Freeze Control Devices Technical Bulletin No. 21A

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Freeze Control Devices

Technical Bulletin

No.

21A

Page 1 of 13

21A.1 Parts List a. Freeze Control Kit

Dry-well assembly 1-1/2" to 3/4" reducing bushing 1-1/2" plumbing tee US and other countries with the same electrical requirements: (1) Len Gordon FC-5 110 Volt (Water Quality) OR (1) Len Gordon FC-6 (Dual, Water Quality and Jets Option) UK and other countries with the same electrical requirements: (1) Len Gordon FC-5 220Volt (Water Quality) (1) Len Gordon FC-5 220Volt (Jets Option)

b. Additional Materials Required (Supplied with pool package) PVC cleaner PVC glue

21A.2 Description The freeze control devices are designed to override the time clock or controller for the PVC piping systems any time the temperature of the water in these pipes reaches a level below where the freeze control is set. The circuit can be adjusted anywhere between freezing temperature of 32°F (0°C) and 100°F (35.5°C). The purpose is to prevent damage to your pool's piping systems when temperatures approach freezing, allowing you to automate the system and insure that the pipes will not burst from the expansion of freezing water. Additionally, it can save you money by eliminating the costly necessity of running the water quality system constantly during cold spells.

21A.3 Additional Considerations There are three models of freeze control units described in this Tech Bulletin. The differences are as follows: US and other countries with the same electrical requirements: FC-5 110 Volt (Water Quality) - Designed to override the timeclock on an installation where jets have not been selected as an option or where the jet plumbing is not subject to freezing. It is merely a controller that monitors the temperature of the water in the plumbing line. When the water's temperature drops below the point the dial is set, it dedicates power straight to the pump, bypassing the timer circuit entirely. Note: This particular unit's in-line plumbing sensor should be installed at the coldest point in the plumbing line before the heater. OR FC-6 (Dual, Water Quality and Jets Option) - This unit is designed to replace the time clock that was provided with the pool. It is internally wired with a plumbing sensor and has a few wiring terminals with which to connect the wiring for the water quality system pump, and the signal wire to the jet pump's controller. Note: Power for the jet controller and pump is on a separate circuit brought directly to the ASMulti Combo-95 controller, not through the FC-6 (Dual) unit. Attempting to power both pumps through this circuit will create an amperage overload. The unit will operate as a normal time clock, activated by the toggles on the outside of the clock face. The jets controller will also act independently, activated only when the poolside air button is pressed. Only when the freeze control circuit is activated will this override the normal function of the two units. UK and other countries with the same electrical requirements: FC-5 220 Volt (Water Quality). If the equipment or piping for the filtration system is subject to freezing conditions, a freeze control device will be necessary. FC-5 220 Volt (Jets Option). If you have ordered the optional Hydrotherapy Jets, you may need a second freeze control device. If the equipment or piping for the hydrotherapy jets is subject to freezing conditions, a freeze control device will be necessary.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 2 of 13

