Hayward HP50A Service manual

SWIMMING POOL HEAT PUMP UNIT
Installation&Instruction Manual
Model HP50A
Hayward Pool Products Canada, Inc.
T: 1-888-238-7665
www.haywardpool.ca
3149010
HP85A

CONTENTS
1. Preface 1
2. Specifications 2
2.1 Performance Data of Swimming Pool Heat Pump Unit 2
2.2 Dimensions for Swimming Pool Heat Pump Unit 3
3. Installation and Connection 4
3.1 Installation of System 4
3.2 Swimming Pool Heat Pumps: Location 5
3.3 How Close to Your Pool? 5
3.4 Swimming Pool Heat Pumps: Plumbing 6
3.5 Swimming Pool Heat Pumps: Electrical Connection 7
3.6 Initial Start-up of the Unit 7
4. Usage and operation 8
4.1 The Functions of the LCD Controller 8
4.2 How to Set Operation Parameters 8
4.3 Usage of the controller 10
5. Maintenance and inspection 11
5.1 Maintenance 11
5.2 Trouble Shooting Guide 11
6. Appendix 12
6.1 Connection of PCB: Illustration 12
6.2 Wiring Diagram 13
6.3 Exploded View and Spare Parts 15
6.4 Parts List and Spare Parts
6.5 Warranty 18
19

1
1. PREFACE
In order to provide our customers with quality, reliability and versatility, this
product has been made to strict production standards. This manual includes
all the necessary information about installation, debugging, discharging and
maintenance. Please read this manual carefully before you open or maintain
the unit. The manufacturer of this product will not be held responsible if
someone is injured or the unit is damaged as a result of improper installation,
debugging, or unnecessary maintenance. It is vital that the instructions within
this manual are adhered to at all times. The unit must be installed by qualified
personnel.
• The unit can only be repaired by qualified installer centre personnel or an
authorised dealer (HVAC).
• Maintenance and operation must be carried out according to the recommended
time and frequency, as stated in this manual.
• Use genuine standard spare parts only.
• ailure to comply with these recommendations will invalidate the warranty.
• The Swimming Pool Heat Pump Unit heats the swimming pool water and keeps the
temperature constant.
This type of pump has the following characteristics:
1. Durable
The heat exchanger is made of PVC & titanium; the tube can withstand prolonged
exposure to corrosives such as chlorine.
2. Quiet operation
The unit comprises an efficient rotary compressor and a low noise fan motor, which
guarantees its quiet operation.
3. Electronic control board
The unit is controlled by a micro-controller, allowing all operation parameters to be
set. Operation status can be displayed on the control panel.

2
2. SPECIFICATI NS
2.1 Performance data of Swimming Pool Heat Pump Unit
*** REFRIGERANT: R410A
Unit HP50A
Heating Capacity kW
BTU/h 14.7 50,000
Heating Power Input kW 2.6
Running Current A 11.8
Compressor Rating Load A 11.3
Compressor Locked Rotor Load A 60
Minimum Circuit Ampactiy A 20
Max. use A 30
Power Supply V/Ph/Hz
Compressor Quantity 1
Compressor(s) Rotary
an Quantity 1
an Power Input W 120
an Rotate Speed RPM 850
an Direction horizontal
Noise (at 1 meter) dB(A) 54
Water Connection inch 1.5
Water low Volume Imperial/US GPM 20
Water Pressure Drop(max) PSI 1.5
Unit Net Dimensions(L/W/H) inch 40.8/16.4/25.6
Unit Shipping Dimensions(L/W/H) inch 44.5/18.5/27.2
Net Weight/Shipping Weight lb. 143/154
1
Model HP85A
24.9
85,000
4.9
23.3
22.3
139
34
55
1
Scroll
2
120
850
horizontal
58
1.5
33
1.74
41.2/17.9/49.2
44.5/18.5/51.2
276/298
1
208-230V /60Hz208-230V /60Hz ~
~

