aquatherm AT550 User manual

© 2008 Aquatherm Heat Pumps, A Division of Calorex USA LLC
NOTICE:
Specifications may change without notice.
SWIMMING POOL
& SPA HEAT PUMPS
INSTALLATION MANUAL
Model AT550
w/Titanium Heat
Exchanger
a Division of Calorex USA L.L.C.
2213 Andrea Lane Ft. Myers FL 33912
888-297-3826 239-482-0606
www.aquathermheatpumps.com
HEAT PUMPS
INFORMATION
PLACEMENT
PLUMBING
ELECTRICAL
HEAT PUMP
OUT IN
FILTER
WATER
PUMP
TO
SPA JETS
TO SPA
SPILLOVER
CHLORINATOR
TO POOL
RETURN
SPA
SPA
POOL
POOL
Jandy™
3-Way Valve VERTICAL
CHLORINATOR
LOOP
FROM
SPA
SUCTION
FROM
POOL
SKIMMER
SUCTION
FROM
POOL
FLOOR
SUCTION
NATIONAL SPA &
POOL INSTITUTE
MEMBER

1
A. Unit Description ........................................................................................ Page 3
B. Heat Pump Placement & Clearances ...................................................... Page 4
C. Plumbing- Water Connections ............................................................Pages 2-6
1. Basic Plumbing
2. Freeze Condition Plumbing
3. Bypass for Flow Rates Over 70 GPM
4. Multi Unit Water Connections
5. Pool/Spa Combination Plumbing
6. Pool/Spa Separate Plumbing
7. Plumbing with Solar
8. Plumbing Above or Below Water Level
D. Winterizing Procedures................................................................................ 6-7
1. Light Freeze Conditions
2. Hard Freeze Conditions
E. Electrical Connections & Wiring......................................................Pages 7-10
1. Supply Wiring 220V
2. Motor Valve Connections
3. Interfacing with External Controls, Jandy & Compool
F. Control Panel Information, Operation & Description......................Page 11
G. Operational Sequence & Troubleshooting Flow Chart ...................... Page 12
TABLE OF CONTENTS
AT550 FACTORY SPECIFICATIONS
Kw/ Input ............................................................................ 4.8
Typical Running Amps ........................................................ 24
Min. Circuit Ampacity .......................................................... 39

A. UNIT DESCRIPTION
AIR DISCHARGE FAN
WARNING: ROTATING
BLADE KEEP HANDS & HAIR
CLEAR!
CONTROLS with
LED READOUT
WATER OUT
2” MALE THREADED
UNION
(INCLUDED)
WATER IN
2” MALE THREADED
UNION
(INCLUDED)
DATA
PLATE
DANGER FROM ELECTRICAL SHOCK & ROTATING FAN !
SHUT OFF ALL POWER BEFORE SERVICING!
CAUTION:
MORE THAN ONE DISCONNECTION MAY BE REQUIRED TO
ELIMINATE ALL POWER TO THIS UNIT INCLUDING POWER TO
THE OPTIONAL TIME CLOCK OVERRIDE!
ELECTRICAL
INSTALLATION
PORT(S)
2
WARNING

1. To allow for proper condensation drainage,
use a level slab to elevate the heat pump to
at least the same height as the pool filter
system slab, or 2 to 3 inches minimum
above grade.
2. Allow the minimum air flow clearances on
top and the sides as shown here. Make sure
the unit can “breathe” well. Do not install
indoors or where the discharge air can ac-
cumulate and be drawn back through the
heater. Make sure the front is accessible
for future service.
3. Keep sprinkler heads at least 6 feet away
from the heat pump. Do not allow the
sprinkler to spray the unit in any way to
prevent damage.
4. If the unit is installed under a roof overhang
or under a roof valley, a gutter or diverter
should be fitted to prevent excessive water
from pouring into the unit.
5. Keep all plants and shrubs trimmed away
from the heater to the minimum clearances
shown here to prevent air coil damage.
6. If the heater is installed above or below
the pool water level by more than 3 feet
you may require an external water flow
switch. See the top of section C8 for more
information.
Minimum Air Flow
& Access
Clearances
B. HEAT PUMP PLACEMENT & CLEARANCES
AIR COIL
AIR FLOW IN
ON 3 SIDES
FAN DISCHARGE
AIR FLOW OUT
WATER IN/OUT PORT
INDICATOR LABEL
2” UNIONS
3
BACK
12” 12”
12”
36”
AIR
COIL
FRONT
Make sure the front is accessible
for future service.
FRONT
2” 6’
60”

