Pentair ThermalFlo User Manual

ThermalFlo

Heat Pump

™

Installation

User's Guide

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

and

Customer Service

If you have questions about ordering Pentair Water Pool and Spa replacement parts, and pool
products, please use the following contact information:

Customer Service (8 A.M. to 5 P.M. — Eastern and Pacific Times)

Phone: [phone]

Fax: [phone]

Technical Support

Sanford, North Carolina (8 A.M. to 5 P.M. — Eastern Time)

Phone: [phone]

Fax: [phone]

Moorpark, California (8 A.M. to 5 P.M. — Pacific Time)

Phone: [phone] (Ext. 5591)

Fax: [phone]

Web site

visit www.pentairpool.com or www.staritepool.com to find information about Pentair products

© 2006 Pentair Water Pool and Spa, Inc. All rights reserved.

This document is subject to change without notice.

1620 Hawkins Ave., Sanford, NC 27330 • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone]

Trademarks and Disclaimers.The Pentair Water Pool and Spa logo, IntelliTouch and EasyTouch are registered trademarks of Pentair Water Pool
and Spa, Inc. ThermalFlo is a trademark of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to
refer to either the entities claiming the marks and names of their products. Pentair Water Pool and Spa, Inc. disclaims any proprietary interest in
trademarks and trade names other than its own.

P/N 473426 Rev. C 10/19/06

Contents

Important Safety Precautions .............................................................................................. iii

Section 1: Introduction ..................................................................................................... 1

ThermalFlo Overview ..............................................................................................1

General Features..................................................................................................... 2

Section 2: Installation ....................................................................................................... 3

Installing the ThermalFlo .......................................................................................... 3

Materials needed for Installation .............................................................................. 3

ThermalFlo Heat Pump Dimensions ........................................................................ 4

Location ...................................................................................................................4

Clearances ..............................................................................................................5

Roof Run-off ............................................................................................................ 5

Equipment Pad ........................................................................................................ 5

i

Drainage and Condensation ....................................................................................6

Lawn Sprinklers ....................................................................................................... 6

Anchor Clamp Installation ........................................................................................ 6

Water Connections .................................................................................................. 7

Standard Plumbing .................................................................................................. 7

Water Connections (Quick Connect)....................................................................... 8

Check Valve Installation .......................................................................................... 8

Automatic Flow Control Valve .................................................................................. 8

Multiple Unit Installation ........................................................................................... 9

Heat Pump & Heater Combination ..........................................................................9

Multiple Heat Pump Connections ............................................................................10

Electrical Connections ............................................................................................. 11

General Information .................................................................................................11

Main Power .............................................................................................................. 11

Bonding.................................................................................................................... 11

Electrical Wiring Diagram ........................................................................................12

Relay Remote Controls ........................................................................................... 13

Connecting ThermalFlo to IntelliTouch or EasyTouch .............................................. 14

ThermalFlo Installation and User’s Guide

ii

Contents, continued

Section 3: Operating the ThermalFlo ...............................................................................15

Initial Start-up Precautions ...................................................................................... 15

Operating the Controller ..........................................................................................16

Controller Panel ....................................................................................................... 16

Indicator Lights / LEDs ............................................................................................ 17

System Indicator LEDs ........................................................................................... 17

Mode Indicator LEDs ............................................................................................... 17

Operation of Controller Buttons ............................................................................... 18

Temperature Setting .................................................................................................18

Mode Selection Buttons ........................................................................................... 18

Auto-Heat/Cool Mode .............................................................................................. 18

Keypad Lockout ....................................................................................................... 18

Troubleshooting the Controller ................................................................................. 19

Controller Error Codes ............................................................................................ 19

Water Pressure Switch Adjustment ......................................................................... 20

Section 4: General Maintenance ...................................................................................... 21

Water Chemistry ...................................................................................................... 21

Winterizing ............................................................................................................... 21

Spring Start-Up ....................................................................................................... 22

Inspection and Service ............................................................................................ 22

Owner Inspection ....................................................................................................22

Professional Maintenance and Service ...................................................................23

Section 5: Troubleshooting .............................................................................................. 25

Section 6: Replacement Parts ..........................................................................................28

Illustrated Parts ....................................................................................................... 28

Replacement Parts List ........................................................................................... 29

ThermalFlo Installation and User’s Guide

IMPORTANT SAFETY PRECAUTIONS

Important Notice:

This guide provides installation and operation instructions for the ThermalFlo HP models
of Heat Pumps. Consult Pentair Water with any questions regarding this equipment.

Attention Installer: This guide contains important information about the installation, operation and safe use of

this product. This information should be given to the owner and/or operator of this equipment after installation or left on
or near the heat pump.

