Coates Electric Pool Heater, 45kw 208V Three Phase, Salt Water Application

The Coates 45kW 208V Three-Phase Electric Pool & Spa Heater for Salt Water Applications (Model 32045CES / 32045CPHS — featuring the "S" saltwater/corrosion-resistant package) is a heavy-duty inline immersion heater engineered for municipal therapy pools, resort aquatic complexes, commercial swim schools, and athletic recovery facilities operating with electrolytic salt chlorine generation systems (typically 2,500 to 4,500+ ppm TDS/NaCl) on a standard 208V 3-phase/4-wire electrical distribution network.

Operating 45kW across 208V 3-phase draws 124.9 Amps per phase (compared to 187.5 Amps on single-phase 240V). The factory saltwater configuration provides upgraded element metallurgy and protective tank barrier coatings to withstand aggressive saline electrolytes, preventing chloride pitting and stress corrosion cracking.

Electrical & Heating Performance

• Model Designation: Coates 32045CES / 32045CPHS series (320 designates 3-Phase 208V; suffix designates Saltwater/Titanium package).

• Heating Capacity: 45 kW (45,000 Watts).

• Thermal Output: 153,546 BTU/hr ($45\text{ kW} \times 3,412.142\text{ BTU/kWh}$).

• Operating Voltage: 208V AC, Three-Phase (3Ø), 3-pole / 3-wire plus ground (or 4-wire Wye), 60 Hz.

• Full Load Amperage (FLA): 124.9 Amps

  $$\text{FLA} = \frac{45,000\text{ W}}{208\text{ V} \times \sqrt{3}} = \frac{45,000}{360.26} \approx 124.91\text{ A} \rightarrow 124.9\text{ A}$$

• Overcurrent Protection (Breaker Sizing): Requires a dedicated 3-pole 160-Amp or 175-Amp circuit breaker conforming to NEC/CEC 125% continuous-duty loading standards ($124.91\text{ A} \times 1.25 = 156.14\text{ A}$ minimum branch rating, standardizing on a 175A 3-pole breaker).

• Conductor Sizing: Minimum #2/0 AWG THHN/THWN copper conductor (rated 75°C/90°C terminals, adjusted for ambient derating and raceway distance).

Salt Water Construction & Metallurgy Upgrades

• Titanium / Incoloy 825 Sheathed Elements: Immersion elements are upgraded from standard alloys to Titanium or high-molybdenum/nickel Incoloy 825 sheathing to resist chloride-induced stress corrosion cracking (SCC), scale accumulation, and localized pitting from dissolved sodium chloride and electrolytic chlorination.

• Passivated / Barrier-Coated Pressure Vessel: Extended cylindrical pressure chamber fabricated from heavy-gauge 316L stainless steel or carbon steel lined with a specialized baked phenolic epoxy/fluoropolymer protective barrier, isolating the tank substrate from saline electrolytic degradation.

• Sacrificial Cathodic Protection: Equipped with an accessible sacrificial zinc or magnesium anode plug port to absorb galvanic action and mitigate stray current erosion in the salt plumbing loop.

• Corrosion-Inhibited Cabinet: Heavy-gauge NEMA 1 industrial painted enclosure finished with an anti-corrosion powder coating to prevent cabinet degradation in high-humidity, salt-vapor mechanical rooms.

Construction & Safety Architecture

• Cabinet & Enclosure: NEMA 1 industrial painted steel cabinet with a removable front panel for terminal inspections, multiple staged heavy-duty 3-pole magnetic contactor servicing, and field wire terminations.

• Integrated Safety Controls:

  • Dual-dial adjustable thermostatic controller calibrated up to 104°F (40°C) for commercial spa compliance.

  • Manual-reset High-Limit safety cutout set to de-energize the magnetic contactor control circuit at 122°F (50°C).

  • Pressure/flow-interlock switch preventing heating element contactors from pulling in during low-flow, pump loss, or deadhead conditions.

Hydraulic & Plumbing Specifications

• Plumbing Connections: Standard 1-1/2" NPT female inlet and outlet ports (adapted via Schedule 80 CPVC unions into 2" or 2-1/2" headers).

• Equipment Sequencing in Salt Systems: Must always be installed upstream of the electrolytic chlorine generator cell (separated by an inline corrosion-resistant check valve) to prevent hyper-concentrated chlorine gas or acidic pockets from pooling inside the heater vessel during pump shutdowns.

• Flow Rate Parameters:

  • Minimum Flow Rate: 25 to 30 GPM (approx. 95 to 114 LPM) required to trip the safety flow switch and prevent localized thermal cavitation across multi-element arrays.

  • Maximum Flow Rate: 60 to 70 GPM (approx. 227 to 265 LPM); filtration loops operating at higher GPM mandate an external plumbed bypass manifold.

• Maximum Working Pressure: 60 PSI (approx. 4.14 bar).

Dimensions, Net Weight & Shipping Weight

• Unit Dimensions: Approximately 24.0" L × 12.0" W × 16.5" H (approx. 61.0 cm × 30.5 cm × 41.9 cm).

• Net Unit Weight: Approximately 82 to 90 lbs (approx. 37.2 to 40.8 kg).

• Packaged Shipping Dimensions: Approximately 26" L × 15" W × 19" H.

• Packaged Shipping Weight: Approximately 96 to 108 lbs (approx. 43.5 to 49.0 kg) in heavy-duty reinforced corrugated carton packaging with dense molded foam protection.

Estimated Temperature Rise Rates

(Calculation: $\text{Rise (°F/hr)} = \frac{153,546\text{ BTU/hr}}{\text{Gallons} \times 8.34\text{ lbs/gal}}$, baseline heat-up rate assuming covered vessel without ambient radiation losses.)