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Aquacal TropiCool TC500 Installation Manual

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®
AquaCal
Installation Manual
®
WATER CHILLER
Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
LTP0099 REV 2e

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  Summary of Contents for Aquacal TropiCool TC500

  • Page 1 ® AquaCal Installation Manual ® WATER CHILLER Important Read this document before operating / installing this product For additional product manuals and operation / installation procedures, please visit www.AquaCal.com LTP0099 REV 2e...
  • Page 3: Table Of Contents

    Table of Contents Contacting AquaCal AutoPilot, Inc. Safety Instructions 1 - Installation 1.1 Positioning Equipment 1.2 Clearances 1.3 Dimensions 1.4 Plumbing 1.4.a Plumbing Requirements 1.4.b Plumbing Diagrams 1.4.c Water Connections to Chiller 1.4.d In-Line Chlorine Feeders 1.4.e Water Flow Rates 1.4.f Maintaining Ability to Winterize 1.4.g Adjusting Water Pressure Switch...
  • Page 4: Contacting Aquacal Autopilot, Inc

    Repair and service of chiller must be performed by an authorized service center. Warranties may be voided if the equipment has been improperly installed, maintained or serviced. If service is deemed necessary, please see "Contacting AquaCal AutoPilot, Inc." on page 1. SAFETY SIGNALS Throughout this document, safety signals have been placed where particular attention is required.
  • Page 5 Failure to heed the following may result in injury or death. WARNING Installation and repairs must be performed by a qualified technician. The chiller contains refrigerant under pressure. Repairs to the refrigerant circuit must not be attempted by untrained and / or unqualified individuals. Service must be performed only by qualified HVAC technicians. Recover refrigerant before opening the system.
  • Page 6: Installation

    1 - Installation Failure to heed the following may result in injury or death. WARNING 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 7: Clearances

    The shipping brackets used to secure the chiller to the pallet are approved mounting (hurricane) brackets. They should be used to anchor the chiller to the pad. ® If needed, contact AquaCal to obtain anchoring kit information. Please have the chiller model number and serial number when requesting support. See "Identifying Model Specifications" on page 25.
  • Page 8: Plumbing

    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. Confirm water provided to chiller is clean and filtered.
  • Page 9 Chiller with water flows greater than maximum listed flow rate See "Water Flow Rates" on page 9. Chiller with Spillover Spa (One filter Pump) Page - 6...
  • Page 10 Chiller with Spillover Spa (Two filter Pumps) Chiller with Solar Panels in Plumbing Circuit Chiller with Gas Heater backup Page - 7...
  • Page 11: Water Connections To Chiller

    Chiller union sizes are specified on diagrams. Connections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions. ® Plumbing unions are available from AquaCal Failure to heed the following may result in damage to equipment. NOTICE Do not use glue on the threaded portion of the equipment’s unions.
  • Page 12: In-Line Chlorine Feeders

    1.4.d In-Line Chlorine Feeders Place in-line chlorinators downstream from the chiller and as low in elevation as possible. If an erosion type feeder is used, it is recommended that a Hartford Loop be installed to protect internal chiller components. A Hartford Loop is not necessary with a Salt Chlorine Generator. Chiller with Hartford Loop 1.4.e Water Flow Rates Maintain water flow rates as indicated.
  • Page 13: Maintaining Ability To Winterize

    The maximum static pressure (or operating pressure) is 50 pounds-per-square-inch (PSI). These specifications relate to the chiller only. Code-specified whole system turnover rates must be satisfied. 1.4.f Maintaining Ability to Winterize Do not glue the threaded portion of the unions. The unions are used to decouple the chiller from the plumbing system during hard freeze conditions.
  • Page 14: Electrical

    Therefor a water flow switch must be used in place of a water pressure switch to determine if incoming water is being sent to the chiller. See "Grid Flow Switch (# 0040S)" on page 27. 9. If chiller continues to operate without water flow, contact AquaCal ®...
  • Page 15 Electrical Standards Standards Title NFPA 70 The electrical installation must conform to the current version of the NEC, and all applicable local and state codes NFPA 70 Article 440 Standard for Safety for Electric Spas, Equipment Assemblies, and Associated Equipment NFPA 70 Article 680 Standard for Safety for Swimming Pool Pumps, Filters, and Chlorinators...
  • Page 16 Minimum and Maximum Operating Voltage The chiller must operate within specified voltages. Failure to heed the following may result in damage to equipment. NOTICE Operating equipment under higher or lower voltage conditions may result in damage to your compressor, motors or other electrical components.
  • Page 17: Incoming Power Access Holes

    1.5.b Incoming Power Access Holes ® (TropiCool TC1500) ® ® (TropiCool TC500) (TropiCool TC1000) Page - 14...
  • Page 18: Access Panels

