Aquacal TropiCal T035 Operation Manual
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- Page 1 ® AquaCal Operation 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 LTM0930 REV 2.02 - (project rel 7.02)
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Page 3: Table Of Contents
Table of Contents Contacting AquaCal AutoPilot, Inc. Safety Instructions 1 - Operation 1.1 Display Door 1.2 Wake Up Heat Pump 1.3 Display Panel 1.4 Activate Heat Mode, Cool Mode, Auto Mode, or Deactivate Equipment 1.5 Set Temperature 1.6 Set Up Programming 1.6.a Setting Date and Time... -
Page 4: Contacting Aquacal Autopilot, Inc
Repair and service of heat pump 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 contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." above. 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 heat pump 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.
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Page 6: Operation
1 - Operation IN THIS SECTION: 1.1 Display Door 1.2 Wake Up Heat Pump 1.3 Display Panel 1.4 Activate Heat Mode, Cool Mode, Auto Mode, or Deactivate Equipment 1.5 Set Temperature 1.6 Set Up Programming 1.6.a Setting Date and Time 1.6.b Using Entry Code to Access Heat Pump 1.6.c Setting Entry Code Option 1.6.d Disabling Entry Code Option... -
Page 7: Display Panel
1.3 Display Panel The following information outlines the operation for a standard installation. Display Panel Control Buttons will operate differently for custom installations; such as when a heat pump is connected to an external controller or multiple heat pump configuration. See "Operating Heat Pump (With an External Controller)"... - Page 8 Display Display Description The heat pump has a user lock enabled. Entry code required See "Using Entry Code to Access Heat Pump" on page 9. No water flow is detected. The filter No water flow pump is off or the heat pump is not receiving the correct water flow.
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Page 9: Activate Heat Mode, Cool Mode, Auto Mode, Or Deactivate Equipment
1.4 Activate Heat Mode, Cool Mode, Auto Mode, or Deactivate Equipment Press "Mode / Enter" button until the desired mode is displayed. HEATING MODE- After the fan and compressor start, the red "Heating" light will activate. COOLING MODE - After the fan and compressor start, the blue "Cooling" light will activate. AUTO MODE - After the fan and compressor start, the heat pump will maintain the set temperature within 1°. -
Page 10: Set Temperature
1.5 Set Temperature Select the pool or spa thermostat. Then press the up or down arrow to set the desired temperature (setpoint) for the water. The heating indicator will illuminate when heating the water. The cooling indicator will illuminate when cooling the water. 1.6 Set Up Programming 1.6.a Setting Date and Time Set the heat pump's time and date using the following steps. - Page 11 Page - 8...
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Page 12: Using Entry Code To Access Heat Pump
1.6.b Using Entry Code to Access Heat Pump If a user entry code has been enabled in the user menu, an entry code will be required to access heat pump options. PLEASE NOTE - If the entry code has been misplaced, the heat pump will need to be reset to factory defaults. After three minutes of inactivity, the heat pump's sleep mode will activate. - Page 13 Page - 10...
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Page 14: Disabling Entry Code Option
1.6.d Disabling Entry Code Option PLEASE NOTE - KEYPAD LOCKED If the heat pump displays a message, the heat pump is in sleep mode. See "Wake Up Heat Pump" on page 3. If an entry code has already been activated, the code must be entered before proceeding to disable. -
Page 15: Configure Variable Speed Compressors
1.6.e Configure Variable Speed Compressors Selected heat pumps have variable speed compressors designed to more quickly and efficiently reach a temperature set point. The compressor's performance can be controlled using a turbo boost mode or two different types of efficiency modes. Turbo Boost Upon demand, the heat pump's compressor can be set to maximum speed to heat or cool the water quickly. - Page 16 Efficiency Mode - Filtration Schedule When using this mode, the compressor's speed is set to heat or cool the water within 60% of the circulation pump's filtration time period. This is the highest efficiency operational mode, providing the lowest cost of operation. Example - If the filtration period is set from 10:00 am to 8:00 pm, the system attempts to bring the water to set point by 4:00 pm at optimal performance.
- Page 17 Set Efficiency Mode to 24 Hour Page - 14...