3
2. SPECIFICATI NS
2.2 Dimensions for the Swimming Pool Heat Pump Unit
Model:HP50A
HP50A
A 650/25.6
B 1000/39.4
C 1015/40.0
D 1035/40.8
E 415/16.3
220/8.7
G 150/5.9
H 338/13.3
SIZE
TYPE
Unit : mm / inch
Water Inlet
Drainage
G
H
F
Water Outlet
C
E
B
A
D
HP85A
1045/41.2
455/17.9
1250/49.2
630/24.8
430/17.0
120/4.8
500/19.7
82/3.3
Model:HP85A
1.5
1.5
3 4
1.5
1.5
1 2

4
3. INSTALLATION AND CONNECTION
3.1 Installation illustration
Installation items:
The factory only provides the heat pump unit; the other items in the illustration are
necessary spare parts for the water system, provided by users or the installer.
Attention:
Please follow these steps when using for the first time
1. Open valve and charge water
2. Make sure that the pump and the water-in pipe have been filled with water
3. Close the valve and start the unit
ATTN: It is necessary that the water-in pipe inlet be higher than the pool surface.
Chlorinator cell Water outlet
Pool
Valve
Water supply
Water inlet Water pump
Sand filter
(or other type filter)
By-pass valve
Installation must be performed in accordance with the requirements of NEC and CEC
by authorized personnel only.
(optional)

5
3. INSTALLATI N AND C NNECTI N
3.2 Swimming Pool Heat Pumps: Location
The unit will perform well in any outdoor location provided that the following three
factors are present:
1. Fresh Air - 2. Electricity - 3. Pool filter piping
The unit may be installed virtually anywhere outdoors. or indoor pools consult the
supplier. Unlike a gas heater, it has no draft or pilot light problem in a windy area.
DO NOT place the unit in an enclosed area with a limited air volume, where the units
discharge air will be re-circulated.
DO NOT place the unit next to shrubs which can block the air inlet. These locations
deny the unit a continuous source of fresh air which reduces its efficiency and may
prevent adequate heat delivery.
3.3 How Close To Your Pool?
Normally, the pool heat pump is installed within 7.5 metres of the pool. The
longer the distance from the pool, the greater the heat loss from the piping.
or the most part, the piping is buried. Therefore, the heat loss is minimal for
runs of up to15 metres (15 metres to and from the pump = 30 metres total),
unless the ground is wet or the water table is high. A very rough estimate of
heat loss per 30 metres is 0.6 Kw-hour (2000BTU) for every 5°C difference in
temperature between the pool water and the ground surrounding the pipe,
which translates to 3% to 5% increase in operating time for the water to reach
the desired temperature.
Air inlet
Air outlet
2500mm
700mm
300mm
700mm
500mm

6
3. INSTALLATION AND CONNECTION
3.4 Swimming Pool Heat Pumps: Plumbing
The Swimming Pool Heat Pumps exclusive rated flow titanium heat exchanger requires
no special plumbing except bypass (please set the flow rate according to the
nameplate). The water pressure drop is less than 1.5psi (10KPa) at maximum flow
rate. Since there are no residual heat or flame temperatures, the unit does not need
copper heat sink piping. PVC pipes can be run straight into the unit.
Location: connect the unit in the pool pump discharge (return) line downstream of all
filter and pool pumps, and upstream of any chlorinators, ozonators or chemical pumps.
*You will need to use 1½” male PVC adapter to connect to heat pump.
Consider addingaquick coupler fitting at the unit inlet and outlet to allow easy draining
of the unit for winterizing and to provide easier access should servicing be required.
Condensation: since the heat pump cools the air down about 4-5°C, water may
condense on the fins of the horseshoe shaped evaporator. If the relative humidity is
very high, this could be as much as several litres an hour. The water will run down the
fins into the basepan and drain out through the barbed plastic condensation drain fitted
on the side of the basepan. This fitting is designed to accept 3/4" clear vinyl tubing
which can be pushed on by hand and run toasuitable drain. It is easy to mistake the
condensation forawater leak inside the unit.
NB:aquick way to verify that the water is condensation is to shut off the unit
and keep the pool pump running. If the water stops running out of the basepan,
it is condensation. AN EVEN QUICKER WAY IS TO TEST THE DRAIN WATER
FOR CHLORINE - if there is no chlorine present, then it's condensation.
From pump
PVC COUPLER
RECOMMENDED
Horizontal view
To pool

