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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

1.5 Electrical

1.5.a Electrical Requirements

1.5.b Incoming Power Access Holes

1.5.c Access Panels

1.5.d Verifying Transformer Setting

1.5.e Three-Phase Adjustment

1.5.f Schematics

1.5.g Connecting an External Controller

1.5.h Programming for an External Controller

1.6 Service Level Programming

1.6.a Service Level Factory Defaults

1.6.b Enter Service Level Programming

1.7 Cleaning Equipment After Installation

2 - Appendix

2.1 Identifying Model Specifications

2.2 Weights

2.3 Cooling Recommendations

2.4 Available Accessories

3 - Troubleshooting

3.1 Fault Codes

3.2 Issues and Resolutions

Содержание TropiCool TC1000

Страница 1: ...ead this document before operating installing this product For additional product manuals and operation installation procedures please visit www AquaCal com AquaCal Installation Manual WATER CHILLER LTP0099 REV 2e ...

Страница 2: ......

Страница 3: ...Electrical Requirements 11 1 5 b Incoming Power Access Holes 14 1 5 c Access Panels 15 1 5 d Verifying Transformer Setting 15 1 5 e Three Phase Adjustment 16 1 5 f Schematics 17 1 5 g Connecting an External Controller 17 1 5 h Programming for an External Controller 19 1 6 Service Level Programming 20 1 6 a Service Level Factory Defaults 21 1 6 b Enter Service Level Programming 22 1 7 Cleaning Equi...

Страница 4: ... and service of chiller must be performed by an authorized service center l Warranties may be voided if the equipment has been improperly installed maintained or serviced l 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 DANGER Failure to heed the foll...

Страница 5: ...n as Hypothermia The symptoms of Hypothermia include shivering although as hypothermia worsens shivering stops clumsiness or lack of coordination slurred speech or mumbling confusion and poor decision making drowsiness or low energy lack of concern about personal welfare progressive loss of consciousness weak pulse and slow or shallow breathing In addition persons having an adverse medical history...

Страница 6: ... normal rainfall Do not allow a roof slope to direct rainwater onto the chiller Have a gutter installed on the roof edge to direct this water away from the chiller Or install the chiller in another location Planning for Condensation The chiller can produce a large amount of condensation The amount of water depends on air temperature and humidity l Install the chiller with enough height to allow fo...

Страница 7: ...uesting support See Identifying Model Specifications on page 25 1 2 Clearances l Proper air circulation is required for the chiller to operate efficiently The following diagrams show the minimum clearances required for the proper operation of the chiller l Avoid storing chemical containers near the chiller The chemicals can cause equipment damage l Avoid placing objects near or on top of the chill...

Страница 8: ... chiller This will not be covered under equipment warranty See Water Flow Rates on page 9 l Install a bypass valve whenever water flow may exceed maximum rating l See Bypass Valve Kit STK0135 on page 26 l For additional guidance testing water flow rates please contact AquaCal 1 4 b Plumbing Diagrams Plumbing diagrams are provided in this section as a planning guide to the sequence of equipment val...

Страница 9: ...Page 6 Chiller with water flows greater than maximum listed flow rate See Water Flow Rates on page 9 Chiller with Spillover Spa One filter Pump ...

Страница 10: ...Page 7 Chiller with Spillover Spa Two filter Pumps Chiller with Solar Panels in Plumbing Circuit Chiller with Gas Heater backup ...

Страница 11: ...nt cement to the female slip socket of the 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 TropiCool TC1500 TropiCool TC500 TropiCool TC1000 ...

Страница 12: ...ty MODEL HEAT EXCHANGER TYPE FLOW RATES MINIMUM MAXIMUM TC500 Titanium Tube in Tube 20 GPM 45 GPM TC1000 Titanium ThermoLink 30 GPM 70 GPM TC1500 Titanium ThermoLink 30 GPM 70 GPM PLEASE NOTE If minimum flow rates are not met chiller performance is reduced and performance will suffer Internal safety devices may deactivate the chiller with the following errors l HP and HP5 l or if equipped error co...

Страница 13: ...sure Switch Adjust water pressure switch when chiller attempts to operate without water flow Before attempting any adjustments confirm the following l The filter is clean l Filter pump is operating l The valves are set to direct the appropriate amount of water through the chiller See Water Flow Rates on page 9 l FLO is displayed or displays intermittently WARNING Failure to heed the following may ...

Страница 14: ...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 1 5 Electrical 1 5 a Electrical Requirements WARNING Failure to heed the following may result in injury or death l The information contained in this section is intend...

Страница 15: ...trical heat pumps air conditioners and dehumidifiers UL1995 CSA C22 2 236 05 Heating and cooling equipment Table 1 Standards Grounding and Bonding Follow local code requirements for properly grounding and bonding chiller 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 ...

Страница 16: ...ment using the same electrical panel as the chiller 2 If measured site voltage is outside listed ranges immediately deactivate equipment until site conditions have been corrected If unsure of chiller equipment rating please see Identifying Model Specifications on page 25 Equipment Rating Minimum Site Voltage Maximum Site Voltage A Voltage 208 to 230 Volts Single Phase 60 hertz 200 Volts 253 Volts ...

Страница 17: ...Page 14 1 5 b Incoming Power Access Holes TropiCool TC1500 TropiCool TC500 TropiCool TC1000 ...