    1.5.c Access Panels ® ® TropiCool TC1500 TropiCool TC1000 ® TropiCool TC500 1.5.d Verifying Transformer Setting Transformer voltage 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 chiller's transformer for the appropriate site voltage.
  • Page 19: Three-Phase Adjustment

    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 for further assistance. See "Contacting AquaCal AutoPilot, Inc." on page 1. Page - 16...
  • Page 20: Schematics

    Please have the complete model and serial number available. See "Identifying Model Specifications" on page 25. 1.5.g Connecting an External Controller To support a direct connection to an external controller, AquaCal ® chillers are equipped with optional terminal blocks. These terminals are on the microprocessor located on the low-voltage side of the electrical enclosure.
  • Page 21 Two-wire controller (with internal thermostat): 1. Deactivate power to chiller. 2. Remove chiller electrical access panel. 3. Route the control wiring to the low voltage side of the electrical enclosure. Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. 4.
  • Page 22: Programming For An External Controller

    1.5.h Programming for an External Controller Configure chiller for external control. Using JAO interface Press "Up" or Press "Up" and Press "Pool / Spa" Press "Pool / Spa" "Down" to "Down" buttons button once. button until LOC is passcode. Default is simultaneously until displayed.
  • Page 23: Service Level Programming

    Re-programming all custom site condition settings will be required when using this reset. For further assistance, please see "Contacting AquaCal AutoPilot, Inc." on page 1. PLEASE NOTE - Before changing multiple program options, it is recommended that the user lock option be disabled.
  • Page 24: Service Level Factory Defaults

    1.6.a Service Level Factory Defaults Certain programming options have been preset at the factory. These options can be overwritten for certain site- specific conditions. Table 2 - Default Program Parameters Chart Default Code Description Range Value Call-Flex Set to off at the factory. Options Pool Dead- Band...
  • Page 25: Enter Service Level Programming

    1.6.b Enter Service Level Programming Press "Up" or Press "Up" and Press "Pool / Spa" Press "Pool / Spa" "Down" to "Down" buttons button once. button until LOC is passcode. Default is simultaneously until displayed. "17". CF1 appears. Programming for a Relay Switch Configure chiller for a relay or flow switch.
  • Page 26: Cleaning Equipment After Installation

    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 see "Contacting AquaCal AutoPilot, Inc." on page 1. 1. Simultaneously Press "Pool / Spa" button and "Up" button until the display shows 888 .
  • Page 27 APPROVED POLISHING AGENTS Simoniz ® ® Glo-Coat Armor All ® Protectant Table 4 - Polishing Agents • The trademarks used in approved cleaning and polishing agents are property of their owners and are not related to AquaCal ® Page - 24...
  • Page 28: Appendix

    2 - Appendix 2.1 Identifying Model Specifications 1. Find Data Plate - The data plate is usually posted on the side of the equipment or the inside of the chiller's access Data Plate Example plate. 2. Find the model number on the data plate. The first letters and numbers indicate the model type.
  • Page 29: Weights

    This will allow the Chiller the time required to cool the water at start-up. After the water has reached the desired temperature, reset the filter pump to normal operating time-frames. 2.4 Available Accessories Accessories may be purchased through an authorized dealer of AquaCal ® products.
  • Page 30 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 chillers to be controlled. Call AquaCal for assistance with correct configuration. See "Contacting AquaCal AutoPilot, Inc." on page 1.
  • Page 31: 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 see "Contacting AquaCal AutoPilot, Inc." on page 1. Failure to heed the following may result in injury or death. WARNING Repairs must not be attempted by untrained or unqualified individuals.
  • Page 32 Determine if an insufficient amount of air is being supplied to the equipment. ® 1. Check for proper fan operation. If fan is not operating, contact AquaCal 2. Check for obstructed air flow around the chiller. See "Clearances" on page 4.
  • Page 33: Issues And Resolutions

    Failure to heed the following may result in damage to equipment. NOTICE Service by unauthorized personnel will void the factory warranty. Please perform the following troubleshooting. For further assistance, please see "Contacting AquaCal AutoPilot, Inc." on page 1. Page - 30...
  • Page 34 Display Panel Not Responding 1. If the chiller is controlled be an external controller, confirm the external controller settings. 2. If the issue is still occurring, disconnect external controller from the chiller. Then check operation at chiller. If display panel responds, the problem lies with the external controller or its installation. Contact the manufacturer of the external control device.
  • Page 35 Chiller Is Running, Not Cooling (Reversing Models) 1. If the chiller is using an external controller, confirm the chiller is programmed properly to allow for cooling. See "Operating Chiller (With an External Controller)" on page 1. 2. Confirm the chiller mode is set to COO operating mode. 3.

This manual is also suitable for:

Tropicool tc1000Tropicool tc1500