21A.4 Installation Instructions 1) Select a place for the in-line plumbing sensor. Its placement is critical for it to be useful as a freeze protector. In general, it should be installed at the coldest point in the plumbing system. Note: The cord set for the sensor is approximately 30 feet long. Do not cut and splice in additional sensor wire. Doing this will affect he calibration of the unit and void the warranty. US and other countries with the same electrical requirements: FC-5 110 Volt (Water Quality): This sensor should be placed in the water quality system's plumbing line somewhere before the heater. OR FC-6 (Dual, Water Quality and Jets Option): This unit's sensor should be placed on the coldest point of the jet's plumbing lines. UK and other countries with the same electrical requirements: FC-5 220 Volt (Water Quality): This sensor should be placed in the water quality system's plumbing line somewhere before the heater. FC-5 220 Volt (Jets Option) : This unit's sensor should be placed on the coldest point of the jet's plumbing lines. 2) Plumb the tee, reducing bushing, and dry-well assemblies into the line at the location selected. 3) Mount the controller in an appropriate location. US and other countries with the same electrical requirements: FC-5 (Water Quality): This controller can be mounted anywhere local code permits. A suggested location would be fairly close to the location of the sensor, keeping in mind that at some point troubleshooting on the unit may be necessary which would require some access. OR FC-6 (Dual, Water Quality and Jets Option): Since this unit replaces the time clock shipped with the pool, we would recommend mounting it to the control board in the same location. UK and other countries with the same electrical requirements: FC-5 240 Volt (Water Quality): This controller can be mounted anywhere local code permits. A suggested location would be fairly close to the location of the sensor, keeping in mind that at some point troubleshooting on the unit may be necessary which would require some access. FC-5 240 Volt (Jets Option): This controller can be mounted anywhere local code permits. A suggested location would be fairly close to the location of the sensor, keeping in mind that at some point troubleshooting on the unit may be necessary which would require some access. 4) Have your licensed local electrician wire the units as shown in the enclosed wiring diagrams. The FC-5 110 Volt (Water Quality) is powered by the same circuit as the water quality time clock. The FC-6 (Dual) has additional wiring concerns. The blue jumper wire on the AS-Multi Combo-95 jet controller needs to be moved to jumper lines 4 and 6. In the UK and other countries with the same electrical requirements, the FC5 220V would be powered by the time clocks. If the hydrotherapy jets were chosen the second FC-5 220 Volt would be powered by the circuit for the AS-2-95 controller. 5) Test the freeze control circuit to assure that it is wired and working properly. To do this, you can turn the dial towards the hottest setting until you hear a click. The click should occur at the point on the dial which matches the pool water temperature. 6) Set the dial for the freeze control circuit to the temperature at which you would like it to turn on.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 3 of 13

21A.4 Wiring Instructions Wiring a Dual Freeze Control (110 or 220 volt, 60Hz) Due to the number of wires being used and the space available under the terminals in the controllers, we recommend running all wires prior to making connections. In some cases it will be necessary to wire nut several wires together and use a pigtail to connect to the terminal. 1) All wires must be 12gauge minimum. 2) Mount the Dual Freeze control and the AS-Multi-Combo controller on a wall close to the equipment. 3) Bring the incoming power wires from the GFI circuit breaker to the Dual Freeze Control. This can be wired for either 110 or 220 volts. Do not attach these wires yet. 4) Bring the incoming power from the GFI circuit breaker to the AS-Multi-Combo. This can also be wired for either 110 or 220 volts. Do not attach these wires yet. 5) Run two switching wires between the Dual Freeze control and the AS-Multi-Combo. Do not attach these wires yet. 6) Run a set of 3 wires between the Dual Freeze Control and the twist lock outlet. Do not attach these wires yet. 7) Run a set of 3 wires between the AS-Multi-Combo and the 1HP jet pump. Do not attach these wires yet. 8) If an optional gas heater has been chosen, run a set of 3 wires between the Dual Freeze Control and the gas heater. Do not attach these wires yet. 9) Wire connections in the AS-Multi-Combo and 1HP pump: a. Attach the ground wires to the ground bar in the AS-Multi-Combo. b. Attach incoming power (Line 1 hot) and one of the switching wires to Terminal #1. c. Remove jumper wire from Terminals #7 and 8. d. Attach other switching wire to Terminal #8. e. Complete incoming power supply connections as shown in Technical Bulletin #6. - For a 110 volt power supply; connect incoming neutral wire and neutral wire to pump to Terminal #2. - For a 220 volt power supply; connect incoming neutral wire to Terminal #2 and other incoming power wire to Terminal #3. f. Complete wiring connections to pump as shown in Technical Bulletin #6 noting that the jumper wire removed in step C is to be placed between Terminals #4 and #6. - For a 110 volt power supply; connect the outgoing hot wire to Terminal #4 (with the jumper wire). The outgoing neutral wire was already connected in step E. - For a 220 volt power supply; connect one of the outgoing hot wires to Terminal #4 (with the jumper wire). Connect the other outgoing hot wire to Terminal #5. g. To wire the motor, follow 1HP jet pump wiring diagram on side of motor. 10) Wire connections in the twist lock outlet: a. Connect ground to green screw. b. If using 110 volts to power filtration pump, wire hot to brass screw and neutral to silver screw. c. If using 220 volts to power filtration pump, wire one hot to brass screw and other hot to silver screw. Note: filtration pump will need to be internally re-wired for 220 volts. Follow the instruction on side of motor. 11) Wire connections in the Dual Freeze Control: a. Wire nut all ground wires together and place under the ground terminal. b. Attach incoming power wires using the Input Wiring Diagram schematic as a guide in Technical Bulletin #21A. - For a 110 volt power supply; connect the incoming hot wire to the black wire and the incoming neutral wire to the white wire, capping the red wire.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 4 of 13