- Page 18 Set Efficiency Mode to Filtration Schedule Page - 15...
- Page 19 Page - 16...
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Page 20: External Equipment
1.7 External Equipment 1.7.a Operating Heat Pump with a Call Flex When a Call Flex has been installed and configured for a heat pump, the circulation pump will respond to commands from the heat pump. Confirm with the installer if a Call Flex accessory has been installed on the system. - Page 21 Configure for Call mode: Page - 18...
- Page 22 Configure for Flex mode: Page - 19...
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Page 23: Operating Heat Pump (With An External Controller)
1.7.b Operating Heat Pump (With an External Controller) If the display indicates the unit is under remote control, an external control device has been configured to control the heat pump. See the external control device manual. Or contact installer or manufacturer of that device. PLEASE NOTE: When using a SMART external control device, the time-out and service modes will deactivate the Heat Pump. -
Page 24: Using Gas Boost
24 Hour Mode This mode is usually used when the circulation pump runs continuously. The gas heater will activate when the water temperature falls 2° F (-16.7° C) below the set temperature and the ambient air temperature is below 60° F (15.6° C). When the set temperature is reached, the gas heater deactivates. -
Page 25: Operating Multiple Connected Heat Pumps
1.7.e Operating Multiple Connected Heat Pumps Each heat pump will indicate whether it is a master or slaved unit on the display. Changes in mode and operation are made on the master (primary) heat pump only. The master heat pump will automatically start and stop the slaved heat pumps in a timed and controlled sequence. Master Heat Pump Slaved Heat Pump 01 Slaved Heat Pump 02... -
Page 26: Maintenance
2 - Maintenance IN THIS SECTION: 2.1 Water Chemistry 2.2 Cleaning Equipment 2.3 Clearances 2.4 Irrigation and Storm Run-Off 2.5 Water Flow Rates 2.6 Adjusting Water Flow Using ΔT (Delta-T) 2.7 Planned Maintenance 2.8 Winterizing 2.1 Water Chemistry Check water chemistry regularly and maintain within recommended levels. Standards vary in different residential and commercial applications. -
Page 27: Cleaning Equipment
Formula 409 ® Cascade ® All Power Plain Detergent (3% Solution) Table 1 - Cleaning Agents • The trademarks used in approved cleaning agents are the property of their owners and are not related to AquaCal ® Page - 24... -
Page 28: Clearances
• The trademarks used in approved polishing agents are the property of their owners and are not related to ® AquaCal 2.3 Clearances Proper air circulation is required for the heat pump to operate efficiently. The following diagrams show the minimum clearances required for the proper operation of the heat pump. -
Page 29: Irrigation And Storm Run-Off
(Top View) ® TropiCal T170 2.4 Irrigation and Storm Run-Off Irrigation water may damage heat pump components. Direct irrigation water away from the heat pump. The heat pump will withstand normal rainfall. Do not allow a roof slope to direct rainwater onto the heat pump. Have a gutter installed on the roof edge to direct this water away from the heat pump. -
Page 30: Adjusting Water Flow Using Δt (Delta-T)
FLOW RATES MODEL HEAT EXCHANGER TYPE MINIMUM MAXIMUM TC500 Titanium Tube-in-Tube 20 GPM (75.7 L/min) 45 GPM (170 L/min) ® TC1000 Titanium ThermoLink 30 GPM (113.6 L/min) 70 GPM (265 L/min) ® TC1500 Titanium ThermoLink 30 GPM (113.6 L/min) 70 GPM (265 L/min) PLEASE NOTE - If minimum flow rates are not met, heat pump performance is reduced and performance will suffer. - Page 31 Temperature Port (Shown with Probe) 1. Adjust the thermostat to its lowest setting with the unit in heating mode. 2. Deactivate the water filtration pump. 3. Confirm that the filters leading to the heat pump are clean. 4. Adjust the valves controlling water headed towards the heat pump to the half-open position.
