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Aquacal TropiCool TC500 Installation Manual

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AquaCal
Installation Manual
Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
LTP0099 REV 1

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  Summary of Contents for Aquacal TropiCool TC500

  • Page 1 ® AquaCal Installation Manual Important Read this document before operating / installing this product For additional product manuals and operation / installation procedures, please visit www.AquaCal.com LTP0099 REV 1...
  • Page 2: Table Of Contents

    Table of Contents Section 1 - Contacting AquaCal AutoPilot, Inc. Section 2 - Safety Section 3 - Installation 3.1 Dimensions 3.2 Positioning Equipment 3.2.a Controlling Irrigation and Rainwater Runoff 3.2.b Planning for Condensation 3.2.c Mounting Pad Requirements 3.2.d Anchoring to Pad 3.3 Plumbing...
  • Page 3 4.13 User Lock Option (Disable) Section 5 - Maintenance 5.1 Water Chemistry 5.2 Cleaning Equipment After Installation 5.3 Winterizing Section 6 - Troubleshooting 6.1 Fault Codes 6.2 Issues and Resolutions Section 7 - Appendix 7.1 Identifying Model Specifications 7.2 Weights 7.3 Access Panels 7.4 Initial Cooling Recommendations 7.5 Available Accessories...
  • Page 4: Section 1 - Contacting Aquacal Autopilot, Inc

    SECTION 1 - CONTACTING AQUACAL AUTOPILOT, INC. For further assistance, please contact AquaCal AutoPilot, Inc. Technical Support. To better assist you, please have the chiller model and serial number available. See "Identifying Model Specifications" on page www.AquaCal.com Website Request Service Online www.AquaCal.com/request-heat-pump-service/...
  • Page 5: Section 3 - Installation

    SECTION 3 - INSTALLATION WARNING - Failure to heed the following may result in injury or death. Installation of this equipment by anyone other than a qualified installer can result in a safety hazard. The information contained throughout the "Installation" section is intended for use by qualified installation technicians familiar with the swimming Pool / Spa safety standards.
  • Page 6: Mounting Pad Requirements

    Follow all applicable local, state, and national requirements regarding wind load anchoring. ® If needed, contact AquaCal Customer Support to obtain the correct anchoring kit information. Please have the chiller model number and serial number when requesting support. See "Identifying Model Specifications" on page 26.
  • Page 7: Water Flow Rates

    ™ TropiCool (Top View) 3.3.b Water Flow Rates Maintain water flow rates as indicated. Please note, these specifications relate to the chiller only. Code- specified whole system turnover rates must be satisfied. CAUTION - Failure to heed the following may result in equipment damage. Water flow exceeding maximum flow rate may damage heat exchanger;...
  • Page 8: Plumbing Diagrams

    The basic plumbing configurations for typical installations are shown. ® If the installation does not closely follow any of the supplied plumbing diagrams, AquaCal Technical Support is available for installation advice and guidance. Air Source Chiller Plumbing Diagrams Chiller with water flows equal or less than maximum listed flow rate See "Water Flow Rates"...
  • Page 9: Water Connections To Chiller

    Connections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions. The Chiller uses 2-inch union connections. ® These unions are available from AquaCal . See "Available Accessories" on page 27. CAUTION - Failure to heed the following may result in equipment damage.
  • Page 10: Maintaining Ability To Winterize

    FLO . 7. Re-install chiller access panel. ® If chiller continues to operate without water flow, contact AquaCal Technical Support. Site-specific factors may require the installation of an external flow switch. See "Available Accessories" on page 27.
  • Page 11: Electrical

    Multiple chillers installed at the same site may benefit from automatic sequencing controllers (ASC) to avoid excessive power drops at start-up. See "Available Accessories" on page 27. ® AquaCal chillers are designed for copper conductors, only. Do not use aluminum wire. 3.4.b Electrical Standards...
  • Page 12: Electrical Knockouts

    3.4.f Electrical Knockouts ™ TropiCool 3.4.g Verifying Transformer Setting Transformer voltage settings must be confirmed and set correctly depending on the measured voltage found on the site. Incorrect settings may cause chiller damage. The following procedure will allow the installer to set the chillers transformer for the appropriate site voltage.
  • Page 13: Programming

    Switch incoming power wires at L2 and L3 on the line side to the contactor. 3. When chiller starts, disconnect power and verify off. Then confirm all line voltage connections are securely tightened. Reconnect power. ® If chiller does not start, contact AquaCal Technical Support. Standard ICM Digital...
  • Page 14: Deactivate Time Delay

    DEFAULT CODE DESCRIPTION RANGE VALUE Set to off at the Call-Flex Options factory. Set at Factory. Do Pool Dead-Band Differential 1° not adjust. Set at Factory. Do Spa Dead-Band Differential 1° not adjust. 0 = "OFF" Compressor Time Delay 1 (4 minutes) 1 = "ON"...
  • Page 15: Reset To Factory Defaults Settings