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For a 220 volt power supply; connect one incoming hot wire to the black wire, the other incoming hot wire to the red wire and the incoming neutral wire to the white wire. c. If using 110 volts to power filtration pump, attach hot wire going to twist lock outlet to Terminal #1 and neutral to Terminal #2. Note: if gas heater option was chosen, attach heater power supply wires here too. d. If using 220 volts to power filtration pump, wire one hot to Terminal #1 and the other hot to Terminal #3. Note: if gas heater option was chosen, attach heater power supply wires here too. e. Attach switching wire going to Terminal #1 in AS-Multi-Combo to Terminal #4. f. Attach switching wire going to Terminal #8 in AS-Multi-Combo to Terminal #5.

Wiring a Single Freeze Control to the Time Clock (110 volts, 60Hz) Due to the number of wires being used and the space available under the terminals in the controllers, we recommend running all wires prior to making connections. In some cases it will be necessary to wire nut several wires together and use a pigtail to connect to the terminal. 1) Ensure that you have a 110 volt time clock. The standard time clock provided by Endless Pools is a 110 volt version. The voltage rating is found on the inside cover of the time clock. 2) Refer to Technical Bulletin #21 and #21A for wiring diagrams of the Time Clock and Single Freeze Control. All wires must be 12gauge minimum. 3) Mount the Single Freeze control and the Time Clock on a wall close to the equipment. 4) Bring the incoming power wires from the GFI circuit breaker to the Time Clock. This must be wired for 110 volts. Do not attach these wires yet. 5) Run four wires between the Single Freeze Control and the Time Clock. Do not attach these wires yet. 6) Run a set of 3 wires between the Time Clock and the twist lock outlet. Do not attach these wires yet. 7) If an optional gas heater has been chosen, run a set of 3 wires between the Time Clock and the gas heater. Do not attach these wires yet. 8) Wire connections in the Single Freeze Control: a. Attach the ground wire to the ground bar. b. Attach incoming power to Terminal #1. c. Attach neutral wire to Terminal #2. d. Attach load wire to Terminal #4. 9) Wire connections in the twist lock outlet: a. Connect ground to green screw. b. Connect hot wire to brass screw. c. Connect neutral wire to silver screw. 10) Wire connections in the Time Clock: a. Wire nut all ground wires together and place under the ground terminal. b. Wire nut all neutral wires together and place under Terminal A. c. Wire nut incoming power wire and outgoing power wire to Freeze Control together and place under Terminal #1. d. Wire nut load wire from freeze control, hot wire from outlet and hot wire from gas heater (if chosen) together and place under Terminal #2.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 5 of 13