Attention User: This manual contains important information that will help you in operating and maintaining this
heat pump. Please retain it for future reference.

WARNING —Before installing this product, read and follow all warning notices and instructions which are

included. Failure to follow safety warnings and instructions can result in severe injury, death,
or property damage. Call [phone] for additional free copies of these instructions.

iii

Codes and Standards

The ThermalFlo HP heat pump is listed by ETL as complying with the latest edition of the “UL Standard for Safety for
Heating and Cooling Equipment”, UL 1995 and CSA C22.2 No. 236.

All Pentair Water heat pumps must be installed in accordance with the local building and installation codes as per the
utility or authority having jurisdiction. All local codes take precedence over national codes. In the absence of local
codes, refer to the latest edition of the National Electric Code (NEC) in the United States and the Canadian Electric
Code (CEC) in Canada for installation.

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 all 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 this guide.

WARNING —To reduce the risk of injury, do not permit children to use this product unless they are closely

supervised at all times.

WARNING —For units intended for use in other than single-family dwellings, a clearly labeled emergency

switch shall be provided as part of the installation. The switch shall be readily accessible to
the occupants and shall be installed at least 5 feet [1.52 m] away, adjacent to, and within sight
of the unit.

ThermalFlo Installation and User’s Guide

iv

IMPORTANT SAFETY PRECAUTIONS (continued)

Consumer Information and Safety

The ThermalFlo series of heat pumps are designed and manufactured to provide many years of safe and reliable service
when installed, operated and maintained according to the information in this manual and the installation codes referred to
in later sections. Throughout the manual, safety warnings and cautions are identified by the “ “ symbol. Be sure to read
and comply with all of the warnings and cautions.

WARNING —The U.S. Consumer Product Safety Commission warns that elevated water temperature can be

hazardous. See below for water temperature guidelines before setting temperature.

WARNING —The following “Safety Rules for Hot Tubs” recommended by the U.S. Consumer Product Safety

Commission should be observed when using the spa.

1. Spa or hot tub water temperatures should never exceed 104° F. [40° C.]. A temperature of 100° F. [38° C.] is considered
safe for a healthy adult. Special caution is suggested for young children. Prolonged immersion in hot water can induce
hyperthermia.

2. Drinking of alcoholic beverages before or during spa or hot tub use can cause drowsiness which could lead to
unconsciousness and subsequently result in drowning.

3. Pregnant women beware! Soaking in water above 100° F. [38° C.] can cause fetal damage during the first three
months of pregnancy (resulting in the birth of a brain-damaged or deformed child). Pregnant women should stick
to the 100° F. [38° C.] maximum rule.

4. Before entering the spa or hot tub, the user should check the water temperature with an accurate thermometer. Spa
or hot tub thermostats may err in regulating water temperatures.

5. Persons with a medical history of heart disease, circulatory problems, diabetes or blood pressure problems should
obtain their physician's advice before using spas or hot tubs.

6. Persons taking medication which induce drowsiness, such as tranquilizers, antihistamines or anticoagulants should
not use spas or hot tubs.

Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above normal body
temperature of 98.6° F. [37° C.]. The symptoms of hyperthermia include: drowsiness, lethargy, dizziness, fainting, and an
increase in the internal temperature of the body.

The effects of hyperthermia include:

1. Unawareness of impending danger.

2. Failure to perceive heat.

3. Failure to recognize the need to leave the spa.

4. Physical inability to exit the spa.

5. Fetal damage in pregnant women.

6. Unconsciousness resulting in danger of drowning.

ThermalFlo Installation and User’s Guide

IMPORTANT SAFETY PRECAUTIONS (continued)

Swimming Pool Energy Saving Tips

It is important to note that a heat pump will not heat a pool as fast as a large gas or electric pool heater. If the pool water is
allowed to cool significantly, it may take several days to return to the desired swimming temperature. For weekend use, it
is more economical to maintain the pool water temperature at or near your desired swimming temperature. If you do not plan
to use your pool for a prolonged period, then you might choose to turn the heat pump completely off or decrease the
temperature setting of the control several degrees to minimize energy consumption.

Pentair offers the following recommendations to help conserve energy and minimize the cost of operating your heat pump
without sacrificing comfort.

1. The American Red Cross recommends a maximum water temperature of 78° F. [25° C.]. Use an accurate pool

thermometer. A difference of 4° F. [2° C.] , between 78° F. and 82° F. [26° C. and 28° C.], will significantly increase energy
consumption.

2. Carefully monitor the water temperature of your pool in the summertime. You can reduce heat pump usage due to warmer

air temperatures.

3. During the winter or when on vacation for longer than a week, turn off the heat pump.

v

4. Find the proper setting on the heat pump temperature control and use the Keypad Lock function to discourage further

adjustments.

