Kopec 525S Troubleshooting guide
Owner’s Manual
& Installation Guide
Model 525S
Model 525TI
Model 600SC
Model 650TI
Model 650SC
Model 700TI
INTRODUCTION
KOPEC
Enterprises, Inc., located in Pompano Beach, Florida,
designs and manufactures the industry’s most cutting-edge
swimming pool heat pumps. We consistently strive to provide our
customers with the best-made pool heaters at the most competitive
prices, and we back it all up with great customer service and
continued support.
Year after year,
KOPEC
heat pumps stand up to the elements
and have environmental and cost benefits that far outweigh other
heating sources, such as gas and propane.
KOPEC
heat pumps
work without fossil fuel dependency and without environmental
pollutants. They also have no safety concerns.
Each of our hand-assembled, hand- tested pumps, meets exacting
specifications and standards. All
KOPEC
products are Safety
Certified by Applied Research Laboratories, and, all the performance
results are confirmed by an independent certified test lab.
KOPEC
offers a large selection of heat pumps for both residential
and commercial pools and spas. Our pool heaters are used in
applications worldwide, for houses, condos, hotels, spas and
Olympic-sized pools.When it’s quality that counts, you can count
on
KOPEC
QUALITY
.
This product can be very simple to use, but it is important to
understand the instructions for operation and precautions for
installation. Please take a few minutes to read this manual
INDEX
Company Introduction Inside Front Cover
General Safety Instructions 2
Unit Installation 2
Plumbing 3
Plumbing Diagrams 4-5
Electrical Installation 6
Electrical Diagrams 7-9
Auto Temp Feature 10-11
Digital Control Instructions 12
Digital Control Electrical Diagrams 13
How to operate your pool heater 14
Features and functions (analog models) 15
Unit Protection 16
Unit Maintenance 17
Winterizing 17
Performance effecting factors 17-18
How does your heat pump heat your pool? 19
Cooling feature 20
Troubleshooting 21-22
Hurricane bracket 23
Warranty 24
Record keeping and notes 24
Unit cabinet description Inside Back Cover
1
GENERAL SAFETY INSTRUCTIONS
All electrical installation must be done by a qualified, licensed electrical
contactor in accordance with all national and local wiring codes.
Unit must be bonded to the pool equipment or a 6 ft. copper rod.
Once installed, always shut off main power to the unit whenever the access
panel is opened or removed.
UNIT INSTALLATION
LOCATION- The placement of the pool heater is very important in insuring
the maximum operating efficiency, while keeping installation costs to a
minimum and allowing access for service and maintenance.
The unit is best suited for outdoor installation and should not be installed
indoors. If the unit must be installed indoors, adequate air exchange must
be provided to insure efficient unit operation. (Please call the manufacturer
for details).
CLEARANCE- Please allow 12 inches of clearance from walls, fences, or
bushes around the sides and back of your unit, and at least 24 inches in
the front for operation and service access. Allow 4 feet of vertical clearance
from the top of the unit to the roof overhang. (This will provide quieter
operation and will prevent re-circulation of cold air into the unit, which will
affect the units heating efficiency).
SPRINKLERS and ROOF RUN OFF- Redirect or cap any sprinklers that
directly hit the unit, and do not install the heater under or near an area
which will subject it to large amounts of water run off. A gutter or downspout
may be needed to protect the heater.
SLAB OR BASE THE UNIT SITS ON- Please provide a secure level
surface at least 36” x 36” for the units base.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical supply to this product must be installed
by a licensed or certified electrician in accordance
with the National Electrical Code and applicable
local codes and ordinances. Improper installation
will create an electrical hazard, which could result
in death or serious injury to pool or spa users,
installers, or others due to electrical shock, and may
also cause damage to property. Read and follow the
specific instructions inside the manual.
