Aquacal TropiCool TC500 User manual

Important
Read 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

Table of Contents
Contacting AquaCalAutoPilot, Inc. 1
Safety Instructions 1
1 - Installation 3
1.1 Positioning Equipment 3
1.2 Clearances 4
1.3 Dimensions 4
1.4 Plumbing 5
1.4.a Plumbing Requirements 5
1.4.b Plumbing Diagrams 5
1.4.c Water Connections to Chiller 8
1.4.d In-Line Chlorine Feeders 9
1.4.e Water Flow Rates 9
1.4.f Maintaining Ability to Winterize 10
1.4.g Adjusting Water Pressure Switch 10
1.5 Electrical 11
1.5.a 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 Equipment After Installation 23
2 - Appendix 25
2.1 Identifying Model Specifications 25
2.2 Weights 26
2.3 Cooling Recommendations 26
2.4 Available Accessories 26
3 - Troubleshooting 28
3.1 Fault Codes 28
3.2 Issues and Resolutions 30
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Contacting AquaCalAutoPilot, Inc.
For further assistance, please contact the distributor or installer of this product.
If unavailable, please contact AquaCal®for a partner in your area. To better assist you, please have the chiller
model and serial number available.
lSee "Identifying Model Specifications" on page 25.
Product Information:
Website www.AquaCal.com
Phone [phone]
Hours 8-5 pm, Eastern M-F
Service Information:
Website www.AquaCal.com/request-heat-pump-service/
SAFETY INSTRUCTIONS
lFor personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the equipment
and within this manual. Repair and service of chiller must be performed by an authorized service center.
lWarranties may be voided if the equipment has been improperly installed, maintained or serviced.
lIf 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 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 equipment.
When installing and using your chiller basic safety precautions must always be followed, including the
following:
DANGER Failure to heed the following will result in injury or death.
lThe chiller utilizes high voltage and rotating equipment. Use caution when servicing.

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WARNING Failure to heed the following may result in injury or death.
lInstallation and repairs must be performed by a qualified technician.
lThe 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.
lImproper water chemistry can present a serious health hazard. To avoid possible hazards, maintain pool / spa water
per standards detailed in this document.
lProlonged 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), 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, or pregnant women, should consult a physician
before immersing in a cold body of water. Children and the elderly should be supervised by a responsible adult.
NOTICE
Failure to heed the following may result in damage to equipment.
lMaintain proper water chemistry in order to avoid damage to pump, filter, pool shell, etc.
lWater flow exceeding maximum flow rate requires a bypass. Damage due to excessive water flow will void
warranty.
SAVE THESE INSTRUCTIONS

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1 - Installation
WARNING Failure to heed the following may result in injury or death.
lInstallation of this equipment by anyone other than a qualified installer can result in a safety hazard.
lThe information contained throughout the "Installation" section is intended for use by qualified installation
technicians familiar with the swimming Pool / Spa safety standards.
NOTICE
Failure to heed the following may result in damage to equipment.
lFailure to protect equipment against corrosive conditions will adversely affect the life of the equipment and will
void equipment warranty.
1.1 Positioning Equipment
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not install equipment inside of a building.
Outdoor Use Only
Do not install equipment inside of a room or building.
lChillers require unobstructed air flow for proper operation. Chillers should never be installed indoors or in a
location where air flow is restricted. See "Clearances" on page 4.
Controlling Irrigation and Rainwater Runoff
lIrrigation water may damage chiller components. Direct irrigation water away from the chiller.
lThe chiller will withstand 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.
lInstall the chiller with enough height to allow for water drainage.
lPlan for water drainage as needed.
nSee "Condensation Drain Kit (# STK0202)" on page 26.
Mounting Pad Requirements
lThe chiller's base must be installed on a flat and level surface that completely supports the entire base.
lBuild the chiller pad out of concrete or other code-approved material.
lConfirm the pad can support the weight of the chiller. See "Weights" on page 26.
lElevate the pad enough to allow for drainage.
lMake sure the pad is flat and level.
lHave the pad extend at least 6 inches from the chiller base in all directions.
lDo not install the chiller on soil or grass.
lDo not allow the chiller base to touch the building's foundation.
lDo not place the chiller directly on a concrete floor. This can case noise to be transmitted to an occupied space. If
necessary install vibration dampers between the chiller base and floor.
lEquipment pad must meet all requirements of authorities having code-related jurisdiction.