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Page 32: Planned Maintenance
PLEASE NOTE - Temperature differences are based on pool water temperatures of 69° to 75° F. (20.5° to 23.8° C) ® For water temperatures outside this range, contact AquaCal . See "Contacting AquaCal AutoPilot, Inc." on page 1. 2.7 Planned Maintenance An annual inspection and maintenance program is strongly recommended starting no later than one year after installation of the heat pump. - Page 33 Recommended Inspection Checklist: 1. Clean Evaporator Coil (As Applicable) 2. Clean Condenser Coil (As Applicable) 3. Check Contactor Points 4. Check Fan Capacitor Values 5. Check Fan Blade Clearances 6. Clean Heat Pump Cabinet 7. Check Flow / Pressure Switch 8.
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Page 34: Winterizing
2.8 Winterizing Failure to properly winterize the heat pump as needed may result in serious equipment damage. Failure to heed the following will result in injury or death. DANGER RISK OF ELECTRICAL SHOCK FROM ENERGY STORED IN CAPACITORS - MODELS EQUIPPED WITH VARIABLE FREQUENCY COMPRESSOR DRIVES STORE ELECTRICITY EVEN AFTER THE POWER HAS BEEN DEACTIVATED AT THE POWER BREAKER. - Page 35 ® Titanium ThermoLink Exchanger (with no Drain) 6. Disconnect the plumbing to the heat pump at connection unions (removal is counter- No Drain clockwise). 7. Allow water to drain completely from the heat pump. 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 36 Titanium Tube-in-Tube Exchanger 6. Disconnect the plumbing to the heat pump at connection unions (removal is counter- Titanium clockwise). Tube-in- 7. Allow water to drain completely from the heat pump. Expect to see a lot of water drain out at Tube first, and then a small amount to continue to drain out over a long period.
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Page 37: Troubleshooting
3 - Troubleshooting IN THIS SECTION: Fault Codes AIR TEMP SENSOR OPEN or AIR TEMP SENSOR SHORT CLOCK LOW BATTERY DEFROST1 SENSOR OPEN or DEFROST2 SENSOR OPEN DEFROST1 SENSOR SHORT or DEFROST2 SENSOR SHORT ERROR AT MASTER UNIT HIGH PRESSURE FAULT HIGH WATER TEMPERATURE HP5 SYSTEM LOCKOUT LOW PRESSURE FAULT... -
Page 38: Fault Codes
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. See "Contacting AquaCal AutoPilot, Inc." on page 1. Failure to heed the following will result in injury or death. -
Page 39: Defrost1 Sensor Open Or Defrost2 Sensor Open
DEFROST1 SENSOR OPEN DEFROST2 SENSOR OPEN ISSUE Open defrost sensor. RESOLUTION A qualified technician should replace the defrost sensor. DEFROST1 SENSOR SHORT DEFROST2 SENSOR SHORT ISSUE Shorted defrost sensor. RESOLUTION A qualified technician should replace the defrost sensor. ERROR AT MASTER UNIT ISSUE The heat pump is slaved to a master heat pump that is displaying a fault code. -
Page 40: High Pressure Fault
Cool Only Units Determine if an insufficient amount of air is being supplied to the equipment. ® 1. Check for proper fan operation. If the fan is not operating, contact AquaCal Technical Support. 2. Check for obstructed airflow around the heat pump. -
Page 41: Hp5 System Lockout
Heat Only Units Place heat pump in heating mode and perform the following troubleshooting. ® 1. Check for proper fan operation. If the fan is not operating, contact AquaCal Technical Support. 2. Check for obstructed airflow around the heat pump. -
Page 42: Lp5 System Lockout
LP5 SYSTEM LOCKOUT ISSUE The heat pump has locked due to five low-pressure faults during one call for heating or cooling. RESOLUTION 1. Deactivate then reactivate power to the heat pump to clear error. 2. Troubleshoot the low-pressure issue causing the error. See "LOW PRESSURE FAULT"... -
Page 43: 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 contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." on page 1. Blank Display ISSUE The Heat Pump may have an incoming power problem. -
Page 44: Displays "Defrosting
Displays Defrosting Displays "DEFROSTING" ISSUE The heat pump has sensed the coil is icing up. See "Ice Forming on the Heat Pump" on page 46. No action is required. RESOLUTION Heat Only Units - Passive Defrost When ice starts to form on the coil, the compressor will stop operating while the fan continues to operate. -