4
HEAT PUMP
OUT IN
FILTER
WATER
PUMP
TO
SPA JETS
TO SPA
SPILLOVER
CHLORINATOR
TO POOL
RETURN
SPA
SPA
POOL
POOL
Jandy™
3-Way Valve VERTICAL
CHLORINATOR
LOOP
FROM
SPA
SUCTION
FROM
POOL
SKIMMER
SUCTION
FROM
POOL
FLOOR
SUCTION
3. BYPASS FOR FLOW RATES OVER 70 G.P.M. Typi-
cally the automatic internal water bypass can handle up to a
1.5 H.P. water pump or 70 G.P.M. If the water pump exceeds
1.5 H.P. then install either of the optional bypasses as shown
below. The installation of a flow meter on the WATER OUT
line is suggested. Adjust the bypass to divert a minimum of
40 to 50 G.P. M. through the heater. Flow meters should be
installed per the manufacturer’s instructions.
1. BASIC PLUMBING. For a pool only
or spa only, install the plumbing piping
as shown. Connections from factory
are 2”unions. Hand tighten then 1/4 to
1/2 snug tight with pliers. Water IN on
the RIGHT, Water OUT on the LEFT.
PLUMB AFTER the FILTER & BEFORE
any CHLORINATORS or CHEMICAL
FEEDERS
C. PLUMBING & WATER CONNECTIONS
4. MULTI UNIT WATER CONNECTIONS
Plumb multiple units as shown below. Use flow meters on each
WATER OUT line if two or more units are plumbed together.
Use ball valves to balance the water flow through each unit.
Using T’s, caps and a minimum 6 inch pipe extension on the
plumbing manifold will help equalize the water flow better than
90˚’s. Flow meters should be installed per the manufacturer’s
instructions.
OUT OUT
IN IN
FLOW
METER
TO
POOL TO
POOL
FROM
FILTER
FROM
FILTER
FLOW
METER
TOP VIEW
TOP VIEW
OUT OUT
IN IN
BALL
VALVE
FLOW
METER
TO POOL
FROM
FILTER CAP
& 6" OF PIPE
TO
POOL
CHLORINATOR
PUMPS OVER 70 GPM
REQUIRE BYPASS HERE
6" TO 8"
HEAT
PUMP
FILTER
FROM
POOL
WATER
PUMP
OUT IN
2. FREEZE CONDITION PLUMBING. See WINTERIZING PROCEDURES on page 7.
5. POOL/SPA COMBINATIONS W/SPILL-OVER
Use this diagram for
a connected pool and
spa, where the spa has
a spill-over type wa-
terfall into the pool.
Where one pump and
one heater are used for
both the pool and spa.
If the water pump ex-
ceeds 1.5 H.P. then in-
stall a external bypass
as shown on page 5.
SEE CHLORINATOR LOOP &
CHECK VALVE REQUIREMENT
ON PAGE 5.