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Anchoring to Pad
lFollow all applicable local, state, and national requirements regarding wind load anchoring.
lThe 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.
lIf 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.
1.2 Clearances
lProper 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.
lAvoid storing chemical containers near the chiller. The chemicals can cause equipment damage.
lAvoid placing objects near or on top of the chiller. This includes shrubbery and lawn furniture. These objects will
reduce performance and efficiency and hinder maintenance access.
(Overhead Clearance) (Top View)
1.3 Dimensions
(TropiCool®TC500) (TropiCool®TC1000)

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1.4 Plumbing
1.4.a Plumbing Requirements
NOTICE
Failure to heed the following may result in damage to equipment.
lDo 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.
lThe chiller must receive water flow within the specified minimum ranges under worst-case conditions such as a
fouled water filter.
lFailure to provide clean filtered water to the chiller can void product warranty.
lWater flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may
damage the chiller. This will not be covered under equipment warranty. See "Water Flow Rates" on page 9.
lInstall a bypass valve whenever water-flow may exceed maximum rating.
lSee "Bypass Valve Kit (# STK0135)" on page 26.
lFor 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, valves, and
fittings.
lThe basic plumbing configurations for typical installations are shown.
lIf the installation does not closely follow any of the supplied plumbing diagrams, AquaCal®Technical Support is
available for installation advice and guidance.
lConfirm water provided to chiller is clean and filtered.
Chiller with water flows equal or less than maximum listed flow rate
See "Water Flow Rates" on page 9.

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Chiller with water flows greater than maximum listed flow rate
See "Water Flow Rates" on page 9.
Chiller with Spillover Spa (One filter Pump)

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Chiller with Spillover Spa (Two filter Pumps)
Chiller with Solar Panels in Plumbing Circuit
Chiller with Gas Heater backup

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Multiple Air Source Chillers
1.4.c Water Connections to Chiller
lChiller union sizes are specified on diagrams.
lConnections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions.
lPlumbing unions are available from AquaCal®.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo 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

Page - 9
1.4.d In-Line Chlorine Feeders
Place in-line chlorinators downstream from the chiller and as low in elevation as possible.
lIf an erosion type feeder is used, it is recommended that a Hartford Loop be installed to protect internal chiller
components.
lA 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. Please note, these specifications relate to the chiller only. Code-
specified whole system turnover rates must be satisfied.
NOTICE
Failure to heed the following may result in damage to equipment.
lWater flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may
damage the chiller. This will not be covered under equipment warranty.
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:
lHP and HP5
lor (if equipped) error codes of LP and LP5
lOperate water filtration devices per manufacturer's specifications. Dirty filters can cause a reduction of water flow
to the chiller. An increase of 7-10 psi higher than the clean filter pressure typically reduces flow rates. This
requires the filter to be cleaned or back-washed.
lKeep baskets free of debris. A large quantity of debris in the pump and skimmer baskets can reduce water flow.
lCheck for improper valve settings. A partially closed valve after the filter, or a full-open bypass around the
chiller, will cause insufficient water flow through the chiller.

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lThe maximum static pressure (or operating pressure) is 50 pounds-per-square-inch (PSI). These specifications
relate to the chiller only.
lCode-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.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will prevent the chiller
from being properly winterized.
1.4.g Adjusting Water Pressure Switch
Adjust water pressure switch when chiller attempts to operate without water flow.
Before attempting any adjustments confirm the following :
lThe filter is clean.
lFilter pump is operating.
lThe valves are set to direct the appropriate amount of water through the
chiller. See "Water Flow Rates" on page 9.
lFLO is displayed (or displays intermittently).
WARNING Failure to heed the following may result in injury or death.
lWater Pressure Switch adjustment procedure to be performed by experienced service personnel only; procedure
must not be attempted by individuals lacking adequate electrical and mechanical experience.
NOTICE
Failure to heed the following may result in damage to equipment.
lIf the chiller continues to operate after a water pressure switch adjustment, deactivate equipment and perform
additional troubleshooting.

Page - 11
1. Remove chiller access panel.
2. Locate the water pressure switch. It will be outside and along
the bottom edge of the electrical enclosure. Exact location
varies by model.
3. Activate filter pump.
4. Apply power to chiller.
5. Slowly rotate the adjustment wheel on the switch. Keep
turning the wheel until the chiller indicates it is receiving
water. The display will no longer display the FLO code.
6. Deactivate filter pump. If correctly adjusted, thechiller will
deactivate and the display will show the FLO code.
7. Re-install chiller access panel.
8. If the chiller continues to operate without water flow, the installation of a grid flow switch may be required.
lThis can become necessary if the chiller is installed below the elevation of the body of water to be cooled.
The standing pressure from the water can cause the water pressure switch to activate when the circulation
pump is off. 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®.
1.5 Electrical
1.5.a Electrical Requirements
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified electricians familiar with electrical
service-industry safety standards and methods.
lLocate the equipment disconnect as near to the chiller as possible. Always satisfy applicable codes and standards.
lNever mount power-disconnects directly to the chiller.
lIn sizing power wiring, be especially aware of up-sizing requirements necessary due to wiring distances. Always
satisfy applicable codes and standards.
lAquaCal®chillers are designed to use copper conductors, only. Do not use aluminum wire.
lMultiple chillers installed at the same site may benefit from automatic sequencing controllers (ASC) to avoid
excessive power drops at start-up. See "Available Accessories" on page 26.