Drainage- A drain fitting is provided in the bottom of the unit. This fitting
allows unit condensation or rainwater to escape, keeping the inside of the
unit relatively dry. Keep the drain fitting clear of leaves or debris to insure
proper drainage. You can divert the drain water by attaching a ½ inch
garden hose to the drain fitting and redirecting it to area better suited for
drainage. (Ask your installer).
PLUMBING
See Plumbing Diagram on pages 4-5
Piping Sequence- Pool -to- water circulating pump -to- filter-pool heater-
-to- check valve -to- chlorinator -to- pool (if a chlorinating device is used,
it must be downstream of the heater, with a flapper-style check valve
installed in a vertical run between it and the heater.) See Page 16 on unit
protection for more details.
Pipe Connections - Water IN from filter is on the RIGHT. Water OUT
to pool is on the LEFT. Normal applications do not require an external
bypass. The unit is equipped with 2 inch unions.
Multiple Unit Installations- All plumbing on multiple installations must be
in PARALLEL by using an equalized manifold supply pipe. DO NOT install
in series. Visit our web site for multiple unit plumbing diagrams
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DANGER
2 3
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical suppplyto this product must be installed by a licensed or certified electrician in accordance with the National Electrical Code and applicable
local codes and ordinances. Improper installation will create an electrical hazard, which could result in death or serious injury to pool or spa users,
installers, or others due to electrical shock, and may also cause damage to property. Read and follow the specific instructions inside the manual.
PLUMBING DIAGRAM
Layout for the correct plumbing setup for the Kopec Pool Heater
Note: Chemical Loop should
be a minimum of 3” higher
than the Chemical Feeder
IN
From Pool & Spa
POOL
PUMP
POOL FILTER
OUT
OUT
IN
OUT
FLAPPER
CHECK
VALVE
OUT
IN
OUT IN
OUT
To Pool & Spa Water Flow
Pipe Size: 1-1/2” or 2”
�
DANGER
4 5
ELECTRICAL
A qualified, licensed electrician, in accordance with all national and local
code requirements, must perform the electrical installation of your Kopec
pool heater.
Standard power supply- 208/240v 60hz- 1 Phase. 3 phase units are
also available.
Breaker Size- 50 amp (models 525 ,650 and 700)
Electrical access and installation- The unit is equipped with a 1” inch
all thread coupling, which is easily adaptable to rigid or flexible conduit, as
well as junction boxes. Remove access panel to expose electrical controls,
then feed main power leads and ground through the units short conduit,
allowing a little slack for service purposes. Hook main power leads to the
top of the main contactor. This contactor will have compressor and fan
leads already connected to the load or bottom side of the contactor. Hook
ground wire to the ground lug mounted near the top of the electrical control
pocket.
Unit Bonding- Unit must be bonded to the pool equipment or a 6 ft. copper
rod. A bonding lug is provided on the bottom right side of the unit. Failure
to bond the unit could damage the units heat exchanger and void the
warranty.
Flexible Conduit- When
codes allow, use flexible
conduit at or near the unit for
easy service access.
Unit disconnect, breaker
or fuse- Per code, a unit
disconnect must be in line
of sight of the unit.
Note- Shut off main power
before removing the units
electrical access panel!
208/240 Volt
208/240 Volt
Fan
White
Compressor
Red
Compressor
White
Fan
Black
Compressor
Black
Fan
Brown
Herm Fan
Fan
Brown/White
BLK
208/240
Volt
TRANSFORMER
GROUND
ELECTRICAL DIAGRAM
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical supply to this product must be installed by a licensed or certified electrician in
accordance with the National Electrical Code and applicable local codes
and ordinances. Improper installation will create an electrical hazard,
which could result in serious injury or death to pool or spa users, installers,
or others due to electrical shock, and may also cause damage to property.
Read and follow the specific instructions inside this manual.
�
DANGER
6 7
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DANGER
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical supply to this product must be installed by a licensed or certified electrician in accordance with the
National Electrical Code and applicable local codes and ordinances. Improper installation will create an electri-
cal hazard, which could result in serious injury or death to pool or spa users, installers, or others due to electrical
shock, and may also cause damage to property. Read and follow the specific instructions inside this manual.