C. PLUMBING & WATER CONNECTIONS
OFF
OFF
OFF
POOL
FILTER POOL
WATER
PUMP
VERTICAL
CHLORINATOR
LOOP
JANDY™
3-WAY VALVE
HEAT PUMP
IN
OUT
FROM
POOL
FLOOR
SUCTION
FROM
POOL
SKIMMER
SUCTION
BYPASS
BYPASS
12 LB
CHECK
VALVE
12 LB
CHECK
VALVE
POOL
CHLORINATOR
SPA
CHLORINATOR
VERTICAL
CHLORINATOR
LOOP
TO POOL
RETURNS
POOL
POOL
SPA
SPA
TO SPA
RETURN JETS
SPA
WATER PUMP
FROM
SPA
SUCTION
SPA
FILTER
6.POOL & SPA SEPERATE
Use this diagram for a separate pool and spa not
connected, and does not have a spill-over. Where
the pool and the spa have separate pump & filter
systems but using the same heater. If the water
pump exceeds 1.5 H.P. then install a external
bypass as shown on page 5.
OFF
OFF
JANDY ™
HEAT PUMP
INOUT
CHLORINATOR
TO POOL
RETURN
FROM
POOL
SKIMMER
SUCTION
FROM
POOL
FLOOR
SUCTION
VERTICAL
CHLORINATOR
LOOP
MOTORIZED
SOLAR
VALVE
FROM
SOLAR
TO
SOLAR AUTOMATIC
SOLAR
CONTROL
DEVICE
WATER
PUMP
FILTER
7. PLUMBING WITH SOLAR.
Plumbing for a system where a solar pool
heater is installed. It
is strongly advised
that an automatic so-
lar control device be
used when used with
the heat pump. If the
water pump exceeds
1.5 H.P. then install
either of the optional
bypasses as shown on
page 5.
The heat pump and solar can be operated
together. The heat pump will share the heating
load with the solar. If the solar is operated on cloudy
days, while raining, at night or at low air temperatures,
it may cool the pool or spa. An automatic solar control
will shut the solar off when there is no solar heat gain,
otherwise it should be shut off manually during these times.
To use the heat pump as a backup to the solar, set the heat pump thermostat 2 to 4 degrees below
the solar’s target temperature setting. Therefore, if the solar is not maintaining water temperature,
the heat pump will come on to assist the solar. Some thermostat fine tuning may be required by the
user.
5

C. PLUMBING & WATER CONNECTIONS
8. PLUMBING & WATER CONNECTIONS FOR ABOVE OR BELOW WATER LEVEL
If you install the heat pump above or below the pool or spa water level by more than 3 feet, the internal
water pressure switch may be effected by the static pressure of the pool water. In some cases it
may be necessary to eliminate the internal water “PRESSURE” switch and install a water “FLOW”
switch. The water flow switch is not effected by changes in water pressure but only water movement.
We suggest installing a 2”, Grid Brand Model 20 flow switch and disabling the internal water pressure
switch. Plumb in the flow switch as shown here. Then run a TWO wire insulated cable from the flow
switch into the heater and attach to the existing water pressure switch leads located on the heater’s
logic board, behind the low voltage service panel and wire as shown below.
POOL
LEVEL
USE
FLOW
SWITCH
USE
FLOW
SWITCH
3 FT.
3 FT.
HEAT PUMP
OUT IN
HEAT PUMP
OUT IN
HEAT PUMP
INOUT
FLOW
SWITCH
6
D. WINTERIZING PROCEDURES
1. LIGHT-FREEZE CONDITIONS
(Air temperature does not remain below 32ºf for more than 4-hours)
In the event your heater will not be used for an extended period, it is recommended pool water
be allowed to circulate through the heater during normally scheduled filtration cycles. If light
freeze conditions are expected, adjust water pump controls for continuous operation throughout
the light freeze episode. Moving water will not freeze under light-freeze conditions. Remain
aware of abnormal climatic conditions; use “hard-freeze” instructions
(Below) if freezing conditions will exceed 4-hours.
CAUTION !
FAILURE TO PROPERLY WINTERIZE HEAT PUMP MAY RESULT IN SERIOUS
EQUIPMENT DAMAGE. FREEZE DAMAGE IS NOT COVERED UNDER THE
HEAT PUMP WARRANTY. FAILURE TO HEED THE FOLLOWING CAN RESULT IN
DAMAGE TO EQUIPMENT AND/OR PROPERTY.

