Aquacal HeatWave SuperQuiet SQ120R Installation Manual Download Page 72

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HIGH WATER TEMPERATURE

ISSUE

Incoming water temperature has exceeded 110° F (43° C) and the unit has been deactivated. The heat
pump will not operate until the incoming water temperature drops to 100° F (38° C) or lower.

RESOLUTION

1. Determine if a gas heater is sending water directly to the heat pump. This situation would need to be

corrected before continuing.

2. If a solar heater is sending water directly to the heat pump, the water can initially be hotter than 110° F

(43° C). After the water from the solar panel normalizes, the fault will no longer display and the heat pump
will resume as needed.

3. If the

HIGH WATER TEMPERATURE

fault continues to display, the water temperature sensor may

require replacement.

HP5 SYSTEM LOCKOUT

ISSUE

The heat pump has locked due to five high-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 high-pressure issue causing the error.

See "

HIGH PRESSURE FAULT

" on the previous page.

roubl

hoot

ing

Summary of Contents for HeatWave SuperQuiet SQ120R

Page 1: ...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 LTP0114 REV 2 03 project rel 7 02 ...

Page 2: ......

Page 3: ... 23 1 6 a Connecting a Call Flex 23 1 6 b Connecting a Chlorinator 25 1 6 c Connecting External Controllers to Heat Pump 26 c 1 Connecting Smart Bus Controllers 27 c 2 Connecting Two wire Controllers with internal thermostat 31 1 6 d Connecting Gas Backup Heater to Heat Pump 33 1 6 e Connecting Multiple Heat Pumps Master Slaved 39 1 6 f Connecting a Pool Spa Switching Relay 44 1 7 Program Heat Pum...

Page 4: ...3 3 Weights 81 3 4 Heating Recommendations 82 3 5 Cooling Recommendations 82 3 6 Available Accessories 82 ii ...

Page 5: ...rvice 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 DANGER Failure to heed the following will result in injury or death WARNING Failure to heed the following may result in injury or death NOTICE Failure to heed the following may result in damage to ...

Page 6: ...perthermia People having an adverse medical history or pregnant women should consult a physician before using a hot tub or spa Children and the elderly should be supervised by a responsible adult l Prolonged immersion in water colder than normal body temperature may cause a condition known as Hypothermia The symptoms of Hypothermia include shivering although as hypothermia worsens shivering stops ...

Page 7: ...w Rates 11 1 4 f Adjusting Water Flow Using ΔT Delta T 13 1 4 g Maintaining Ability to Winterize 15 1 4 h Adjusting Water Pressure Switch 15 1 5 Electrical 16 1 5 a Electrical Requirements 16 1 5 b Incoming Power Access Holes 19 1 5 c Access Panels 20 1 5 d Verifying Transformer Setting 21 1 5 e Three Phase Adjustment 22 1 5 f Schematic Location 22 1 6 External Equipment 23 1 6 a Connecting a Call...

Page 8: ...Requirements l The heat pump s base must be installed on a flat and level surface that completely supports the entire base l Build the heat pump pad out of concrete or other code approved material l Confirm the pad can support the weight of the heat pump See Weights on page 81 l Elevate the pad enough to allow for drainage l Make sure the pad is flat and level l Have the pad support the entire hea...

Page 9: ...er operation of the heat pump l Avoid storing chemical containers near the heat pump The chemicals can cause equipment damage l Avoid placing objects near or on top of the heat pump This includes shrubbery and lawn furniture These objects will reduce performance and efficiency and hinder maintenance access Overhead Clearance Top View Top View TropiCal T170 1 Installation ...

Page 10: ...6 1 3 Dimensions HeatWave SuperQuiet SQ120R SQ125 SQ145 SQ166R and SQ225 TropiCool TC1500 TropiCal T035 T055 and T075 TropiCool TC500 TropiCal T090 T115 and T135 TropiCool TC1000 TropiCal T170 1 Installation ...

Page 11: ... on page 11 l Install a bypass valve whenever water flow may exceed the maximum rating l See Bypass Valve Kit STK0135 on page 82 l For additional guidance testing water flow rates please contact AquaCal l A safety enhancing Over Temperature Alarm kit is strongly recommended for all spa applications See Over Temperature Alarm Kit on page 83 1 4 b Plumbing Diagrams Plumbing diagrams are provided in ...

Page 12: ...Page 8 Heat Pump with water flows greater than the maximum listed flow rate See Water Flow Rates on page 11 Heat Pump with Spillover Spa One filter Pump 1 Installation ...

Page 13: ...Page 9 Heat Pump with Spillover Spa Two filter Pumps Heat Pump with Solar Panels in Plumbing Circuit Heat Pump with Gas Heater backup 1 Installation ...

Page 14: ... plumbing unions l Plumbing unions are available from AquaCal NOTICE Failure to heed the following may result in damage to equipment l Do not use glue on the threaded portion of the equipment s unions A glued in place union will prevent the equipment from being properly winterized HeatWave SuperQuiet SQ120R SQ125 SQ145 SQ166R SQ225 TropiCool TC1500 TropiCool TC500 TropiCool TC1000 TropiCal T035 T0...

Page 15: ...atisfied NOTICE Failure to heed the following may result in damage to equipment l Water flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may damage the heat pump This will not be covered under the equipment warranty MODEL HEAT EXCHANGER TYPE FLOW RATES MINIMUM MAXIMUM SQ120R Titanium ThermoLink 30 GPM 113 6 L min 70 GPM 265 L min SQ125 Titanium The...

Page 16: ... safety devices may deactivate the heat pump with the following errors l HIGH PRESSURE FAULT l HP5 SYSTEM LOCKOUT l LOW PRESSURE FAULT l LP5 SYSTEM LOCKOUT l Operate water filtration devices per manufacturer s specifications Dirty filters can cause a reduction of water flow to the heat pump An increase of 7 10 psi 48 to 69 kPa higher than the clean filter pressure typically reduces flow rates This...