Wiring a Single Freeze Control to the Time Clock (220 volts, 60Hz) Due to the number of wires being used and the space available under the terminals in the controllers, we recommend running all wires prior to making connections. In some cases it will be necessary to wire nut several wires together and use a pigtail to connect to the terminal. 1) Ensure that you have a 220 volt time clock. The standard time clock provided by Endless Pools is a 110 volt version. The voltage rating is found on the inside cover of the time clock. 2) Refer to Technical Bulletin #21 and #21A for wiring diagrams of the Time Clock and Single Freeze Control. All wires must be 12gauge minimum. 3) Mount the Single Freeze control and the Time Clock on a wall close to the equipment. 4) Run a set of four incoming power wires from the GFI circuit breaker to the Time Clock. This must be wired for 220 volts. Do not attach these wires yet. 5) Run six wires between the Single Freeze Control and the Time Clock. Do not attach these wires yet. 6) Run a set of 3 wires between the Time Clock and the twist lock outlet. Do not attach these wires yet. 7) If an optional gas heater has been chosen, run a set of 3 wires between the Time Clock and the gas heater. Do not attach these wires yet. 8) Wire connections in the Single Freeze Control: a. Attach the ground wire to the ground bar. b. Attach incoming power (Line 1) to Terminal #1. c. Attach neutral wire to Terminal #2. d. Attach other incoming power (Line 2) to Terminal #3 e. Attach one load wire to Terminal #4. f. Attach other load wire to Terminal #5. 9) Wire connections in the twist lock outlet: a. Connect ground to green screw. b. Connect hot wire (Line 1) to brass screw. c. Connect hot wire (Line 2) to silver screw. 10) Wire connections in the Time Clock: a. Wire nut all ground wires together and place under the ground terminal. b. Wire nut all neutral wires together. c. Wire nut incoming power wire (Line 1) from breaker and outgoing power wire to Freeze Control (from Terminal #1) together and place under Terminal #1. d. Wire nut other incoming power wire (Line 2) from breaker and other outgoing power wire to Freeze Control (from Terminal #3) together and place under Terminal #3. e. Wire nut load wire from freeze control (from Terminal #4), hot wire from outlet (Line 1) and hot wire from gas heater (if chosen) together and place under Terminal #2. f. Wire nut load wire from freeze control (from Terminal #5), hot wire from outlet (Line 2) and hot wire from gas heater (if chosen) together and place under Terminal #4. 11) If optional gas heater was chosen, wire heater per manufacturers instruction for 220 volts.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 6 of 13

Wiring a Single Freeze Control to the Hydrotherapy Jet Controller (110 volt, 60Hz) Due to the number of wires being used and the space available under the terminals in the controllers, we recommend running all wires prior to making connections. In some cases it will be necessary to wire nut several wires together and use a pigtail to connect to the terminal. 1) Refer to Technical Bulletin #6 and #21A for wiring diagrams of the AS-Multi-Combo and Single Freeze Control. All wires must be 12gauge minimum. 2) Mount the Single Freeze control and the AS-Multi-Combo on a wall close to the equipment. 3) Run three wires for the incoming power from the GFI circuit breaker to the AS-Multi-Combo. This must be wired for 110 volts. Do not attach these wires yet. 4) Run four wires between the Single Freeze Control and the AS-Multi-Combo. Do not attach these wires yet. 5) Run a set of 3 wires between the AS-Multi-Combo and the 1HP pump. Do not attach these wires yet. 6) Wire connections in the Single Freeze Control: a. Attach the ground wire to the ground bar. b. Attach incoming power to Terminal #1. c. Attach neutral wire to Terminal #2. d. Attach load wire to Terminal #4. 7) Wire connections in the AS-Multi-Combo: a. Attach ground wires to the ground bar. b. Wire nut all neutral wires together and place under Terminal #2. c. Wire nut incoming power (hot) wire from circuit breaker and outgoing power wire to Freeze Control together and place under Terminal #1. d. Remove jumper wire from Terminals #7 and #8. e. Place one end of the jumper wire removed in step D under Terminal #6. f. Wire nut the other end of the jumper wire and the hot wire to the 1HP pump together and place under Terminal #4. g. Place the load wire from the Freeze Control under Terminal #8. 8) Wire the 1HP pump as per the manufacturer’s directions for 110 volts on the side of the pump. 9) Turn on power to the Hydrotherapy Jets. Do not attempt to operate the Jets or Freeze Control until completing the following phase test that requires a multi-meter to verify that the wiring has been completed properly. a. Take a voltage reading between Terminal#1 of the AS-Multi-Combo and Terminal #1 of the Single Freeze Control. b. If the voltage reading is 0 volts then the installation has been completed properly. c. If the voltage reading is 220 volts, then two of the wires have been switched. Follow steps 6 and 7 again to ensure that the wiring is completed properly. 10) Test the freeze control operation by turning the temperature knob clockwise (to a higher temperature setting than the actual water temperature) and the jet pump should turn on. 11) Test the Hydrotherapy Jet operation by pressing the air button for the Jets.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 7 of 13