7
3. INSTALLATI N AND C NNECTI N
3.5 Swimming pool heat pumps: electrical connection
NOTE: although the unit heat exchanger is electrically insulated from the rest of the unit, this simply prevents
the flow of electricity to or from the pool water. Grounding the unit is still required to protect you against short
circuits inside the unit.
NOTE: ensure that the available electrical Power supply and the network frequency are matched to the required
operating current, taking account of the appliance’s specific location and the current required to supply any
other appliances connected to the same circuit.
1) See the wiring diagram chapter 6.3;
2) Ensure that the unit is supplied with the specified voltage. The terminal block is located on the right side of
the unit. There are three connections for the Power supply and two connections for the filtering pump control
(Enslavement). The Power supply line must be properly matched with a motor supply type fuse or a main
circuit breaker to protect the circuit against voltage surges (refer to the nameplate for the voltage);
3) Always shut down the main Power supply before opening the electrical control box.
3.6 Initial Start-up
Start-up Procedure. After installation is completed, you should follow these steps:
1) Switch on the filtering pump; verify flow to and from the pool.
2) Check that all the water valves are open and that the water flows into the unit before switching on heating or
cooling;
3) Ensure that the unit is connected correctly to the main Power supply (refer to the wiring diagram or chapter 6);
4) Rotate the fan by hand to ensure that it turns freely and that the turbine is properly tightened with the motor
shaft;
5) Check that the condensate drainage hose is properly attached and free of any blockages;
6) Switch on the power supply to the unit, then press the On/Off key on the wire controller;
7) Ensure that no ALARM code is displayed when the unit is ON (see Trouble shooting guide);
8) Set the water flow using the by-pass valve (see chapter 3.1) as described for each different model (see the
control panel or chapter 2) to obtain a 2°C difference in water temperature.;
9) After running a few minutes make sure the air leaving the unit is cooler (between 5-10°C);
10) With the unit operating turn the filter pump off. The unit should also turn off automatically;
11) Allow the unit and pool pump to run 24 hours per day until desired pool water temperature is reached.
When the set water-inlet temperature is reached, the unit shuts off. The unit will now automatically restart (as
long as your pool pump is running) when the pool temperature drops more than 2°C below set temperature.
Water low Switch - the unit is equipped with a flow switch that turns it on when the pool pump is running and
shuts it off when the pump shuts off. This switch is the same type used in all gas pool heaters and is factory
adjusted for normal pool installations. If the pool water level is more than a few feet above or below the
thermostat knob of the unit, your dealer may need to adjust it at initial start-up.
Time Delay - the unit is equipped with a 3 minute built-in solid state restart delay to protect control circuit
components and to eliminate restart cycling and contactor chatter. This time delay will automatically restart the
unit approximately 3 minutes after each control circuit interruption. Even a brief power interruption will activate
the 3 minute restart delay and prevent the unit from starting until the 3 minute countdown is completed. Power
interruptions during the delay period will have no effect on the 3 minute countdown.