8 9
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DANGER
�
DANGER
Remove jumper for remotes without thermostats.
When using 2 wire remotes use H & C connections
only. Set unit to spa position.
Remove jumper for remotes without thermostats.
Make sure pool heater’s thermostats are at maximum setting.
AUTO TEMP FEATURE
(Pool Mode Only)
The Auto Temp feature is standard in all Kopec Enterprises, Inc. pool heater
models. To activate this feature additional installation by an electrician is
required. Electrical installation instructions are on page 11 of this manual.
An additional copy of the instructions for the electrician can be found
behind the control panel in the component pocket of the heater.
In the Time Clock mode your heater will operate only during the water
circulating pump time clock run period (normally 6-8 hours a day depending
on pump and pool size). When the time clock run period ends the pump
and heater will turn off and stay off until the time clock and pump comes on
again the next day. During the off period it is common for the Low Water/
Trouble light to be on if the water drops below the desired temperature
setting. This is an indication the unit wants to turn on but will not until the
water pump turns on via the time clock period.
In the Auto Temp mode your heater will override the time clock setting,
turn on the water pump and operate whenever the pool temperature drops
below the desired setting. The heater will be able to run when it needs to
anytime day or night which will insure your desired temperature will be
maintained at all times. Auto Temp is a convenient feature for inconsistent
swim applications, morning swimming, therapeutic needs and during the
cooler months when time clock periods would need to be increased to
maintain desired pool temperatures.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical supply to this product must be installed by a licensed or
certified electrician in accordance with the National Electrical Code and
applicable local codes and ordinances. Improper installation will create
an electrical hazard, which could result in serious injury or death to pool
or spa users, installers, or others due to electrical shock, and may also
cause damage to property. Read and follow the specific instructions
inside this manual.
�
DANGER
10 11
TITAN 700TI
Digital Control Operator Instructions
When the unit is powered on the digital controller will display the current
water temperature flowing through the unit.
To select pool or spa mode: Press the hand button to select pool or spa
position.
To adjust water temperature: Press the up and down arrows to change to
the desired water temperature setting.
There will be up to a 10 minute time delay before the unit will turn on.
To lock digital control access: Press and hold the hand button for 5 seconds
to lock or unlock digital control access.
To activate “Auto Temp” feature: Press and hold the hand button and the
up arrow to enable or disable the Auto Temp feature.
Remote Control: For remote control interfacing press and hold the hand
button and the down arrow to access the remote control menu. Press the
up or down arrow to select the desired remote control option. For remotes
WITHOUT thermostats select the pool/spa option. For remotes WITH
thermostats select the T-stat option.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION
The electrical supply to this product must be installed by a licensed or certified electrician in accordance with the National Electri-
cal Code and applicable local codes and ordinances. Improper installation will create an electrical hazard, which could result in
serious injury or death to pool or spa users, installers, or others due to electrical shock, and may also cause damage to property.
Read and follow the specific instructions inside this manual.
�
DANGER
12 13
HOW TO OPERATE YOUR POOL HEATER
(Analog Models Only)
Once the plumbing and electrical installations are complete, you’re now
ready to turn on your pool heater. But first, here are some tips before
starting your unit.
Water Flow- This is critical to the efficient operation of your unit, (see
troubleshooting).
Make sure your filter is clean and your circulating pump is on before
starting your unit.
Also, confirm all plumbing valves are adjusted to allow maximum water
flow to the unit. (DO NOT bypass any water away from unit unless
your circulating pump is oversized.)
Turn off any waterfalls or fountains to improve heating time.
Scroll Compressors- It is not uncommon for units equipped with scroll
compressors to require 2-3 initial start-up attempts after sitting for extended
periods without operating.