Page 45: Displays "Set To Switch Remotely
"SET TO SWITCH REMOTELY" Displays ISSUE "SET TO SWITCH If when pressing the "Pool / Spa" button the display flashes the message REMOTELY", the heat pump is using a remote relay switch or a 3-wire controller. RESOLUTION The Pool and Spa thermostat automatically switch when using these modes. Operation manually will not be available when using these external devices. -
Page 46: Heat Pump's Tripping Breaker
The heat pump breaker(s) keeps tripping. RESOLUTION ® 1. If AquaCal heat pumps have been connected using a multiple heat pump configuration, the configuration may be incorrect. Please confirm settings or contact installer of equipment. 2. Have an electrician confirm breakers are correct type, in good condition, and properly sized for the heat pump. -
Page 47: Heat Pump Is Running, Not Heating
Heat Pump Is Running, Not Heating ISSUE The heat pump is running. But the water is not heating. RESOLUTION 1. If the heat pump is using an external controller, confirm it is set correctly. See "Operating Heat Pump (With an External Controller)" on page 20. If the heat pump is still not running correctly with this device, contact the installer of the device or the device’s manufacturer for further assistance. -
Page 48: Heat Pump Is Running, Not Cooling
Heat Pump Is Running, Not Cooling ISSUE The heat pump is running. But the water is not cooling. RESOLUTION 1. If the heat pump is using an external controller, confirm the heat pump is programmed properly to allow for cooling. See "Operating Heat Pump (With an External Controller)"... -
Page 49: Ice Forming On The Heat Pump
Ice Forming on the Heat Pump Ice Forming on the Heat Pump ISSUE When conditions are too cold for proper operation, the heat pump will enter a defrost mode. This prevents ice from building up on the evaporator coil. RESOLUTION Heat Only Units: The heat pump may develop a fine layer of white frost on the outside coil before entering the defrost mode. -
Page 50: Water Coming From Heat Pump
Water Coming From Heat Pump ISSUE The water may be normal condensation produced as a by-product of the heat pump's refrigeration process. The heat pump can produce up to 8 to 10 gallons (30 to 38 liters) of condensation per hour depending on the humidity of the ambient air. -
Page 51: Appendix
4 - Appendix IN THIS SECTION: 4.1 Factory Defaults 4.2 Identifying Model Specifications 4.3 Weights 4.4 Heating Recommendations 4.5 Cooling Recommendations 4.6 Available Accessories 4.1 Factory Defaults Certain programming options have been preset at the factory. These options can be overwritten for site- specific conditions. -
Page 52: Identifying Model Specifications
Installer Menus MENUS DEFAULT OPTIONS SET MULTI-UNIT MODE MASTER SLAVED SMART SET EXT. CTRL MODE 2WIRE 3WIRE 12 Hour SET TIME FORMAT 12 Hour 24 Hour SET DATE FORMAT Fahrenheit SET TEMPERATURE UNITS Fahrenheit Celsius SET BACKUP HEAT MODE SCHEDULED 24HR SET ENTRY CODE ENABLED SET USER ENTRY CODE... - Page 53 Model Number Example Page - 50...
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Page 54: Weights
4.3 Weights NOTE: Specifications subject to change. Model Type Model Number Install Weight ® 180 Pounds TropiCal T035 (81.6 kg) ® 180 Pounds TropiCal T055 (81.6 kg) ® TropiCal 200 Pounds T075 (90.7 kg) ® TropiCal 255 Pounds T090 (115.7 kg) ®... -
Page 55: Heating Recommendations
This will allow the Heat Pump 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. 4.6 Available Accessories Accessories may be purchased through an authorized dealer of AquaCal ® products. - Page 56 (345 kPa). Liquid Blankets An invisible liquid heat barrier designed to retain heat and extend the swimming season. ® ® AquaCal recommends Lo-Chlor Aqua Blanket ™ Over Temperature Alarm Kit This kit is an additional safety device. It disables the heat pump if any malfunction occurs that allows the water temperature to surpass a safe level.
- Page 57 Plumbing Unions 2 Inch Unions - (# PLS2627) Temperature Port Kit (# STK0096) This port can be used to adjust water flow using Delta-T. The kit comes with port, installation components, and a temperature probe. Page - 54...