7
E. ELECTRICAL CONNECTIONS AND WIRING
MAKE SURE TO TURN OFF ALL POWER TO UNIT INCLUDING POWER
TO POOL PUMP TIMER PRIOR TO MAKING ANY ELECTRICAL CON-
NECTIONS. SPECIFICATIONS ARE SUBJECT TO CHANGE. ALWAYS
REFER TO WIRING DIAGRAM LOCATED ON THE BACK OF THE UNIT’S
PLASTIC FRONT COVER AND DATA PLATE ON LEFT SIDE OF PLASTIC
FRONT PANEL.
1. SUPPLY WIRING 220V
• Remove plastic front panel from unit.
• Locate and remove electric box high voltage cover located on left side of electric box.
• Determine sealtight length and slip plastic adaptor over conduit. Run conduit and proper
2. HARD-FREEZE CONDITIONS
(Air temperature remains below 32ºf for more than 4-hours)
WARNING !
TO AVOID INJURY FROM ROTATING EQUIPMENT, DISCONNECT ELECTRICAL
POWER FROM HEAT PUMP BEFORE PROCEEDING WITH INTERNAL DRAIN
WINTERIZING PROCESS. FAILURE TO HEED THE FOLLOWING MAY RESULT
IN PERMANENT INJURY OR DEATH.
1. Disconnect all electrical power to the heater; turn off circulating pump.
2. At the two (2) connection unions, disconnect the plumbing to the heater (removal is
counterclockwise).
3. Locate the drain plug at outside, lower front of heater. (see figure 1)
If the unit does not have an external drain plug, remove the exterior front panel of the unit.The
internal drain plug is located at the base of the heat exchanger (see figure 2). Follow the same
procedure as with an external drain plug.
4. Using a 5/8”, box-end wrench, remove the drain plug (removal is Counterclockwise).
5. Permit all water to drain from the condenser and then replace the plug: thread the plug in
clockwise until just snug, then apply an additional 1/8 turn.
6. To prevent insects and vermin from entering the plumbing during the winterized period,
partially reconnect the two (2) plumbing connection unions: couple each union one or two
threads; this will permit condensation to drain, but will prevent most insects and animals from
entering the plumbing circuit.
7. Next season: to ready the heat pump for use, simply retighten plumbing connection unions.
Hand-tight is generally sufficient.
D. WINTERIZING PROCEDURES
FIGURE 2
INTERNAL
DRAIN PLUG
FIGURE 1
EXTERNAL
DRAIN PLUG

8


POWER
SUPPLY
SEALTITE
BUSHING
E. ELECTRICAL CONNECTIONS AND WIRING
size wire from power supply to the unit’s main contactor located on the right side of high
voltage compartment. The ground wire connection is located on the base of the box to the
left of the contactor. A knock out is located on the bottom of the box just below the contactor.
A sealtight fitting must be used to attach the conduit to the electric box. All other models
require minimum #8 copper stranded wire. Model AT 1200 requires #6 wire.
• Replace electric box high voltage cover.
• Replace plastic front panel and place conduit and plastic adaptor in slot provided on right
side of unit.
• Run a #8 solid copper
wire from the bond lug
located on the right
side of unit to pool
pump bond wire or a
7 ft. copper rod driven
into the ground.
• Turn power to unit and
timeclock on.