Page 17: ...ding to the heat pump are clean 4 Adjust the valves controlling water headed towards the heat pump to the half open position 5 Adjust the valves controlling water leading away from the heat pump to a fully open position 6 Activate the pool water filtration pump 7 Slowly raise the thermostat temperature until the heat pump activates l After a three minute delay the heat pump s compressor will start...

Page 18: ...Link T090 3 to 6 F 1 7 C to 3 3 C Titanium ThermoLink T115 3 to 7 F 1 7 C to 3 9 C Titanium ThermoLink T135 4 to 8 F 2 2 C to 4 4 C Titanium Tube in Tube T170 3 to 7 F 1 7 C to 3 9 C Titanium Tube in Tube TC500 2 to 5 F 1 1 C to 2 8 C Titanium ThermoLink TC1000 2 to 5 F 1 1 C to 2 8 C Titanium ThermoLink TC1500 3 to 7 F 1 7 C to 3 9 C Table 1 Temperature Chart PLEASE NOTE l Temperature differences...

Page 19: ...layed or displays intermittently DANGER Failure to heed the following will result in injury or death l 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 Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routin...

Page 20: ... Requirements DANGER Failure to heed the following will result in injury or death l 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 Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routing wiring to control...

Page 21: ...ing and cooling equipment Table 2 Standards Grounding and Bonding Follow local code requirements for proper grounding and bonding of heat pump equipment l A bonding lug has been provided on the lower right hand corner of the front access panel Surge Suppression The use of approved commercial surge protectors is strongly recommended Sizing the Electrical Service Refer to equipment data plate for sp...

Page 22: ...as the heat pump 2 If measured site voltage is outside listed ranges immediately deactivate equipment until site conditions have been corrected If unsure of heat pump equipment rating please see Identifying Model Specifications on page 79 Equipment Rating Minimum Site Voltage Maximum Site Voltage A Voltage 208 to 230 Volts Single Phase 60 hertz 200 Volts 253 Volts B Voltage 208 to 230 Volts Three ...

Page 23: ...ncoming Power Access Holes HeatWave SuperQuiet SQ120R SQ125 SQ145 SQ166R and SQ225 TropiCool TC1500 TropiCal T035 T055 and T075 TropiCool TC500 TropiCal T090 T115 and T135 TropiCool TC1000 TropiCal T170 1 Installation ...

Page 24: ...VES STORE ELECTRICITY EVEN AFTER THE POWER HAS BEEN DEACTIVATED AT THE POWER BREAKER Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routing wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines HeatWave SuperQuiet TropiCool TC1500 TropiCal T035 T055 and T075 TropiCool TC1000 TropiCool TC500 TropiCal T170 1 ...

Page 25: ...des NEC and or State and Local guidelines WARNING Failure to heed the following may result in injury or death l The information contained in this section is intended for use by qualified technicians familiar with electrical service industry safety standards and methods Example of heat pump transformer Varies between models 1 Turn heat pump on by adjusting the thermostat to call for heating or cool...

Page 26: ...ing may need to be adjusted l The phase monitor is located inside the electrical panel Three Phase Monitor 1 Deactivate power to the unit Confirm that power is off to all three legs using an electrical test meter set for the correct voltage 2 Switch position of the incoming power wires at each leg as follows re connect power and attempt to restart the unit If the unit fails to start disconnect pow...

Page 27: ...g wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines WARNING Failure to heed the following may result in injury or death l This section is only for qualified installers who are familiar with the swimming pool and spa safety standards l The installer must be familiar with service industry techniques NOTICE Failure to heed the following may result in d...

Page 28: ...Page 24 Configure Call Flex Enter Installer Menus then proceed 1 Installation ...

Page 29: ...ACITORS MODELS EQUIPPED WITH VARIABLE FREQUENCY COMPRESSOR DRIVES STORE ELECTRICITY EVEN AFTER THE POWER HAS BEEN DEACTIVATED AT THE POWER BREAKER Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routing wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines WARNING Failure to heed the following may result in ...

Page 30: ... Controllers to Heat Pump To support a direct connection to an external controller AquaCal heat pumps are equipped with optional removable terminal blocks on the microprocessor The microprocessor is located on the low voltage side of the electrical enclosure DANGER Failure to heed the following will result in injury or death l RISK OF ELECTRICAL SHOCK FROM ENERGY STORED IN CAPACITORS MODELS EQUIPP...

Page 31: ...ort RS 485 Do not use the outside power or ground connection on the port c 1 Connecting Smart Bus Controllers External Controller Communication Port Wire Connections 1 Deactivate power to heat pump and external controller 2 Remove electrical access panels on the heat pump and external controller 3 Route 22 gauge 2 conductor low voltage wires from the external controller communication port com port...

Page 32: ... The solar option is to be used for the heat pump l Check Jandy documentation for any further dip switch settings 6 If additional sensors are required on the external controller install them on the external controller now Example Pentair EasyTouch and Pentair IntelliTouch Some controllers require an additional sensor be connected to the external controller s power supply circuit board at the solar...

Page 33: ...Page 29 Configure for Smart Bus Controller Enter Installer Menus then proceed 1 Installation ...

Page 34: ... B Confirm wiring Confirm wires are oriented properly on the heat pump s Port B of the microprocessor a Deactivate power to heat pump and external controller b Remove the access panel on the heat pump c Reverse wires on Port B d Reinstall electrical access panel 7 Reactivate power to the controller 8 Reactivate power to the heat pump C If fault continues to occur check with the manufacturer of the...

Page 35: ...guidelines WARNING Failure to heed the following may result in injury or death l This section is only for qualified installers who are familiar with the swimming pool and spa safety standards l The installer must be familiar with service industry techniques Figure 4 1 Deactivate power to heat pump 2 Remove heat pump electrical access panel 3 Route 22 gauge minimum 2 conductor low voltage wires fro...

Page 36: ...Page 32 Configure 2 wire controller Enter Installer Menus then proceed 1 Installation ...