Time Delay- There is a built in 5-10- minute start-up time delay to protect the
compressor from short cycling under unequilized refrigerant conditions.
Dual Thermostats- Your unit is equipped with two thermostats for
convenient pool/spa temperature settings.
How to set the pool/spa temperature (analog model only) Purchase
an inexpensive floating thermometer and place in your pool. Locate
pool thermostat control knob (knob on left) and turn to the maximum
setting (clockwise). In 5-10- minutes, the unit will turn on and begin
heating. Monitor the water temperature as it increases. Depending on
the temperature of the pool at start-up, heat up time could take as much
as 24-48 hours. Once the pool has reached your desired temperature,
slowly turn the temperature control knob
counter clockwise, (down) until the unit shuts
off. The temperature is now set. Repeat
steps for spa temperature setting.
Tip- The unit will automatically maintain
your desired temperature, providing your
circulating pump is running via your pool
time clock. Circulating pump operation
time may need to be increased on the time
clock, depending on outside temperature
conditions or desired water temperature.
FEATURES AND FUNCTIONS
(Analog Models Only)
Pool/Spa switch- This switch, located between the temperature knobs
allows you to easily switch from pool to spa temperature settings without
re-adjusting control knobs.
Tip- When switching from one mode to the other, always turn the plumbing
valves to the correct position. For ex: when in pool thermostat mode,
plumbing valves need to be adjusted so water is coming from and going
to the pool.
Convenient on/off switch- This switch simply turns off the unit,
eliminating the need to turn down the temperature setting or shutting off
your breaker.
Tip-This feature should be used only when the unit will be off for extended
periods of time, such as vacation or during the summer.
Power On Light- This green light indicates there is power to the unit.
Trouble/Service Light- This red light indicates low or no water flow or
a low voltage electrical problem. Make sure your filter is clean and your
circulating pump is on. If you have confirmed you have good water flow,
call for service.
Tip- In temperatures below 45 degrees, the unit will shut down to
protect the Compressor. If this happens, the red light will come
on. The unit will start
automatically when
temperature increases
near 50 degrees and
the red light will go
out. Do not call for
service under these
conditions. Allow
enough time for the
outside temperature
to increase.
14 15
UNIT PROTECTION
It is your responsibility to maintain the correct chemical balance in your
pool and spa water. Improper or inconsistent chemical maintenance could
cause damage to your pool/spa equipment, pool surface or lining, pool
heater and also could be harmful to your health. Here are a few tips to
avoid these problems.
Install any chlorinating devise down stream of heater with a check valve
and plumbing loop between the heater and the chlorinator.
DO NOT
inject chlorine gas into your pool or spa.
DO NOT
use floating chlorine tablet feeders.
DO NOT
put solid chlorine tablets in the skimmer.
Maintain a consistent, chemically - balanced pool. Depriving a pool of
chemicals, then “shocking” it with heavy chemicals is an incorrect and
sometimes damaging practice when performed too often. This is common
for homeowners who are out of town for extended periods of time .
If the heat exchanger in the unit is deprived of water for several days, high
chlorine gas could cause excessive corrosion. Even if power to the unit is
turned off, be sure that water can still circulate through the unit at all times,
especially during the summer months when no heat is required.
Make sure your unit is electrically bonded, as described in the electrical
section of this manual. This will help prevent electrolysis, which could
damage the heat exchanger in your pool heater.
The following are recommended water quality readings. These readings
should be maintained at all times to ensure good health while protecting
your pool heater .
PH Level 7.2-7.8
Total Alkalinity 80-100 PPM (parts per million)
Total Dissolved Solids below 1200 PPM
Chlorine Concentration (free) 1.0- 2.0 PPM
Note- Damage due to abusive water chemistry or electrolysis is not
covered under warranty. Please have your water checked regularly by a
pool professional.
WINTERIZING YOUR POOL HEATER
During a short term freeze, run your circulating pump continuously to
prevent damage to your filter, pump and pool heater.