Страница 18: ... 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 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 me...

Страница 19: ...service industry safety standards and methods If a three phase unit fails to operate at start up the orientation of the line voltage field wiring 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...

Страница 20: ...er must be familiar with service industry techniques l Deactivate power while routing wiring to control board NOTICE Failure to heed the following may result in damage to equipment l The wire size connecting the controller must be 16 gauge 2 conductor or larger low voltage wire l Use direct connection dry contact provided on the microprocessor for external controllers Dry Contact Connection Points...

Страница 21: ...e Follow all National Electric Codes NEC unless State or Local guidelines supersede 4 Connect the controller wires to the microprocessor as follows l Connect Low or Pool wire to X l Connect High or Spa wire to Z l Connect Common wire to Y 5 Reattach chiller access panel 6 Apply power to chiller 7 Program chiller for a three wire controller See Using JAO interface on page 19 Three wire controller w...

Страница 22: ...ess Up or Down to passcode Default is 17 Press Pool Spa button once Press the Pool Spa button until JAO is displayed Press Up or Down button l 0 none l 2 two wire l 3 three wire Using FS2 interface Press Up and Down buttons simultaneously until CF1 appears Press Pool Spa button until LOC is displayed Press Up or Down to passcode Default is 17 Press Pool Spa button once Press the Pool Spa button un...

Страница 23: ... chiller s warranty l Resetting the microprocessor to access a locked keypad will reset all settings to factory default including any installer entered configuration Re programming all custom site condition settings will be required when using this reset l For further assistance please see Contacting AquaCal AutoPilot Inc on page 1 PLEASE NOTE Before changing multiple program options it is recomme...

Страница 24: ...at factory Do not adjust DEL Compressor Time Delay 1 4 minutes Set to on at 4 minutes at the factory Do not adjust dSC Defrost Sensor Factory Calibrated Set at factory Do not adjust dFd Defrost Delay Factory Calibrated Set at factory Do not adjust FS2 Flow Switch Automatic Thermostat Switching Option 0 0 No Switch 1 Enable Switch JAO External Controller 0 0 No Controller 2 Two Wire Controller 3 Th...

Страница 25: ...n provide automatic pool spa thermostat switching Press Up and Down buttons simultaneously until CF1 appears Press Pool Spa button until LOC is displayed Press Up or Down to passcode Default is 17 Press Pool Spa button once Press the Pool Spa button until FS2 is displayed Press the Up or Down l 0 not active l 1 enable PLEASE NOTE Once the FS2 feature has been activated the POOL SPA button will no ...

Страница 26: ...nt is completely dry NOTICE Failure to heed the following may result in damage to equipment l Do not use a pressure cleaner to wash chiller Damage to chiller components may result If using a hose end spray nozzle adjust spray pattern to low strength only l Do not spray water directly into the interior of the chiller damage to components may result l Do not use chemicals on the display panel Cleani...

Страница 27: ... panels with fresh water wipe and buff panels using a dry soft cloth 3 Allow chiller 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 cleaning and polishing agents are property of their owners and are not related to AquaCal ...

Страница 28: ...usually posted on the side of the equipment or the inside of the chiller 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 equipment s specifications Data Plate Example Model Number Example ...

Страница 29: ... temperature 3 Temporarily set the filter pump for continuous operation l This will allow the Chiller the time required to cool the water at start up l 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 Bypass Valve Kit STK0135 l When high f...

Страница 30: ... be controlled Call AquaCal for assistance with correct configuration See Contacting AquaCal AutoPilot Inc on page 1 Grid Flow Switch 0040S l Used for automatic pool spa thermostat switching l This switch can also be used in place of the water pressure switch This may be needed when the pool spa elevation is higher than the chiller A higher elevation of the water can cause a false signal to the ch...

Страница 31: ...orized personnel will void the chiller warranty FLO Indicator ISSUE Low or no water detected RESOLUTION 1 Confirm the filter pump is on 2 If a multiple speed filter pump is being used run at a higher speed to determine if the error persists Do not exceed maximum flow rate for your model 3 Confirm water is not being diverted away from the chiller l See Water Flow Rates on page 9 FS Indicator ISSUE ...

Страница 32: ...witch is showing as open RESOLUTION 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 3 Check for dirty or blocked evaporator coil See Cleaning Equipment After Installation on page 23 HP5 Indicator ISSUE The chiller has loc...

Страница 33: ...til incoming water temperature drops to 100 F or lower RESOLUTION 1 Determine if another heat source gas heater solar heater etc is heating water being sent directly to the chiller with the OtA indicator This situation will need to be corrected before continuing 2 Rule out an incorrect reading from the water temperature sensor Verify existing water temperature with an accurate thermometer If chill...

Страница 34: ...ostat should be set below the current water temperature 4 If an error code is displayed diagnose and correct the cause of the code See Fault Codes on page 28 Chiller s Tripping Breaker 1 Have an electrician confirm breakers are in good condition and properly sized for the chiller 2 Multiple chillers installed at the same site may benefit from special automatic sequencing controllers to avoid exces...

Страница 35: ...er flow Chiller equipment will generally be set to run 24 hours a day in commercial applications Ice Forming on the Chiller 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 Cool Only Units l The heat pump may enter defrost mode if the water flow rate falls below the acceptable range l If the ambient ...

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