Page 37: ...ury or death l 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 Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routing wiring to control board l Follow all National Electric Codes NEC and or State and Loca...

Page 38: ...wires from the gas heater to the low voltage side of the heat pump s electrical enclosure Depending on the gas heater s circuit boards use the following connection points from the gas heater l Use the Com and Pool connection points from the gas heater See Figure 5 l Or replace the jumper wire from the Fireman s Switch on the gas heater with two wires leading to the heat pump See Figure 6 Gas Heate...

Page 39: ...er will activate if the water temperature falls two degrees below the set temperature When the set temperature is reached the gas heater will be deactivated See Configure for 24 Hour Mode below n The Heat Pump will continue to maintain the set temperature l Scheduled mode commonly used for residential applications n The circulation pump operates on the circulation pumps regular on off schedule n T...

Page 40: ...Page 36 1 Installation ...

Page 41: ...Page 37 Configure for Scheduled Mode Enter Installer Menus then proceed 1 Installation ...

Page 42: ...Page 38 1 Installation ...

Page 43: ...chniques NOTICE Failure to heed the following may result in damage to equipment l The wire size connecting the heat pumps must be 22 gauge 2 conductor low voltage wire Be sure that the size of the wire will allow at least two wires per connection point l Do not attempt to connect heat pump equipment in multiple configurations with previous HP7 and HP7R versions of the microprocessor See Figure 7 N...

Page 44: ...ps appropriately as a master unit and slaved units Master Slaved 01 Slaved 02 etc to simplify configuration and future operation 9 Reattach access panels Multiple Heat Pump Connection Points to Port C Figure 9 10 Apply power to master heat pump Confirm the mode is set to SYSTEM OFF 11 Apply power to the next heat pump and confirm the mode is set to SYSTEM OFF Do this for each heat pump 12 Program ...

Page 45: ...Page 41 1 Installation ...

Page 46: ...Go to the next connected heat pump and configure it as a slaved unit with a heat pump address of 01 Each additionally connected heat pump will require a unique heat pump address 02 03 etc Enter Installer Menus then proceed 1 Installation ...

Page 47: ...Page 43 1 Installation ...

Page 48: ...OMPRESSOR DRIVES STORE ELECTRICITY EVEN AFTER THE POWER HAS BEEN DEACTIVATED AT THE POWER BREAKER Wait for 2 minutes after the shut down of equipment before servicing l Deactivate power while routing wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines WARNING Failure to heed the following may result in injury or death l This section is only for qualif...

Page 49: ...led switch route wires to the low voltage side of the electrical enclosure The third wire is not used Follow all National Electric Codes NEC unless State or Local guidelines supersede 5 Connect the wires to the jumper provided Polarity is not important 6 Reattach heat pump access panel 7 Apply power to heat pump 8 Configure the heat pump to accept the pool spa relay switch See Configuring Switch b...

Page 50: ...Page 46 1 Installation ...

Page 51: ...Page 47 1 7 Program Heat Pump for the Customer 1 7 a Setting Date and Time Set the heat pump s time and date using the following steps 1 Installation ...

Page 52: ... Time and Date Format The heat pump s time and date format can be customized Customize Time The time can be displayed in 24 hour military time the default display is 12 hour Enter Installer Menus then proceed 1 Installation ...

Page 53: ...Page 49 1 Installation ...

Page 54: ...Page 50 Customize Date The date can be displayed as Day Month Year the default is Month Day Year Enter Installer Menus then proceed 1 Installation ...

Page 55: ...Page 51 1 Installation ...

Page 56: ...Page 52 1 7 c Selecting Celsius or Fahrenheit Set the water temperature to show in either Fahrenheit default or Celsius Enter Installer Menus then proceed 1 Installation ...

Page 57: ... When using this mode the compressor is set to its maximum speed until the temperature set point is reached l The compressor speed will then lower to maintain that temperature set point This will continue as long as there is water flow l See Set Efficiency Mode to 24 Hour on page 55 Efficiency Mode Filtration Schedule When using this mode the compressor s speed is set to heat or cool the water wit...

Page 58: ...Page 54 Turbo Boost 1 Installation ...

Page 59: ...Page 55 Set Efficiency Mode to 24 Hour 1 Installation ...

Page 60: ...Page 56 Set Efficiency Mode to Filtration Schedule 1 Installation ...

Page 61: ...Page 57 1 Installation ...

Page 62: ...he heat pump goes into the sleep mode for the first time NOTICE Failure to heed the following may result in damage to equipment l Before enabling the entry code feature be sure to record the code If lost the heat pump will require a program reset to regain access This reset may require additional configuration by the installer 1 Installation ...

Page 63: ...Page 59 1 Installation ...

Page 64: ...isplaced the heat pump will need to be reset to factory defaults l After three minutes of inactivity the heat pump s sleep mode will activate 1 7 g Resetting Factory Defaults If needed the installer can reset programming to the heat pump s factory default settings See Factory Defaults on page 78 PLEASE NOTE This will reset any external device configurations Enter Installer Menus then proceed 1 Ins...

Page 65: ...Page 61 1 Installation ...

Page 66: ...f the heat pump damage to components may result l Do not use chemicals on the display panel Cleaning 1 Wash cabinet using a low pressure water hose A high pressure water stream will cause damage to the aluminum fins of the heat pump This damage is not covered under the product warranty 2 While the heat pump is still wet use an approved cleaning agent to clean the exterior of the heat pump Do not u...

Page 67: ...anels with fresh water wipe and buff panels using a dry soft cloth 3 Allow heat pump interior and surrounding equipment to air dry for several hours prior to restoring electrical power APPROVED POLISHING AGENTS Simoniz Wax Glo Coat Armor All Protectant Table 4 Polishing Agents The trademarks used in approved polishing agents are the property of their owners and are not related to AquaCal 1 Install...

