @
240
VH
EATI
NG
ELE
MEN
T, 1
5kW
@ 2
40V
HEA
TIN
G E
LEM
ENT,
18k
W @
240
V
2901
5054
2201
0954
2100
1000
2300
1521
2200
3820
2200
2001
2903
4620
2300
0105
4400
0250
2000
6009
2000
6010
2000
6011
5445
3630
2418
1512
5445
3630
2418
1512
1823
2736
4655
6882
1721
2533
4250
6375
43
32
22
22
43
32
22
22
3381
2CE33
815C
E3381
8CE33
824C
PH33
830C
PH33
836P
HS333
845P
HS33385
7PHS4
3411
2CE34
115C
E3411
8CE34
124C
PH34
130C
PH34
136P
HS334
145P
HS334
154P
HS438
0VO
LT41
5 VO
LT
11
11
11
11
11
11
11
11
11
22
22
22
22
22
22
22
22
22
11
11
11
11
11
11
11
11
11
11
11
12
22
21
11
11
22
22
11
11
11
11
11
11
11
11
11 1
11
11
11
11
11
11
11
11
11
11
11
11
11
1 11
12
22
22
21
11
22
22
22
22
22
24
44
44
44
42
22
22
2000
6039
HEA
TIN
G E
LEM
ENT,
9kW
@ 2
40V
1
11
22
12
32
32
1
22
23
32 2
1 3
2903
4648
PILO
T LI
GH
T, A
MBE
R, P
L39
11
11
11
11
11
11
11
11
11
2901
6310
FUSE
, F5,
1A
@ 6
00VA
C F
NQ
-R-1
3
12
32
3
2 12
2
1 1
14
44
42
22
22
33
33
33
22
211
11
11
11
11
11
111
11
11
11
11
33
22
11
1
220V
OLT
3225
7PHS4
3224
5PHS3
3223
6PHS3
3223
0CPH
3222
4CPH
3221
8CE
3
22
22
23
3414
211
894
7963
4739
311215
1824
3036
4554
3225
4PHS4
57 150 4 3
11
11
11
11
1
3221
5CE
3221
2CE
3227
2PHS4 72 18
9 4 2 3 1 1 3 1 4 4
1421
0060
10R
ELAY
, 30A
MP,
240
V C
OIL
, K8
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
111
11
18
TEM
P C
ON
TRO
L, T
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501
11
11
11
11
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11.
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WER
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TRIB
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RO
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6. F
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8. T
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OT
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ENT,
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ESET
10. P
ILO
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H, L
IGH
TED
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/OFF
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. TEM
PER
ATU
RE
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IT S
WIT
CH
12. H
EATI
NG
ELE
MEN
T13
. HEA
TIN
G E
LEM
ENT
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14. F
LOW
REL
AY15
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UEN
CE
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ER (W
HEN
REQ
UIR
ED)
16. C
ON
TAC
TOR
(4-P
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)17
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NTA
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R (3
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LE)
18. H
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SIN
G19
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SEL
20. E
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RE
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TE:
REF
EREN
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THE
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L H
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R P
ARTS
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T FO
RC
OM
PON
ENT
PAR
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UM
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S AN
D Q
UAN
TITI
ES.
2
3 4
5 6
7
8
9
10
11
12
13
1516
17
18
19
20
DPH
-ILL
D
14
6
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1218
D
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OW
ER
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IT; A
S N
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C
ON
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L C
IRC
UIT
14
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G.
IN
SU
LATE
D, M
INIM
UM
.3.