9
OR PR TN
WH
P COM. S
JUMPERS
SEE
NOTE #4
FOR AQUALINK/COMPOOL
REMOVE METAL JUMPER TERMINAL
"HTR" POSITIONS
2 WIRE CABLE
#14-16 AWG
COMPOOL
PC BOARD
GREEN TERMINAL BAR
POSITIONS 1 & 2
JANDY AQUALINK PC BOARD
To interface the “Digital Logic” digital control heat pump models with the Jandy AquaLink RS series
or Compool, run a 2 wire (16 A.W.G. or larger) insulated cable from the device to the heat pump.
Remove the 6 screws from the heaters front service access panel and open. Look for the heater’s
solid state circuit board located inside the top portion of the electrical compartment mounted on the
rear wall. Locate, remove and discard the ”METAL JUMPER TAB” attached to the bottom terminal
bar and labeled “Jandy/Compool”. Then, run a 2 wire cable from the 2 position terminal where the
metal jumper tab was, through the heater’s low voltage access port, then to the AquaLink RS or the
Compool control.
NOTE for AquaLink RS and Compool: Turn both heater thermostats all the way up and set the
mode selector switch to pool and do not use the heater controls as the Jandy or Compool now has
thermostatic control over the heater.
for AquaLink
Attach the 2
wire cable to
positions #1
and position
# 2 on the 10
slot, green ter-
minal bar inside
the AquaLink’s
power center.
*See the con-
trollers instal-
lation guide
also.
for Compool
Attach the 2
wire cable to
the Compool’s
power center
board located
on the termi-
nals labeled
“HTR” *See
the controllers
installation
guide also.
5. INTERFACING DIGITAL LOGIC CONTROL MODELS
with Jandy™Aqualink RS & Compool
E. ELECTRICAL CONNECTIONS AND WIRING

10
#12 HIGH/SPA
#13 COMMON
#14 LOW/POOL
OR PR TN
WH
KEY PAD TERMINAL
DEF.
SENSOR
HIGH
PRESS.
WATER
PRESS.
LOW
PRESS. T.C.O.
JUMPERS
SEE
NOTE #4
DEG. F
T.C.O.
TEST
COMP.
RELAY
240 VACFAN
POOL
SENSOR
POOL
SWITCH TERMINALS HIGH/SPA
COMM.
LOW/POOL
3 WIRE
CABLE #10 HIGH/SPA
#11 LOW/POOL
#12 COMMON
Attach the other end of the 3 wire cable
to the AquaSwitch as follows:
#12 For the HIGH/SPA
#13 For the COMMON
#14 For the LOW/POOL
• If you are using a Jandy AquaSwitch or JI2000 control run a 3 wire cable from the control to the
heater. Remove the 6 screws from the heaters front service access panel and open. Look for the
heater’s solid state circuit board located inside the top portion of the electrical compartment mounted
on the rear wall. Locate the 3 terminals labeled POOL SPA SWITCH. Attach the 3 wire cable as
shown below. Do not remove any jumpers. Run the wire through the heater’s low voltage access
port.
• Next, attach the 3 wire cable to the HEATER to the three terminal positions labeled POOL SPA
SWITCH
LEFT POSITION= LOW/POOL
CENTER POSITION= COMMON
RIGHT POSITION= HIGH/SPA
Attach the other end of the 3 wire cable
to the JI2000 as follows:
#10 For the HIGH/SPA
#11 For the LOW/POOL
#12 For the COMMON
5. INTERFACING DIGITAL LOGIC CONTROL MODELS
with Aquaswitch or JI2000
E. ELECTRICAL CONNECTIONS AND WIRING
6. COMPOOL Cp3800, Cp3600 & Cp3400 Series Equipment
Heat pumps require a relay kit (Model RLY-LX) be added. The HTR connection used for gas
heaters cannot be used.
To wire a heat pump:
1. At the Power Center, install the relay into the high voltage compartment. Plug control wire
into the EHTR relay socket on the Power Center circuit board.
2. Run a 2-conductor cable from the heater to the Power Center,
3 At the heater, remove jumper and connect 2-conductor cable to the terminals.
4. At the Power Center, connect 2-conductor cable to LINE 1 and LOAD 1of the relay terminal
block.
5. Turn thermostat settings all the way up on the heat pump.