Page 68: ...UT 70 SMART COMM FAULT 70 VARIABLE DRIVE FAULT 70 WATER TEMP SENSOR SHORT or WATER TEMP SENSOR OPEN 70 Issues and resolutions Blank Display 71 Display Panel Not Responding 71 Displays DEFROSTING 72 Displays NO SYSTEM FIRMWARE 72 Displays NO POOL SPA WATER FLOW 72 Displays SET TO SWITCH REMOTELY 73 Displays SET UNIT MODEL NUMBER 73 Heat Pump Not Running 73 Heat Pump s Tripping Breaker 73 Heat Pump ...

Page 69: ...death l Repairs must not be attempted by untrained or unqualified individuals l The heat pump contains refrigerant under high pressure Repairs to the refrigerant circuit must not be attempted by untrained or unqualified individuals Service must be performed only by qualified HVAC technicians Recover refrigerant before opening the system NOTICE Failure to heed the following may result in damage to ...

Page 70: ...OR SHORT or 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 RESOLUTION The error at the master heat pump must be corrected before the slaved unit will resume operation 2 Troubleshooting ...

Page 71: ...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 l See Clearances on page 5 3 Check for a dirty or blocked evaporator coil l See Cleaning Equipment After Installation on page 62 Heat and Cool Units Reversing Place heat pump in heating mode and perform t...

Page 72: ... heat pump the water can initially be hotter than 110 F 43 C After the water from the solar panel normalizes the fault will no longer display and the heat pump will resume as needed 3 If the HIGH WATER TEMPERATURE fault continues to display the water temperature sensor may require replacement HP5 SYSTEM LOCKOUT ISSUE The heat pump has locked due to five high pressure faults during one call for hea...

Page 73: ...e maximum flow rate for the model 3 Confirm water is not being diverted away from the heat pump l See Water Flow Rates on page 11 l See Adjusting Water Flow Using ΔT Delta T on page 13 4 The water pressure switch may be incorrectly calibrated l See Adjusting Water Pressure Switch on page 15 Heat and Cool Units Reversing Place heat pump in heating mode and perform the following troubleshooting 1 Ch...

Page 74: ...ing a smart bus connection point RESOLUTION 1 Confirm a smart bus external controller is being used l If not set external controller mode to none instead of SMART o See Configure for Smart Bus Controller on page 29 2 Confirm connection points from the external controller to the heat pump are correctly configured l See Connecting Smart Bus Controllers on page 27 3 If using a smart bus external cont...

Page 75: ...t be attempted by untrained or unqualified individuals Service must be performed only by qualified HVAC technicians Recover refrigerant before opening the system NOTICE Failure to heed the following may result in damage to equipment l Service by unauthorized personnel will void the factory warranty Please perform the following troubleshooting For further assistance please contact AquaCal See Conta...

Page 76: ... temperature rises above 38 F 3 3 C the compressor is restarted and cooling resumes l If the coil s temperature remains below 38 F 3 3 C the compressor will remain off Heat and Cool Units Active Defrost Hot refrigerant gas will be sent through the coil to rapidly remove ice or frost During this process the melting of the ice may appear as steam coming off the heat pump This is normal Displays NO S...

Page 77: ... pump are both turned on l If the display still does not illuminate it is recommended that the heat pump installer or electrician confirm the heat pump is receiving power 2 Confirm correct mode is selected 3 Confirm thermostat is set correctly l When heating the water is desired the thermostat should be set above the current water temperature l When cooling the water is desired the thermostat shou...

Page 78: ...mode is set to heat 3 Confirm thermostat is set to the desired water temperature 4 Confirm valves are positioned to heat the correct body of water either the pool or the spa If heating a spa that overflows into a pool confirm the spa is isolated when being heated not flowing into the pool 5 Confirm heat pump is transferring heat into the water l Measure the temperature of air discharge coming out ...

Page 79: ...pa If cooling a spa that overflows into a pool confirm the spa is isolated when being cooled not flowing into the pool 5 If an error code is displayed determine and correct the condition causing the code l See Fault Codes on page 65 6 Confirm heat pump is transferring heat out of the water l Measure the temperature of air discharge coming out of the heat pump s fan If the air is between 8 to 10 F ...

Page 80: ...alling below 32 F 0 C for more than 8 hours winterize equipment Heat and Cool Units with Active Defrost or Icebreaker l During freezing conditions pool or spa heating will continue Frost or ice may develop during the countdown to the active defrost up to 50 minutes This is normal See Displays Defrosting on page 72 l The heat pump will enter an active defrost stage to remove the accumulated frost a...

Page 81: ...ion or a possible leak RESOLUTION 1 Deactivate heat pump leaving the filter pump on After several hours determine if the water is still coming from the heat pump 2 If using chlorine or bromine as a pool spa sanitizer test the water around the heat pump using a test strip If the test strip indicates that chlorine or bromine is present a leak may exist PLEASE NOTE If desired a kit is available to re...

Page 82: ...cific conditions NOTICE Failure to heed the following may result in damage to equipment l Unauthorized adjustments in Service Menus not shown may void the heat pump s warranty User Menus MENUS DEFAULT OPTIONS SET GAS BOOST OFF OFF ON SET TIME DATE USER TO SET SET BACKUP HEAT MODE OFF OFF SCHEDULED 24HR SET ENTRY CODE ENABLED OFF OFF ON SET USER ENTRY CODE 01 SET CALL FLEX MODE OFF OFF CALL FLEX In...

Page 83: ... USER ENTRY CODE 01 SET CALL FLEX INSTALLED NO YES NO SET CALL FLEX MODE OFF OFF CALL FLEX 3 2 Identifying Model Specifications 1 Find Data Plate The data plate is usually posted on the side of the equipment or the inside of the heat pump s access plate 2 Find the model number on the data plate The first letters and numbers indicate the model type 3 The complete model number identifies the equipme...

Page 84: ...Page 80 Model Number Example 3 Appendix ...