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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
IEC 60335-1-2001 Household and similar electrical appliances - Safety -
General Requirements
IEC 60335-2-40 2006 Household and similar electrical appliances - Safety –
Particular requirements for electrical 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.
lA 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 specific information required to size electrical service and over-current
protection of chiller. Sizing is based on data plate information, wire size, wiring devices, and over-current
protection per applicable local codes and standards. See "Identifying Model Specifications" on page 25.

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Minimum and Maximum Operating Voltage
The chiller must operate within specified voltages.
NOTICE
Failure to heed the following may result in damage to equipment.
lOperating equipment under higher or lower voltage conditions may result in damage to your compressor, motors or
other electrical components. This damage will not be covered by product warranty.
1. Measure site voltage. The site voltage MUST be measured under “FULL LOAD” conditions. Activate all
equipment 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
B Voltage
(208 to 230 Volts)
Three Phase 60 hertz
200 Volts 253 Volts
D Voltage
(380 to 420 Volts)
Three Phase 50 hertz
361 Volts 441 Volts
G Voltage
(460 Volts)
Three Phase 60 hertz
437 Volts 483 Volts
H Voltage
(200 to 240 Volts)
Single Phase 50 hertz
180 Volts 264 Volts

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1.5.b Incoming Power Access Holes
(TropiCool®TC1500)
(TropiCool®TC500) (TropiCool®TC1000)

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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.
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified technicians, familiar with electrical
service-industry safety standards and methods.

Page - 16
Example of chiller
transformer
(Varies between models)
1. Turn chiller on by adjusting the thermostat to call for cooling. If more than
one chiller is on site, turn them all on. Allow time for all chiller compressors
to activate.
2. Measure the running site voltage.
3. Confirm transformer tap is set for the measured site voltage. If more than one
voltage tap is shown, select the voltage nearest to the running site voltage.
PLEASE NOTE -
lIf more than one voltage is shown on the equipment’s data plate, the factory default setting is
usually the higher voltage on the transformer.
lAs an example, a "208/230" voltage will be set to "240" from the factory.
1.5.e Three-Phase Adjustment
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified technicians, familiar with electrical
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.
lThe 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 power. Verify off and proceed to
next leg.
lSwitch incoming power wires at L1 and L2 on the line side to the contactor.
lSwitch incoming power wires at L1 and L3 on the line side to the contactor.
lSwitch incoming power wires at L2 and L3 on the line side to the contactor.
3. When chiller starts, disconnect power and verify off. Then confirm all line voltage connections
are securely tightened. Reconnect power.
lIf chiller does not start, contact AquaCal®for further assistance. See "Contacting AquaCalAutoPilot,
Inc." on page 1.

Page - 17
1.5.f Schematics
Schematics are located on the inside of the equipment access panel.
PLEASE NOTE:
lSpecifications are subject to change without notice.
lSchematics are available by calling AquaCal®Customer Support. See "Contacting
AquaCalAutoPilot, Inc." on page 1.
lPlease have the complete model and serial number available.
lSee "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.
WARNING Failure to heed the following may result in injury or death.
lThis section is only for qualified installers who are familiar with swimming pool and spa safety standards.
lThe installer must be familiar with service industry techniques.
lDeactivate power while routing wiring to control board.
NOTICE
Failure to heed the following may result in damage to equipment.
lThe wire size connecting the controller must be 16-gauge, 2-conductor or larger, low-voltage wire.
lUse direct connection (dry contact) provided on the microprocessor for external controllers.
Dry Contact Connection Points to the
Microprocessor
Please confirm the type of external controller to be installed
and follow the appropriate instructions.
lAtwo-wire controller (with an internal thermostat).The
user can set and adjust the temperature at the controller's
screen.
lAthree-wire controller (with an "OFF" position). The
user adjusts the temperature at the heat pump. The user
can select pool or spa mode or turn off the heat pump using
the controller.
lAthree-wire controller (without an "OFF" position).
The user adjusts the temperature at the heat pump. The
user can select pool or spa mode, but must turn off the heat
pump at the heat pump display panel.