Kopec 525S Troubleshooting guide

Owner’s
Manual
&
Installation Guide
Owner’s
Manual
&
Installation Guide
Model
525S
Model
525TI
Model
650TI
Model
650SC
Model
700TI

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 ele-
ments and have environmental and cost benefits that far
outweigh other heating sources, such as propane gas.
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 prod-
ucts are Safety Certified by Applied Research
Laboratories and all the performance results are con-
firmed by an independent certified test lab.
KOPEC offers a large selection of heat pumps for both res-
idential 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 ....................................................P - 1
General Safety Instructions.................................P 2
Unit Installation...................................................P 2
Plumbing.......................................P 3
Plumbing Diagrams.............................P 4-5
Electrical Installation...................................P  6
Electrical Diagrams..................................P 7-9
Auto Temp Feature.......................................P 10-11
Digital Control Instructions.................................P 12
Digital Control Electrical Diagrams ............................. .P 13
How to operate your pool heater..................................P 14
Features and functions (analog models).....................P 15
Unit Protection..................................................P 16
Unit Maintenance.........................................................P 17
Winterizing....................................................P 17
Performance effecting factors..........................P 17-18
How does your heat pump heat your pool?.................... P 19
Cooling feature.....................................................P 20
Troubleshooting............................................P 21-22
Hurricane bracket.............................................P 23
Warranty............................... Back Cover
Record keeping and notes...................Inside back cover
Unit cabinet description.......................P 24
P-1

GENERAL SAFETY INSTRUCTIONS
All electrical installation must be done by a qualified, licensed electrical con-
tactor 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.
LOCATION- The placement of the pool heater is very important in insuring
the maximum operating efficiency, while keeping installation costs to a mini-
mum 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 effect 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.
UNIT INSTALLATION
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION. The elec-
trical supply to this product must be installed by a licensed or certified electri-
cian 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 ‰ inch garden hose to
the drain fitting and redirecting it to area better suited for drainage. (Ask your
installer).
PLUMBING See page (4 ) Plumbing Diagram
Piping Sequence- Pool- water circulating pump-filter-pool heater- check valve-
chlorinator- pool (if a chlorinating devise is used, it must be downstream of the
heater, with a check valve installed 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 more multiple unit plumbing diagrams.
P-2 P-3

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.
Note: Chemical Loop should
be minimum of 3 Higher
than the Chemical Feeder
Plumbing Diagram
Layout Diagram for the
correct plumbing setup for
the Kopec pool heater
Flapper
Check
OUT
OUT
OUT
OUT
OUT
OUT
IN
IN
IN
IN
POOL
FILTER
POOL
PUMP
From Pool & Spa
Water Flow
Pipe Size 1 1/2or 2
To Pool & Spa
Chemical
Feeder
3
P-4 P-5

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- 208/240v60hz- 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 war-
ranty.
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 dis-
connect must be in line of
sight of the unit.
Note- Shut off main power
before removing the units
electrical access panel!
ELECTRICAL
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.
P-6 P-7

Rem ove Ju m p e r forrem oteswithoutthermostats.
Whenusing 2 wire rem otesuse H&C connections
only. Se tunitto
spa position.
123
4
5678
910 11 12
14
13
CUBE
RELAY
Ju n e 2003
Rem ove Ju m p e r forrem oteswith thermostats. Makesu re
poolheaters Th e rmostats are atmaximum se tting.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION. The electrical suppplyto this product must
be installed by a licensed or certified electricianin 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,
andmayalsocausedamagetoproperty.Readandfollow thespecificinstructionsinsidethe manual.
!
DANGER
P-8 P-9
Remove Jumper for remotes without thermo-
stats. When using 2 wire remotes use H&C
connections only. Set unit to spa position. Remove Jumper for remotes with thermostats.
Make sure 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 installa-
tion by an electrician is required. Electrical installation instruc-
tions 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 applica-
tions, 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 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.
P-10 P-11

* 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 a 10 minute time delay before the unit will turn on
* To lock digital control access: Press and hold for 5 seconds the hand but-
ton to lock or unlock digital control access.
* To activate Auto Temp feature: Press
and hold for 5 seconds 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 thermo-
stats select the pool/spa option.
For remotes WITH thermostats
select the T-stat option.
!
DANGER
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 spausers, installers,or othersdue toelectrical shock, and may alsocause damageto property.Readandfollowthe specific instructionsinsidethe manual.
P-12 P-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 trou-
bleshooting).
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 circling
pump is oversized.)
Turn off any waterfalls or fountains to improve heating time.
Scroll Compressors- It is not uncommon for units equipped with scroll com-
pressors to require 2-3 initial start-up attempts after sitting for extended peri-
ods 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 models only) Purchase an inex-
pensive 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 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 tem-
perature setting.
Tip- The unit will automatically main-
tain your desired temperature, provid-
ing 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 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, plumb-
ing 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 peri-
ods 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.
P-14 P-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 prob-
lems.
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 chemi-
cals, 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
Note- Damage due to abusive water chemistry or electrolysis is not covered under war-
ranty. Please have your water checked regularly by a pool professional.
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
WINTERIZING YOUR POOL HEATER
During a short term freeze, run your circulating pump continuously to prevent
damage to your filter, pump and pool heaters.
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 burst-
ing.
In addition to loosening the unions on the heater, please find the heat exchang-
er drain fitting located on the bottom right hand side of the heater. Push in the
gray retainer ring while pulling out the gray plug. Once drained simply push
the plug back into the drain fitting.
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 EFFECTING 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 below are a few factors to consider when evaluating your
unit’s performance.
P-16 P-17

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 pumped 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.
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 tem-
perature 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 condi-
tions.
Outside air temperature- The warmer it is, the easier it is to maintain tempera-
ture. 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.
P-18 P-19

Cooling Options
(analog models only)
TROUBLESHOOTING
(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 spe-
cial refrigerant reversing valve along with addition 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 rat-
ing 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 your desired setting simply switch to
cool mode on the heater control panel. Your Kopec pool heater will automat-
ically 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 con-
trols.
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 serv-
ice 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 num-
ber 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 5-10 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
5-10 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.
P-20 P-21

Kopec Enterprises Hurricane
Bracket Instructions
P-23
(6)  Hurricane Brackets
Part # KEI-0316
Important!
Brackets Must be Installed
Every 12 Inches
on the Left and Right Side of the Unit.
* Please NOTE: Installation Instructions in accordance with
Florida Building Code 301.13.1 option #3.
(2) … x 1 ‰ Tapcon
Concrete Screws with
Gasketed Washers Per Bracket
Drill (2)  3/16
Pilot Holes 2 Deep
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 plumb-
ing 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.
P-22

P-24
Warranty
06
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:
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
3033-9 NW 25th Avenue
Pompano Beach, Fl 33069
Phone: [phone] / Fax: [phone]
Toll Free: 866-917-8998
Kopecheatpumps.net

3033-9 NW 25th Avenue
Pompano Beach, FL 33069
phone: [phone] / Fax: [phone]
Toll Free: 866-917-8998
www.kopecheatpumps.net