Page 85: ... TropiCal T135 287 Pounds 130 kg TropiCal T170 326 Pounds 148 kg HeatWave SuperQuiet SQ120R 268 Pounds 121 6 kg HeatWave SuperQuiet SQ125 268 Pounds 121 6 kg HeatWave SuperQuiet SQ145 328 Pounds 148 8 kg HeatWave SuperQuiet SQ150VS 350 Pounds 158 8 kg HeatWave SuperQuiet SQ166R 328 Pounds 148 8 kg HeatWave SuperQuiet SQ225 328 Pounds 148 8 kg TropiCool TC500 215 Pounds 97 5 kg TropiCool TC1000 285...

Page 86: ...plication If unsure of equipment cooling capability review equipment data plate See Identifying Model Specifications on page 79 1 Confirm heat pump mode has been set to cooling mode 2 Set thermostat to desired water temperature 3 Activate Turbo Boost Mode if equipped 4 Temporarily set the filter pump for continuous operation l This will allow the Heat Pump the time required to cool the water at st...

Page 87: ...lse signal to the heat pump indicating water is flowing through the heat pump when it isn t l This kit is not to be used on applications exceeding 50 PSI 345 kPa Liquid Blankets l An invisible liquid heat barrier designed to retain heat and extend the swimming season l AquaCal recommends Lo Chlor Aqua Blanket Over Temperature Alarm Kit l This kit is an additional safety device It disables the heat...

Page 88: ...umbing Unions l 2 Inch Unions PLS2627 Temperature Port Kit STK0096 l This kit can be used to adjust water flow using Delta T l The kit comes with a port installation components and a temperature probe 3 Appendix ...

Page 89: ......

Page 90: ...000 461001 200K BTU HR 460730 460731 200K BTU HR HD ASME 461032 250K BTU HR 460732 460733 250K BTU HR HD 460806 250K BTU HR ASME 460771 460772 250K BTU HR HD ASME 461020 300K BTU HR 460734 460735 400K BTU HR 460736 460737 400K BTU HR HD 460805 400K BTU HR ASME 460775 460776 400K BTU HR HD ASME 461021 FOR YOUR SAFETY This product must be installed and serviced by authorized personnel qualified inpo...

Page 91: ...ervice and Tecnincal Support If you have questions about ordering Pentair Aquatic Systems replacement parts and pool products please call Phone 800 831 7133 Fax 800 284 4151 8 A M to 4 30 PM Eastern Time Pacific Time Web sites www pentairpool com www staritepool com P N 472592 Rev L 8 14 ...

Page 92: ... Intake Duct with 3 inch PVC Pipe Indoor Installation 19 20 Corrosive Vapors and Possible Causes 20 Vent Installation Indoor Installation for U S or Outdoor Shelter for Canada 21 Vertical Venting Negative Pressure 21 23 Horizontal or Vertical Venting Positive Pressure 24 Connecting Special Gas Venting 24 26 Outdoor Shelter Vent Installation 27 Garage or Utility Room Installation 27 ControlPanelInd...

Page 93: ...rating Btu hr X 1000 3 Fuel Type LP Propane gas or NA Natural gas 4 Construction STD Standard Model HD Heavy Duty Model ASME ASME Certified Model HD ASME Heavy Duty ASME Model Section 1 Heater Identification Information Section 1 Heater Identification Information HEATER IDENTIFICATION INFORMATION HIN MT 250 NA ASME MT MASTERTEMP FUEL TYPE CONSTRUCTION MODEL SIZE BTU INPUT in 1000 of BTU HR H I N H...

Page 94: ...nty may be void if for any reason the heater is improperly installed and or operated Be sure to follow the instructions set forth in this manual If you need any more information or if you have any questions regarding to this pool heater please contact Pentair Aquatic Systems at 800 831 7133 WARRANTY INFORMATION The MasterTemp pool and spa heater is sold with a limited factory warranty Specific det...

Page 95: ... or blood pressure problems should obtain their physician s advice before using spas or hot tubs 6 Persons taking medication which induce drowsiness such as tranquilizers antihistamines or anticoagulants should not use spas or hot tubs WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the heater Do not use this heater if any part has been ...

Page 96: ...r smell Symptoms of carbon monoxide exposure or poisoning include dizziness headache nausea weakness sleepiness muscular twitching vomiting and inability to think clearly IF YOU EXPERIENCE ANY OF THE ABOVE SYMPTOMS IMMEDIATELY TURN OFF THE POOL HEATER LEAVETHEVICINITYOFTHEPOOLORSPAANDGETINTOFRESHAIRIMMEDIATELY THE POOL HEATER MUST BE THOROUGHLY TESTED BY A GAS PROFESSIONAL BEFORE RESUMING OPERATIO...

Page 97: ...s and restrictions Locate the heater away from propane gas storage and filling equipment as specified by the Standard for the Storage and Handling of Liquefied Petroleum Gases CAN CSA B149 2 latest edition or ANSI NFPA 58 latest edition WARNING Risk of fire carbon monoxide poisoning or asphyxiation if exhaust venting system leaks Only qualified service technicians should attempt to service the hea...

Page 98: ...cent to the heater or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the heater The pan must not restrict air flow The heater may not be installed within 5 ft 1 5M of the inside surface of a pool or spa unless it is separated by a solid fence wall or other permanent barrier CONSUMER INFORMATION AND SAFETY WAR...

Page 99: ...igh limit switch HLS which opens if the heat exchanger outlet temperature goes above 135 F 57 C and the air flow switch AFS which senses the pressure drop across the air metering orifice the automatic gas shut off AGS switch which opens if the heat exchanger outlet temperature goes above 140 F 60 C the stack flue sensor SFS which shuts down the heater if the flue gas temperature reaches 480 F 249 ...

Page 100: ...ent and related components Some states require installation and repair by licensed personnel If this applies in your state be sure your contractor bears the appropriate license See Figure 2 for Outdoor and Indoor Installations SPECIFICATIONS DIMENSIONS IN INCHES Figure 2 21 0 53 3 cm 32 61 82 8 cm 23 02 58 5 cm 28 15 71 5 cm 16 40 6 cm TOP FRONT EXHAUST SIDE PLUMBING SIDE 10 13 25 7 cm 5 6 14 2 cm...