11
LED READOUT:
1. GREEN POWER LIGHT: This light indicates
that the heater has control power. WARNING:
This is not a line power indicator and caution
should be used since more than one power dis-
connection may be required to isolate the heater
electrically.
2. HEATER ON/OFF BUTTON: Green light on
POWER button is lit when heater is turned on.
3. MODE SELECT BUTTONS-POOL or SPA:
The heater has two thermostat modes for two different desired temperature settings, one for
pool mode and one for spa mode. If you do not have a spa, use the pool mode only. If you
have a spa/pool combination, you have options available to automate pool and spa heating
functions.
4. THERMOSTAT BUTTONS: Pressing the + button will raise the set temperature. Pressing
the - button will lower the set temperature. When either button is pressed the LED display
will begin to flash. The flashing numbers indicate the thermostat setting.
5. GREEN HEATING LIGHT: This light indicates that the unit is heating and the compressor
is running. The compressor starts after a 3 to 5 minute time delay. NOTE: The water pump
must be running in order for the heater to run.
LED STATUS CODE READOUTS:
LF This light indicates there is no water flow through the heater. The heater is designed to shut
off when the water pump is not pumping water through the heater. If LF is on while the water
pump is running, the water pump may not be supplying enough flow for the heater to operate
properly.
DF This readout indicates that the internal defrost safety control has disabled the heater. During cold
weather where the air temperature drops below approximately 45 to 50 degrees (depending on
humidity), the defrost sensor is designed to disable the compressor only. When the air temperature
has increased to the operational range the compressor will come on and start heating again.
HP This readout out indicates high refrigerant pressure. The high refrigerant pressure switch is
designed to shut the compressor and fan off if a heat buildup occurs for whatever reason. Typically
the high refrigerant pressure switch will trip if the water flow through the heater is restricted. It
may also trip if the air flow is restricted through the heater. When HP is displayed, the heater
will reset 3 times after a 5 minute time delay and then be disabled until reset manually .
To reset, turn the unit off then back on.
CONTINUOUS TEMPERATURE READOUT =
CURRENT WATER TEMPERATURE
FLASHING TEMPERATURE READOUT = THERMOSTAT SETTING
F. “DIGITAL LOGIC” CONTROL PANEL INFORMATION

12
Water Pump
Starts Flowing
Water Pressure
SW Closes
Thermostat
Sensor
Heater
Stays Off
Low Pressure
Switch
Low Pressure
Switch Opens
LF displayed on LED
Low Pressure
SW Closed
All OK
LF Readout
Displayed on LED
T-Stat Relay
Closes
High Pressure
Switch
High Pressure
SW Closed
All OK
High Pressure
Switch Open
Heater Shuts Off
HP Displayed
Too Much Refrig.
or Low Water Flow
or Bad Hi Switch
Fan Starts
To Run
220V Power
To Heater
Green Power Light
On
Water Rises To
Set Temp.
Water Press. SW
Stays Open
No Water Flow
To Heater or
Bad Water SW
Compressor Runs
or 3 to 5 Min.
Delay Activates
Heater & Green
Heating
Light Go Off
Water Pump
Timer Activates
Compressor Stops
Fan Runs
T-Stat Relay
Does Not Close
Heater Does
Not Activate
After Delay Period
Wait for Heater to
Attempt to Restart
Again
Possible Bad
T-Stat Board,
Pot or Sensor
1 Hour Time
Delay Activates
Water Temperature
is Below Setting
Water Tempera-
ture
Compressor Starts
Green Heating
Light ON
Time Delay Passes or
Air Temp. Increases
Safety Control Resets
Compressor
Restarts
or Below 45 to 50˚F
Air Temp or
Bad Low Press.
or Below 45 to 50
Deg. Air Temp
G. OPERATIONAL SEQUENCE & TROUBLESHOOTING FLOW CHART
Shut unit OFF
Then Back ON to
Try Again
TIME DELAYS:
3 minute compressor delay on break & power up.
30 second compressor delay when switching pool/spa modes.
5 minute compressor delay when T.C.O. enables in pool mode.
T.C.O. will shut off after a 5 minute delay when: switching from spa to pool mode, when temperature
is reached in pool mode, or if LF (low water flow) is displayed on LED.
When HP is displayed unit must be turned off then back on to reset.
HI = BAD TEMP. SENSOR
LO = BAD TEMP. SENSOR
for “Digital Logic”
Digital Control
Models

a Division of Calorex USA L.L.C.
2213 Andrea Lane Ft. Myers FL 33912
888-297-3826 239-482-0606 Fax [phone]
www.aquathermheatpumps.com
HEAT PUMPS