8
4. USAGE AND OPERATION
4.1 Function of the LCD controller
User Interface and Usage as the following:
4.2 Usage of the controller
1) Electrify
After checking everything is okay, electrify and enter into standby state, with the screen
showing as the following:

9
4. USAGE AND PERATI N

10
4. USAGE AND PERATI N
4) Set Clock
6) KEYLOCK
Keyboard lock

11
5. MAINTENANCE AND INSPECTI N
5.1 Maintenance
•Check the water supply device and the release often. You should avoid the condition of no water or air
entering into the system as this will influence the unit's performance and reliability. You should clear the
pool/spa filter regularly to avoid damage to the unit as a result of a clogged filter.
• The area around the unit should be dry, clean and well ventilated. Clean the side heating exchanger regularly
to maintain good heat exchange and conserve energy.
• The operation pressure of the refrigerant system should only be serviced by a certified technician.
• Check the power supply and cable connection often. Should the unit begin to operate abnormally, switch it off
and contact your qualified technician.
• Discharge all water in the water pump and water system, so that freezing of the water-inlet the pump or water
system does not occur. You should discharge the water at the bottom of the water pump if the unit will not be
used for an extended period of time. You should check the unit thoroughly and fill the system with water fully
before using it for the first time after a prolonged period of no usage.
• Installation must be performed in accordance with the NEC/CEC by authorized person only.
5.2 Trouble Shooting Guide

12
6. APPENDIX
6.1 Connection of PCB Illustration

13
6. APPENDIX
6.2 Wiring Diagram
FM
C2
BLK BLU
RED
Controller
TO POWER
SUPPLY TO PUMP
COMP
208-230V~/60Hz
CC CR
CS
BLK
RED WHT
CS CR
BLK WHT
P
4V
L1L212
C1
KM1
CC
OUT1OUT2
OUT3
OUT4
AC-N
3 4 3 4
CN19
GND
T5
GND
GND
GND
T2
CN1 CN2
12V
NET
GND
KYIN
GND
HTP
GND
LP
GND
HP
GND
TIME
GND
PC1000
OUT5
GND
T1
T4
T3
FS HPLP
BLU
Y/G
BRN
t
5K
t
5K
t
5K
t
5K
4V
KM1
L1
22
IT
IT
OT
OT
AT
AT
FS FS LP LP
HP HP
CT
CT
RED
L1
K1
P
L2
L1
L2
13
24
5
6
7
8
01
L2
TC
12V
HP50A
CC
4V
L2
L2 L2
L2
L2
L2L2
L2L2
L2L2
L2
L1
L2
t
5K
SUT
SUT
EEV
5
AT Ambient temperature
COMP Compressor
CTCoil temperature
FMFan motor
IT Inlet water temperature
LP Low pressure protection
OTOutlet water temperature
4V4 way valve
FS Flow switch
TC Transformer
HPHighpressure protection
SUT Suction temperature
EEV Electronic expand valve
KM1Contactor of compressor
L1

6. APPENDIX
6.2 Wiring Diagram
TO PUMP
L1L2
BLK WHT
P
L2
L2
4V
OUT1OUT2
OUT3
OUT4
AC-N
3 4 3 4
CN19
GND
T5
GND
GND
GND
T2
CN1 CN2
12V
NET
GND
KYIN
GND
HTP
GND
LP
GND
HP
GND
TIME
GND
PC1000
OUT5
GND
T1
T4
T3
FS HPLP
BLU
Y/G
BRN
t
5K
t
5K
t
5K
t
5K
t
5K
4V
EEV
5
KM1
2
ITITOTOTATAT
FS FS LP LP
HP
CTCT
SUTSUT
RED
L1 K1
P
L2
L2
13
24
5
6
7
8
02
HP85A
TC
12V
L2
CC
COMP
CS
2
1
5
KS
C2
KS
CR
BLK
WHT
RED
CS
KM1
L1
CC
CS
2
CS
KS
L2
L2
CS
CR
CH
KM1
L1
L2L11
L1
L2
L2
CC CC
C1
CC
CC
CS
CS
CR
TO POWER SUPPLY
208-230V~/60Hz
L1
L1
L2
L1
L2L2
2
L2 L2
L2
L2
L2
L1
L1
Controller
HP
L2
13
24
5
6
7
8
01
FM1
C3
BLK BLU
RED
L2
FM2
C4
BLK BLU
L2
L2
L2 L2
F
RED
L2
L2
AT Ambient temperature
COMP Compressor
CTCoil temperature
FMFan motor
IT Inlet water temperature
LP Low pressure protection
OTOutlet water temperature
4V4 way valve
FS Flow switch
TC Transformer
HPHighpressure protection
SUT Suctiontemperature
EEV Electronic expand valve
KS Relay coil of compressor start
CH Compressor heater
KM1Contactorof compressor
14