Page 101: ... that could prevent flow through the heater except for pool installations as noted below or winterizing valves where needed To switch flow between the pool and spa use a diverter valve Do not use any valve that can shut off the flow Install the chemical feeder downstream of the heater Install a chemical resistant one way check valve between the heater and the chemical feeder to prevent back siphon...

Page 102: ...g a pressure suction differential Do NOT sanitize the pool by putting chlorine tablets or sticks into the skimmer s When the pump is off this will cause a high concentration of chlorine to enter the heater which could cause corrosion damage to the heat exchanger CAUTION Exercise care when installing chemical feeders so as to not allow back siphoning of chemical into the heater filters or pump When...

Page 103: ...p between static and dynamic The gas supply must be installed in accordance with the National Fuel Gas Code ANSIZ223 1 or standard CSA B149 1 Natural Gas and Propane Installation Codes as applicable and all applicable local codes Install a manual shut off valve and a sediment trap and union located outside the heater panels see Figure 6 Do not use a restrictive gas cock The following minimum gas p...

Page 104: ...a CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE WARNING Risk of fire and explosion Improper installation incorrect adjustment alteration service or maintenance of the Combination Gas Control Valve can lead to fire or explosion causing loss of life personal injury and or property damage If it is necessary to adjust the gas valve this must be done by only by a qualified service...

Page 105: ... s i r e t a e h e l i h w e d a m s g n i d a e r r o s t n e m t s u j d a y n A s m e l b o r p e c n a m r o f r e p n i t l u s e r OUTDOOR INSTALLATION For heaters located outdoors using the built in stackless venting system WARNING Risk of explosion if a unit burning propane gas is installed in a pit or other low spot Propane is heavier than air Do not install the heater using propane in pi...

Page 106: ...he heater from any property line set back requirements see the installation diagram below If installing the heater next to or near an air conditioning unit or a heat pump allow a minimum of 36 in 91 4 cm between the air conditioning unit and the heater CAUTION VENTING GUIDELINES OUTDOOR INSTALLATION Check local building codes for setback requirements Force Air Inlet Property Line 4 4 4 3 SIDE VIEW...

Page 107: ...vice access it is advisable to allow for sufficient clearance on at least one door panel Figure 10 Section 3 Installation Instructions HEATER CLEARANCES General Requirements INDOOR INSTALLATION U S OR OUTDOOR SHELTER CANADA The following clearances must be maintained from combustible surfaces TOP 6 in 15 cm EXHAUST SIDE 6 in 15 cm HEADER SIDE 6 in 15 cm DOOR PANELS 6 in 15 cm Note For service acce...

Page 108: ...ly for proper combustion and ventilation of the surrounding area The minimum requirements for the air supply specify that the room in which a heater is installed should be provided with two permanent air supply openings one within 12 inches 30cm of the ceiling the other within 12 inches 30cm of the floor for combustion air in accordance with the latest edition of ANSI Z223 1 or the National Fuel G...

Page 109: ...f e R s e v i s e h d a n o i t c u r t s n o c y r d n u a l d n a g n i n a e l c y r D s a e r a s p a o s y r d n u a l r o s t n e g r e t e d s e h c a e l B s r e n a e l c d n a s e x a W e n i r o l h c g n i n i a t n o c m u i d o s r o m u i c l a c e n i r o l h c g n i n i a t n o c e d i r o l h c NOTE Each 90 degree elbow reduces the maximum horizontal PVC air intake duct run by 12...

Page 110: ...or the standards CSAB149 1 and B149 2 Canada Read VERTICAL VENTING NEGATIVE PRESSURE before using this table Table 7 Permitted Minimum and Maximum Vent Heights By Size and Heater Model NOTE Vent must be at least eight 8 feet away from nearest vertical surface Vents extending five 5 feet or moreabovetheroofmustbebracedorguyed Consultyourlocalcodeofficialsfordetailedinformation r a l l o C e u l F l...

Page 111: ...ll vent parts come from that manufacturer and are specified by the manufacturer for your system Follow manufacturer s instructions local code requirements National Fuel Gas Code requirements U S or standards CSA B149 1 and B149 2 Canada carefully during assembly and installation Section 3 Installation Instructions 6 15 cm Minimum Clearance to Combustible Materials Listed Termination Cap Storm Coll...

Page 112: ...her low temperature tubing Follow drain manufacturer s installation instructions 5 Use Listed fire stop for floor and ceiling penetrations Use Listed thimble for wall penetrations Use a Listed roof flashing roof jack or roof thimble for all roof penetrations Do not fill the space around the vent that is the clear air space in the thimble or fire stop with insulation The roof opening must be locate...

Page 113: ...nstructions Table 8 l a t n o z i r o H r o l a c i t r e V t n e V s a G l a i c e p S n i 4 s w o b l E 0 9 f o o N M t e e F n i h t g n e L m u m i x a M 0 M 3 1 2 t f 0 7 1 M 7 7 1 t f 8 5 2 M 0 4 1 t f 6 4 3 M 4 0 1 t f 4 3 4 M 7 6 t f 2 2 e c n a d r o c c a n i r o M 4 3 t o o f e n o s i h t g n e l t n e v m u m i n i M d n a l a c o l d n a n o i t c u r t s n i s r e r u t c a f u n a ...

Page 114: ...essary without putting a strain on the heater or vent body It is recommended to slope the horizontal pipe runs up from the heater at least 1 4 per foot 2cm M Install Approved condensate drains at low points where condensate might collect Plumb condensate drains to a drain through hard piping or high temperature tubing such as silicone rubber or EPDM rubber do not use vinyl or other low temperature...

Page 115: ...al must be located Canada See Figure 16 at least 10 feet 3 3M from any opening into a building at least 12 3M above finished grade or the normally expected snow accumulation level whichever is higher at least 4 feet 1 2M horizontally from electric meters gas meters regulators and relief equipment at least 7 feet 2 1M above grade adjacent to walkways or similar traffic areas Allow at least three fe...