Wiring a Single Freeze Control to the Hydrotherapy Jet Controller (220 volt, 60Hz) Due to the number of wires being used and the space available under the terminals in the controllers, we recommend running all wires prior to making connections. In some cases it will be necessary to wire nut several wires together and use a pigtail to connect to the terminal. 1) Refer to Technical Bulletin #6 and #21A for wiring diagrams of the AS-Multi-Combo and Single Freeze Control. All wires must be 12gauge minimum. 2) Mount the Single Freeze control and the AS-Multi-Combo on a wall close to the equipment. 3) Run four wires for the incoming power from the GFI circuit breaker to the AS-Multi-Combo. This must be wired for 220 volts. Do not attach these wires yet. 4) Run five wires between the Single Freeze Control and the AS-Multi-Combo. Do not attach these wires yet. 5) Run a set of 3 wires between the AS-Multi-Combo and the 1HP pump. Do not attach these wires yet. 6) Wire connections in the Single Freeze Control: a. Attach the ground wire to the ground bar. b. Attach incoming power Line 1 to Terminal #1. c. Attach neutral wire to Terminal #2. d. Attach incoming power Line 2 to Terminal #3. e. Attach load wire to Terminal #4. 7) Wire connections in the AS-Multi-Combo: a. Attach all ground wires to the ground bar. b. Wire nut incoming neutral wire from circuit breaker and neutral wire to Freeze Control together and place under Terminal #2. c. Wire nut an incoming power wire from circuit breaker (Line 1) and outgoing Line 1 power wire to Freeze Control together and place under Terminal #1. d. Wire nut other incoming power wire from circuit breaker (Line 2) and outgoing Line 2 power wire to Freeze Control together and place under Terminal #3. e. Remove jumper wire from Terminals #7 and #8. f. Place one end of the jumper wire removed in step E under Terminal #6. g. Wire nut the other end of the jumper wire and Load 1 hot wire to the 1HP pump together and place under Terminal #4. h. Place Load 2 to pump under Terminal #5. i. Place the load wire from the Freeze Control under Terminal #8. 8) Wire the 1HP pump as per the manufacturer’s directions for 220 volts on the side of the pump. 9) Turn on power to the Hydrotherapy Jets. Do not attempt to operate the Jets or Freeze Control until completing the following phase test that requires a multi-meter to verify that the wiring has been completed properly. a. Take a voltage reading between Terminal#1 of the AS-Multi-Combo and Terminal #1 of the Single Freeze Control. b. If the voltage reading is 0 volts then the installation has been completed properly. c. If the voltage reading is 220 volts, then two of the wires have been switched. Follow steps 6 and 7 again to ensure that the wiring is completed properly. 10) Test the freeze control operation by turning the temperature knob clockwise (to a higher temperature setting than the actual water temperature) and the jet pump should turn on. 11) Test the Hydrotherapy Jet operation by pressing the air button for the Jets.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 8 of 13

Diagram for use in the US and other countries with the same electrical requirements.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A

Page 9 of 13

Diagram for use in the US and other countries with the same electrical requirements.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A Page 10 of 13

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A Page 11 of 13

Diagram for use in the UK and other countries with the same electrical requirements.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A Page 12 of 13

Diagram for use in the UK and other countries with the same electrical requirements.

Endless Pools Inc.

11/25/06

Freeze Control Devices

Technical Bulletin

No.

21A Page 13 of 13

Endless Pools Inc.

11/25/06