6. APPENDIX
6.3 Exploded view and spare parts
15
HP50 A
921 5 67 8 23
10
18
11
12
20
16
13
19
14
15
17
2
3
4

16
6. APPENDIX
6.5 Main Parts List & Spare Parts - HP50A
SN Part Code Part Name Part Number
1 3407-1202 Evaporator HPCxCND1930
2 3512-2213 Fan net HPCxFPR1930
3 3404-3301 Fan motor HPCxAFM1930
4 3500-2701 Axis blower fan HPCxFAN1930
5 2004-1437 4 way valve HPCxVAL1931
6 20000-110041 Compressor HPCxCMP1931
7 20000-360005 Water flow switch HPCxWFS1931
8 32012-120009 Titanium tube heat exchanger HPCxHEX1931
9 2001-1351 Drain plug HPCxPLG1930
10 2001-3605 High pressure switch HPCxHPS1931
11 32012-220002 Front panel HPCxFPL1930
12 32012-220001 Cover HPCxCOV1930
13 2001-3907 Terminal HPCxTER1931
14 20000-220068 Water proof cover HPCxMCB1930
15 2000-3501 Fan capacitor HPCxCAP1930
16 95005-310152 LCD controller HPCxWCL1931
17 35005-310031 Main control board HPCxMCL1931
18 2000-3603 Low pressure switch HPCxLPS1930
19 2000-3505 Compressor capacitor HPCxCOM1930
20 20000-360006 AC contactor HPCxCON1930
21 20000-140153 Needle valve HPCxNVL1931
22 2000-3242 Sensor, water, air HPCxTEM1930
23 2003-1402 Electronic expansion valve HPX2000-1402

17
6. APPENDIX
6.3 Exploded view and spare parts
HP85A
23
4
6
3
22
24
11
27 26 221 510 18 98
16
13
1
7
17
2515
19
12
20
14

18
6. APPENDIX
6.4 Main Parts List and Spare Parts - HP85A
SN Part Code Part Name Part Number
1 32018-120002 Evaporator HPX32018-120002
2 32012-210080 Fan net HPX32012-210080
3 3404-3301 Fan motor HPCxAFM1930
4 3500-2701 Axis blower fan HPCxFAN1930
5 2001-1491 4 way valve HPCx2001-1491
6 20000-110039 Compressor HPX20000-110039
7 20000-360005 Water flow switch HPCxWFS1931
8 32018-120003 Titanium tube heat exchanger HPX32018-120003
9 2001-1345 Drain plug HPX2001-1345
10 2001-3605 High pressure switch HPCxHPS1931
11 32018-220003 Upper front panel HPX32018-220003
12 32008-220021 Cover HPX32008-220021
13 2000-3242 Sensor, air & water HPCxTEM1930
14 20000-220068 Waterproof cover HPX20000-220068
15 2000-3501 Fan capacitor HPCxCAP1930
16 20000-360007 AC Contactor HPCx20000-36007
17 95005-310145 Main control board HPCX95005-31145
18 95005-310152 LCD Controller HPCX95005-310152
19 2000-3510 Compressor capacitor 60µF HPCX2000-3510
20 20000-360035 Relay HPCX2000-36035
21 2000-3603 Low pressure switch HPCXLPS1930
22 32018-220004 Lower front panel HPX32018-220004
23 2000-1440 Liquid separator HPX2000-1440
24 20000-140177 Electronic expansion valve HPX20000-140177
25 2000-3524 Compressor capacitor 98µF HPCX2000-3524
26 20000-140150 High pressure needle valve HPX20000-140150
27 20000-140153 Low pressure needle valve HPCXNVL1931