Page 116: ...test edition Consult local codes and fire protection authorities about specific installation restrictions The heater is design certified by CSA International for installation on combustible flooring in alcoves basements in closet or utility rooms in the U S GARAGE OR UTILITY ROOM INSTALLATION In Canada the heater must be installed in a room that is not normally occupied and has no openings directl...

Page 117: ...K Check that horizontal vent pipe runs slope uniformly at least 1 4 per foot 2cm per meter to condensate drain s No sags no dips no high or low spots Check that vent is supported at elbows tees and horizontal and vertical runs according to manufacturer s instructions and code requirements Check that vent supports and wall and ceiling penetrations allow free movements up down and sideways without p...

Page 118: ...th local codes or in the absence of local codes with the National Electrical Code or the Canadian Electrical Code as applicable Abonding lug is provided on the outside of the panel under the vent for this purpose 3 Electrical power circuits to the pool heater must follow local codes and National Electrical Code or Canadian Electrical Code as applicable 4 All wiring between the heater and devices n...

Page 119: ...nect a 3 Wire Control Connect wires between the control board terminals on the heater and the external relays as shown in Figure 23 Use at least 2 relays per heater to allow for an OFF setting on each heater mode Select relays that can handle logic level switching DO NOT apply line voltage to control board terminals Move jumper as shown on Figure 23 to enable external control and to disable the he...

Page 120: ...NECTION Spa Line Common Line Pool Line IGNITION CONTROL MODULE DIAGNOSTIC INDICATOR F1 F2 24 VAC S1 240 S1 120 L1 L1 L2 BM FL F1 L2 S2 TH IND VALGND GND GND BLOWER Line 2 120 VAC IGNITER TRANS Line 1 Ground JUNCTION BOX F I R E M A N S S W I T C H Replace jumper with leads to Fireman s Switch field installed 24VAC SEC Y W Y W Y R Y O Y BL O W W BK BK O GY GY BK BK R Y BK W BL Y BK W BL GY GY GY GY...

Page 121: ... 24 VAC 24V OPERATING CONTROL 24 VAC LOGIC TH IND AIR FLOW SWITCH HI LIMIT SWITCH WATER PRESSURE SWITCH COM NO AGS SWITCH VAL GAS VALVE THERMISTOR SENSOR STACK FLUE SENSOR NOTES 1 AND TH L1 L2 F1 F2 S1 24 VAC S2 GND IND VAL ARE CONNECTED ON THE IGNITION MODULE 2 3 PIN AND SOCKET CONNECTOR IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED THEY MUST BE REPLACED WITH TYPE 1...

Page 122: ... call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the Fire Department C Use only your hand to turn the gas control on or off Never use tools If you cannot change the ON OFF setting by hand don t try to repair it call a qualified service technician Forced or attempted repair may result in a fire or explosion D Do not us...

Page 123: ...nt must be above actual water temperature or burner will not fire See OPERATING the CONTROL PANEL 14 The blower should come on immediately and after about 20 seconds the burner should fire When operating for the first time the burner may not fire on the first try because of air in the gas line If it does not fire at first push the OFF switch wait five minutes and again push the POOL or SPAON switc...

Page 124: ...eset the switch so that it is open when the pump is off and closed when the pump is running Turn the star wheel on the switch clockwise to raise setting heater below the pool and counterclockwise to lower the setting heater above the pool see Figure 29 Test the switch after resetting NOTICE When the heater is mounted more than five feet 1 5M above or four feet 1 2M below the deck level a Pressure ...

Page 125: ...l return to the actual pool spa temperature In addition to the digital temperature display there are five indicator lights The POOL ON light indicates that the pool water temperature is governing operation of the heater The SPA ON light indicates that the spa water temperature is governing operation of the heater The HEATING light comes on and stays on when the burner is firing This light should b...

Page 126: ...er Locate the yellow button on the corner of the control board 3 Push the Max Temp Set Point button on the back of the control board see Figure 33 The following sequence should happen A The unit will come on and the POOL ON light will come on B Press the STEMP or T TEMP pad on TOP of the panel to set maximum pool temperature C Wait up to 30 seconds the POOL ON light will go off and the SPA ON ligh...

Page 127: ...ot fire or no red LED s come on replace Control Board YES Is green POOL or SPA LED on Is red SERVICE SYSTEM LED on Is red SERVICE HEATER LED on Turn off power to heater for about 5 seconds and turn back on Make sure tempera ture setting is above water temperature Wait one minute Do any diagnostic LED s on back of board AGS AFS SFS HLS PS or THERMISTOR come on and stay on NOTICE Any or all of the d...

Page 128: ...Check for 24 VAC at sec ondary of Transformer Check for Line Voltage at Transformer primary pins White connects to Pin 3 on Transformer Black to Pin 2 Orange to Pin 1 240V check Pin1 to Pin 3 120V check Pin 2 to Pin 3 Jumper Fireman s Switch at Terminal Board and depress POOL or SPA ON button on membrane pad Does SPA or POOL LED come on Leaving jumper in place check for 24 VAC between Fireman s Sw...

Page 129: ... above minimum flow requirement Model Flow 200 20 gal min 76 LPM 175 20 gal min 76 LPM 250 25 gal min 95 LPM 300 30 gal min 114 LPM 400 40 gal min 151 LPM Is red SERVICE HEATER LED on YES YES NO YES NO NO Is red SERVICE SYSTEM LED on Verify that pump is on filter is not blocked and the water flow is above the minimum requirement Check that water pressure is within the adjustment range of the Press...

Page 130: ...t 24 seconds after call for heat SEE NOTE 2 Turn off power to heater for 5 seconds and turn back on Make sure tempera ture setting is above water temperature Wait one minute Does heater fire and stay on Did Blower come on Verify that gas is flow ing to burner during ignition try Observe gas meter for move ment during ignition try wait for about 30 seconds after calling for heat Check for 24 VAC be...