Most Models -
During a long-term hard freeze, disconnect the unions on the heater and
remove all the water from the heat exchanger to prevent the pipes from
bursting (use a wet/dry vaccuum if needed to remove all water).
Note- Freeze damage is not covered by warranty so please take every
precaution during freezing conditions.
UNIT MAINTENANCE
Your Kopec pool heater is basically maintenance free!
Keep the condensation drain fitting free of any leaves or debris.
Hose off any debris that may be in the evaporator fins to ensure good
airflow.
Clean plastic cabinet occasionally to maintain the bright shiny color
PERFORMANCE AFFECTING FACTORS
It is very important to understand that heat pump pool heaters are designed
to maintain temperature and do not heat quickly. Initial heat up time could
be as much as 24-48 hours, because it is necessary to heat the concrete
walls in the pool, as well as the water. Once your desired temperature
is reached, the heat pump will maintain the temperature, providing the
circulating pump run time is adequate, depending on temperature desired,
size of pool and outside weather conditions. Listed on the next page are a
few factors to consider when evaluating your unit’s performance.
16 17
Size of your pool- Most of your heat loss is through the surface area of
the pool. The larger the pool, the quicker it will lose temperature.
Wind- Since surface area is the biggest cause of heat loss, the more wind
you have across your pool increases your heat loss even more. Normal
wind speed is 2-3 mph.
Water temperature maintained- If you want a higher temperature,
you’ll have to run the unit longer to maintain it. The greater the difference
between air temperature and water temperature means more heat loss
and longer run time.
Pool cover- Covers reduce the surface heat loss and unit run time, which
will reduce operational costs and help temperature maintenance in cooler
conditions.
Outside air temperature- The warmer it is, the easier it is to maintain
temperature. The unit has more heat to gather from the air and there is
less surface heat loss, which greatly reduces run time and operational
costs. The cooler it is, the more heat loss, which increases run time
requirement.
Waterfalls, Spillways and Fountains- These features increase heat
loss. Shut off features to cut down heat loss and improve heater’s
performance.
How does your Kopec Heat Pump heat your pool?
A heat pump uses a refrigerant technology to gather heat in the outside
air and transfers it to your pool water. This technology is used because
refrigerant can absorb and transfer heat.
The circulating fan pulls air through the evaporator coil which acts as a
heat collector. The very cold liquid refrigerant in the evaporator absorbs
the warmth from the outside air, which in turn changes the state of the
refrigerant from a liquid to a gas. The refrigerant gas is then drawn into
the compressor where it is compressed and increases to a very high
temperature.
This extremely hot gas then flows into the heat exchanger, where the heat
transfer begins. As the cool pool water flows through the heat exchanger,
the hot gas gives up its heat,which increases the water temperature.
Once the refrigerant gives up its heat, it returns to a liquid state, then
passes through an expansion valve and into the evaporator coil to start
the process all over again.
18 19
COOLING OPTIONS
(Analog Models Only)
The cooling option enables you to cool your pool in the hot summer months
when pool water can become too warm and is no longer refreshing. With
a special refrigerant reversing valve along with additional components and
wiring the cooling option can be activated with a simple flip of a switch.
Depending on your model the cooling BTU’s will range from 62,000
81,000. The BTU rating is based on the actual cooling capacity of the
compressor in the unit. This rating is different from the heating rating but
more than adequate considering it takes less BTU’s to cool water than it
does to heat.
When the pool temperature remains above you desired setting simply
switch to “cool” mode on the heater control panel. Your Kopec pool heater
will automatically cool the pool to the desired temperature setting. For
cooler pool water turn down the pool thermostat knob towards the blue
color on the dial.
Note* Cooling option does not operate with the spa thermostat control.
Note* Cooling option is not available in models equipped with digital
controls.