ALL
WIR
ING
TO
BE
105
°C
NO
T U
SE
D
CR
7
GR
OU
ND
PO
OL
GR
OU
ND
EN
CLO
SU
RE
TER
MIN
AL
HE
ATE
R G
RO
UN
D
THR
EE
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0V-1
2, 1
5 &
18k
W
AB
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SS A
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NG
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OM
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WW
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RB
WW
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RB
4. L
EG
EN
D;
R
= R
ED
B =
BLA
CK
W =
WH
ITE
#8
PL1
"ELE
ME
NT"F5F5
1
#8#8
#2
BR
ASS
#1
CO
PPER
#3
ALU
MIN
UM
TB1
1 2 3 4
ISO
LATE
D
BU
S
NOCOM
K8
FLO
W
RS2
TS1
PL4 "RESET”
PL2
"FLO
W"
J4J3TS
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AC
AC
CN
O
J9
BW
R
TEM
P
7
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C
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L C
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UIT
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D, M
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UM
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ALL
WIR
ING
TO
BE
105
°C
NO
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SE
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CR
7
GR
OU
ND
PO
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OU
ND
EN
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SU
RE
TER
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AL
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ATE
R G
RO
UN
D
THR
EE
PH
AS
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4 &
30kW
AB
CBU
SS A
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ATI
NG
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ME
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OM
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NE
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ME
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7
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1
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#8#8
#8
#2
BR
ASS
#1
CO
PPER
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ALU
MIN
UM
TB1
1 2 3 4
ISO
LATE
D
BU
S
NO COM
K8FL
OW
RS2
TS1
PL4 "RESET”
PL2
"FLO
W"
J4J3TS
3J1 J2
AC
AC
CN
O
J9
BW
R
TEM
P
8
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P
OW
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IT; A
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OTE
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C
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L C
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14
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IN
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TED
, MIN
IMU
M.
3. A
LL W
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G T
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E 1
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NO
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SE
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CR
7
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OU
ND
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ND
EN
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E
TER
MIN
AL
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ATE
R G
RO
UN
D
THR
EE
PH
AS
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6 &
45k
W
AB
CBU
SS A
SSEM
BLY
HE
ATI
NG
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ME
NTS
C
OM
PO
NE
NT
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ATI
ON
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SE
E IN
STR
UC
TIO
N M
AN
UA
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R2.
COIL
COIL
COIL
WW
RB
RB
WW
W
RB
RB
W
RB
RB
4. L
EG
EN
D;
R
= R
ED
B =
BLA
CK
W =
WH
ITE
#8
PL1
"ELE
ME
NT"
CR
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R7
F5F5
1
#8#8
#8#8
#8#8
#8#8
#2
BR
ASS
#1
CO
PPER
#3
ALU
MIN
UM
TB1
1 2 3 4
ISO
LATE
D
BU
S
NO COM
K8FL
OW
RS2
TS1
PL4 "RESET”
PL2
"FLO
W"
J4J3TS
3J1 J2
AC
AC
CN
O
J9
BW
R
TEM
P
9
E3M
5472
E
P
OW
ER C
IRC
UIT
; 8 A
WG
C
ON
TRO
L C
IRC
UIT
14
AWG
.
INSU
LATE
D, M
INIM
UM
.3.
ALL
WIR
ING
TO
BE
105°
C
NO
T U
SED
GR
OU
ND
PO
OL
GR
OU
ND
ENC
LOSU
RE
TER
MIN
ALH
EATE
R G
RO
UN
DA
BC
BUSS
ASS
EMBL
Y
C
OM
PON
ENT
IDEN
TIFI
CAT
ION
.
SEE
INST
RU
CTI
ON
MAN
UAL
FO
R2. 4.
LEG
END
;
R =
RED
B =
BLAC
KW
= W
HIT
E
HEA
TIN
G E
LEM
ENTS
#8
W
R RBB
W
PL1
"ELE
ME
NT"
F5F5
1
#8#8
#8#8
#8#8
#8#8
#8#8
#8
#2
BR
ASS
#1
CO
PPER
#3
ALU
MIN
UM
TB1
1 2 3 4
ISO
LATE
D
BU
S
NO COM
K8FL
OW
RS2
TS1
PL4 "RESET”
PL2
"FLO
W"
J4J3TS
3J1 J2
AC
AC
CN
O
J9
BW
R
TEM
P
CR
7
COIL
CR
7
COIL
CR
7
COIL
CR
7
COIL
W
R RBB
WW
R RBB
WW
R RBB
W
10
PL3
"ELE
ME
NT"
COIL
2. S
EE IN
STR
UC
TIO
N M
ANU
AL F
OR
C
OM
PON
ENT
IDEN
TIFI
CAT
ION
.
BUSS
ASS
EMBL
YC
BA
HEA
TER
GR
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15
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Kent, WA 98035 coatesheater.com