Page 131: ...s good your meter will read some voltage between 0 and 240 VAC Exactly what reading you get will depend on the meter but with a good ICM the reading won t be 0 VAC or 240 VAC but somewhere in between IMPORTANT READ ME FIRST Gas flows during igni tion try but burner does not fire NO NO YES Go back to chart HEATER WILL NOT FIRE C Page 41 Check voltage across igniter leads OK Replace Ignition Control...

Page 132: ...r punctured Replace Air Flow Switch AFS If problem persists replace Blower Replace Blower Verify correct connection of wiring between 24 VAC and IND terminals on Ignition Control Module and Control Board and replace Control Board YES YES NO NO NO YES YES NO AFS on Does Blower operate THERMISTOR on Verify Thermistor wiring If OK replace Thermistor Disconnect Blower and check for line voltage betwee...

Page 133: ... open circuit 0 shorted Does sensor check OK Clean tighten pins as needed Reset power to Heater and retry Heater should fire NOT OK NO NO NO NO NO SFS on Replace Stack Flue Sensor Correct Fuel Supply reset Heater and retry Heater should fire correctly Repeat checks on fuel supply Thermal Regulator check for correct orifices etc DONE DONE YES YES YES YES NO NO YES NO OK YES Replace Heater Control B...

Page 134: ...lame current is not Check for wet or damaged igniter with normal but flame does being sensed low resistance to ground Replacewith not stay lit new igniter Verify burner flameholder is properly grounded Ignition Control Module Heat Exchanger Troubleshooting SYMPTOM CAUSE REMEDY Boiling in heat exchanger Low water flow to heater pump and or filter May be accompanied by Heat exchanger plugged Service...

Page 135: ... the user Call a qualified service technician if you suspect that the burner may require maintenance PRESSURE RELIEFVALVE NOT FACTORY INSTALLED Canadian code requires and some U S local codes may require installation of a Pressure Relief Valve PRV Purchase separately and install P N 460925 a 3 4 pressure relief valve complying with the ANSI ASME Boiler and Pressure Vessel Code having a capacity eq...

Page 136: ... If air temperatures are expected to drop below freezing 32 F 0 C shut down the heater and winterize it For outdoor heaters in freezing climates shut the heater down and drain it for winter as follows 1 Turn off electrical supply to the heater and pump 2 Close main gas control valve and manual gas valve located outside the heater Turn switch on heater gas valve to OFF 3 In northern climates where ...

Page 137: ...N R172288 between the heater and the chlorinator to prevent concentrated chemicals from back siphoning into the heater Back siphoning is most likely to occur when the pump stops creating a pressure suction differential Do NOT sanitize the pool by putting chlorine tablets or sticks into the skimmer s When the pump is off this will cause a high concentration of chlorine to enter the heater which cou...

Page 138: ...gher or bromine residual is 6 0 ppm or higher See your local pool supply store for help in properly balancing your water chemistry RULE Chemicals that are acid lower pH Chemicals that are alkaline raise pH ALKALINITY High or Low Total alkalinity is a measurement of the total amount of alkaline chemicals in the water and control pH to a great degree It is not the same as pH which refers merely to t...

Page 139: ...aler If your dealer cannot supply you call Customer Support at 1 800 831 7133 For complete Electrical System parts breakdown Key Nos 1 through 4 See Page 53 For complete Burner System parts breakdown Key Nos 5 through 7 See Page 51 For complete Water System parts breakdown Key Nos 8 through 9 see Page 52 1 2 3 5 6 4 8 9 7 Section 6 Maintenance Replacement Parts ...

Page 140: ...EMP HEATER REPLACEMENT PARTS For heaters manufactured between 1 12 2009 and 10 31 2013 clamp lid tub design Note Kits also include Clamp Assembly O Ring and Silicon Tube see page 52 Combustion Chamber Gasket Lid Nut Washer 9x CLAMP LID TUB DESIGN Section 6 Maintenance Replacement Parts ...

Page 141: ...y No 13 14 16 17 18 19 77707 0008 77707 0008 77707 0008 77707 0008 16 Bottom Outer Insulation Blanket 17 1 Bottom Inner Insulation 18 1 Top Insulation 19 Top Outer Insulation Blanket Lower Enclosure Insulation 42001 0074S 42001 0074S 42001 0074S 42001 0074S 20 One Piece Metal Elbow Combustion Chamber Cover Assembly 474094 474094 474094 474094 21 Metal Vent Cover 42002 0005S 42002 0005S 42002 0005S...

Page 142: ...001 0060S 42001 0060S 42001 0060S 42001 0060S 10 Manifold 1 11 5 16 Washer S S 10 12 5 16x18x2 3 4 Hex Cap screw 10 13 Connector Tube O Ring 2 14 Connector Tube Kit Includes 1 Connector Tube and 1 O Ring 2 77707 0017 77707 0017 77707 0017 77707 0017 15 Thermal Regulator Kit Incl Key No 16 17 18 19 and Spring Clip 77707 0010 77707 0010 77707 0010 77707 0010 16 Thermal Regulator Includes Spring Clip...

Page 143: ...1 0053S 42001 0053S 42001 0053S 42001 0053S 8 Terminal Board 1 1 1 1 1 1 42001 0056S 42001 0056S 42001 0056S 42001 0056S 9 Fireman s Switch Fuse 1 25A 1 1 4 32850 0099 32850 0099 32850 0099 32850 0099 10 Ignition Control Module 1 42001 0052S 42001 0052S 42001 0052S 42001 0052S 11 Transformer 120 240V 1 42001 0107S 42001 0107S 42001 0107S 42001 0107S 12 Air Flow Switch 42001 0061S 42001 0061S 42001...

Page 144: ...Rev L 8 12 13 MASTERTEMP Pool and Spa Heater Installation and User s Guide 55 N TES ...

Page 145: ...s in the United States and or other countries Unless expressly noted names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa Inc Those names and brands may be the trademarks or registered trademarks of those third parties Because we are continuously improvi...

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