TROUBLESHOOTING
(Analog Models Only)
Your Kopec pool heater is very easy to troubleshoot. 60% of service calls
are customer or installation related. You will be charged for a service call
if a service person is dispatched and there is nothing wrong with your
unit. Please take a few minutes to read through this section to avoid these
charges before calling for service. When calling for service, please have
your model and serial number available.
Note- unauthorized personnel servicing your unit will void your
warranty
Unit not starting. Green power light off- Breaker or fuse may be off.
Reset or replace. If new installation, the unit may be wired wrong by
electrician. If the unit still does not run, call for service.
Unit not starting. Green power light on- Unit could be in time delay
mode. Wait full 5 minutes. Remember, do not turn thermostat up and
down during the time delay mode. The time delay will reset and start over
every time thermostat is adjusted. Check the temperature setting and the
temperature of the pool. The pool may be at the desired temperature,
therefore will not run. If you’re not sure of the water temperature, adjust
the thermostat to the maximum setting and wait 5 full minutes. Unit still
does not run, call for service.
Unit not starting. Red trouble light on- If outside temperature is below
45 degrees, wait until it warms up to at least 50 degrees. Check water flow.
The following causes of low water flow are:
Pump may be off. Adjust time clock so pump will run longer if needed.
Dirty filter or clogged pump basket.
Where applicable, plumbing valves could be turned in the wrong position,
which could restrict or prevent water from getting to the heater.
Pool pump could be too small. At least a 1HP pump is suggested for
adequate water flow.
20 21
TROUBLESHOOTING CONTINUED
If new installation, the unit could be piped backwards. Remember, water
IN is on the RIGHT and water OUT is on the LEFT.
Note If your heater is in a pool / spa application, operate the heater in
both pool and spa plumbing modes. If the unit runs in one mode and not
the other, then it is likely that the problem is in the plumbing and not the
heater.
Unit still not starting, call for service.
Unit is running, but not heating If cool air is blowing out of the top of
the unit, then the unit is heating. Your circulating pump run time may have
to be increased. (See the factors that effect performance section of this
manual).
Note Remember that the unit will not run without water and your circulating
pump time clock controls the amount of time the pump runs. If this is an
initial start up, very cool or high desired temperature condition, you will
have to increase your time clock pump-running period accordingly.
If you have considered all operating conditions and reviewed the factors
that effect performance section of this manual, then call for service.
Unit is leaking water The leak is normal condensation or an internal
plumbing leak. Shut off unit for at least 2 hours and leave circulating pump
on. If leak stops, then it is normal condensation. If the leak continues, call
for service.
KOPEC ENTERPRISES HURRICANE
BRACKET INSTRUCTIONS
22 23
Drill (2) – 3/16” Pilot
Holes 2” Deep
(6) – Hurricane
Brackets
Part # KEI-0316
Important!
Brackets Must be Installed
Every 12 Inches on the Left and
Right Side of the Unit.
(2) – ¼” x 1 ½” Tapcon
Concrete Screws with
Gasketed Washers Per Bracket
Please NOTE: Installation Instructions in accordance with Florida
Building Code 301.13.1 option #3.
GENERAL INFORMATION
Serial #: _________________________________________
Model: _________________________________________
Date of Purchase: _________________________________
Purchased From: __________________________________
Installed By: ______________________________________
Note: A serial # is required when calling for service. Service will not
be performed without a serial # or proof of date of purchase.
NOTES:
WARRANTY
The warranty varies depending on the date of purchase, unit model and
the geographic location of the unit. Please refer to our web-site for a full
description of your units warranty coverage. Kopecheatpumps.net
Kopec Enterprises Inc.
3033-9 NW 25th Avenue
Pompano Beach, Fl 33069
Phone: 954-917-8998 / Fax: 954-917-8994
Toll Free: 866-917-8998
Kopecheatpumps.net
24
3033-9 NW 25th Avenue
Pompano Beach, FL 33069
Phone: 954-917-8998 / Fax: 954-917-8994
Toll Free: 866-917-8998
www.kopecheatpumps.net
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