    DO NOT perform this operation if unsure of site specific settings or how to reset them on the chiller. ® If a qualified technician is unavailable, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1.
  • Page 16: Control Panel

    4.3 Control Panel The following information outlines the operation for a standard installation. Control Panel 4.4 Buttons Buttons Description Sliding your finger across the buttons from left to right will Display Lock temporarily disable the display lock. Select either the pool or the spa thermostat. Pool / Spa Used to increase temperature set point and navigate Up Arrow...
  • Page 17: Factory Defaults

    Service Level Programming must only be attempted by authorized service centers. Unauthorized adjustments in the Service Menu (beyond the LOC menu) may void chiller's warranty. ® If the issue reoccurs, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1.
  • Page 18: Setting Operating Mode

    4.8 Setting Operating Mode PLEASE NOTE Do not attempt to operate chiller in heat modes HEA or ACH. This is not an active feature on this equipment. Cool Deactivate Heating / Cooling modes only available Mode Chiller on select equipment. Confirm chiller features before setting a mode.
  • Page 19: User Lock Option (Entering Pass Code)

    Hold "UP" and Press "POOL / Press "UP or Press "POOL / "DOWN" until SPA" button until "DOWN" button to SPA" button to CF1 displays. ELC is displayed. change or add a lock in the numerical password password. Press "POOL / Press "Up"...
  • Page 20: User Lock Option (Disable)

    4.13 User Lock Option (Disable) Hold "UP" and Use "UP" button Press "Pool / Spa" Press "POOL / "DOWN" buttons to enter existing button to unlock. SPA" button until until CF1 is password. ULC is displayed displayed. Press "DOWN" button until "0" is displayed.
  • Page 21: Cleaning Equipment After Installation

    CHEMISTRY LEVEL CHART (RESIDENTIAL) CHEMICAL POOLS SPAS Total 80 – 120 ppm 80 – 120 ppm Alkalinity Calcium 200 – 400 150 – 250 ppm Hardness Total 1,500 ppm above start-up total dissolved solids in Dissolved 0 – 1,500 ppm spas •...
  • Page 22: Winterizing

    • The trademarks used in approved cleaning and polishing agents are property of their owners and are not ® related to AquaCal 5.3 Winterizing WARNING - Failure to heed the following may result in injury or death. Deactivate all electrical power to chiller before performing hard freeze procedures.
  • Page 23 ® Titanium ThermoLink Exchanger (with no Drain) 1. Reinstall front access panel. No Drain 2. Disconnect the plumbing to the chiller at connection unions (removal is counter-clockwise). 3. Allow water to drain completely from the chiller. Expect to see a lot of water drain out at first, and then a small amount to continue to drain out over a long period.
  • Page 24: Section 6 - Troubleshooting

    A fault code indicates a specific issue or condition that will require action before the equipment can resume operating. Please perform the following troubleshooting. ® If the issue reoccurs, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1. WARNING - Failure to heed the following may result in injury or death.
  • Page 25 ISSUE This is a control system error. RESOLUTION 1. Deactivate then reactivate power to reset controls. ® 2. If the issue reoccurs, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1. DpC or DpO Indicator ISSUE Shorted or open defrost sensor.
  • Page 26: Issues And Resolutions

    1. Deactivate then reactivate power to the chiller to clear error. 2. Troubleshoot the high-pressure issue causing the error. See "HP Indicator" on page 22. ® 3. If the issue reoccurs, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1.
  • Page 27 If control panel responds, the problem lies with the external controller or its installation. Contact the manufacturer of the external control device. ® 3. For further assistance, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1.
  • Page 28 2. Deactivate chiller, leaving the filter pump on. After several hours, determine if water is still coming from the chiller. ® 3. If the issue reoccurs, please contact AquaCal Technical Support. See "Contacting AquaCal AutoPilot, Inc." on page 1. Page - 25...
  • Page 29: Section 7 - Appendix

    SECTION 7 - APPENDIX 7.1 Identifying Model Specifications 1. Find Data Plate - The data plate is usually posted on the Data Plate Example side of the equipment or on the control panel access plate. 2. Find the model number on the data plate. The first letters and numbers indicate the model type.
  • Page 30: Weights

    Site voltage drop is minimized and utilities are not subjected to large in-rush demands of electrical current. ® Part number is based on number of chiller's to be controlled. Call AquaCal Customer Support for assistance with correct configuration.
  • Page 31 External Flow Relay (Grid Flow) Switch Kit (0040s) Used when the pool / spa elevation is higher than the chiller. Used when a variable two-speed filter pump set on low-speed mode does not provide enough water pressure to activate a chiller’s water pressure switch. Also used for automatic pool / spa thermostat switching.

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