5. Set the pump time clock to start the pump no earlier than 6:00 AM during the pool-heating season. This is the time when

nightly heat loss balances.

6. Where possible, shelter the pool from prevailing winds with well-trimmed hedges or other landscaping, cabanas, or

fencing.

7. Always use a pool cover when practical. Besides providing a valuable safety feature, a pool cover will reduce heat

loss, conserve chemicals, and reduce the load on filter systems.

ThermalFlo Installation and User’s Guide

vi

IMPORTANT SAFETY PRECAUTIONS (continued)

General Installation Information

1. Installation and service must be performed by a qualified installer or service agency, and must conform to all
national, state, and local codes.

2. The ThermalFlo heat pump gets electrical power from an external source and provides a dual electronic
thermostat control system for pool/spa combinations or preheat convenience.

3. This heat pump is specifically designed for heating fresh water swimming pools and spas. Do not use it as a
general service heater. Consult your dealer for the appropriate Pentair Water products for these applications.

General Specifications

Installation Location Certified for use:

Outdoor use only.

Water Pipe/Heater Connection — Plastic 2” PVC (Unions included)

Flow Rate

Maximum 125 gpm [475 lpm]
Minimum 30 gpm [110 lpm]
Maximum Working Water Pressure 50 psi

Electrical Supply Voltage Requirements 1-Phase 208/230 VAC 60Hz

Requirements 1-Phase

HP 500 50 A
HP 700 50 A
HP 900 60 A
HP 1200 60 A
HP 1200R 60 A

Warranty Information

The ThermalFlo heat pump is sold with a limited factory warranty. Details are specified on the warranty card. Make all
warranty claims to an authorized Pentair Water dealer or directly to the factory. Claims must include the heat pump serial
number and model (this information can be found on the rating plate), installation date, and name of the installer. Shipping
costs are not included in the warranty coverage. The warranty does not cover damage caused by improper assembly,
installation, operation, winterizing, field modification, or failure to earth bond and properly ground the unit. Any changes to
the heat pump, evaporator, heat exchanger, wiring, or improper installation may void the warranty.

ThermalFlo Installation and User’s Guide

Section 1

Introduction

ThermalFlo Overview

The ThermalFlo heat pump gets electrical power from an external source and provides a dual electronic
thermostat control system for pool/spa combinations or preheat convenience.

ThermalFlo HP heat pumps transfer the heat from the outside air to your pool, providing the most energy
efficient pool and spa heating available. Compared to gas, oil, or electric heaters, ThermalFlo HP heat pumps
operate up to 80% less, saving you hundreds of dollars in energy costs each year. Our heat pumps are not only
highly efficient, they’re also clean and safe to operate. ThermalFlo HP heat pumps are ETL-listed pool heat
pumps using R410-A, the environmentally safe and clean refrigerant.

The non-polluting ThermalFlo HP Heat Pump is so energy efficient, it will keep your pool comfortably warm
for far less than gas or electric heaters.

This heat pump is specifically designed for heating fresh water swimming pools and spas. Do not use it as
a general service heater. Consult your dealer for the appropriate Pentair Water products for these applications.

1

ThermalFlo

ThermalFlo Installation and User’s Guide

2

General Features

• Dual digital thermostats offer precise temperature control to maintain the desired separate water
temperatures in pool/spa combinations without overheating or wasting energy.

• Long-life corrosion resistant composite cabinet stands up to severe climates and pool chemicals.

®

• High efficiency Trane

• Self-diagnostic control panel monitors and troubleshoots heat pump operations to ensure safe, dependable
operation.

• Cupronickel heat exchanger resists external corrosion and heat loss.

• Each unit undergoes a finishing process to ensure corrosion resistance and long life.

• Elevated base pan for positive drainage of condensation.

• 2-inch plumbing connections for easy installation.

• Separate isolated electrical compartment prevents internal corrosion, extends heater life.

• Compatible with IntelliTouch

compressor is the most energy efficient, durable, and quiet compressor available.

®

and Easytouch® control systems.

• ETL listed for safe operation.

ThermalFlo Installation and User’s Guide

Section 2

Installation

The following general information describes how to install the ThermalFlo heat pump.

Note: Before installing this product, read and follow all warning notices and instructions starting
on page iii.

Installing the ThermalFlo

Only a qualified service person should install the ThermalFlo heat pump.

Materials needed for Installation

The following items are needed and are to be supplied by the installer for all heat pump installations:

1. Plumbing connections (2 inch).

3

2. Level surface for proper drainage.

3. Suitable electrical supply line. See rating plate on unit for electrical specifications. A junction box is not

needed at the heat pump; connections are made inside of the heat pump electrical compartment. Conduit
may be attached directly to the heat pump jacket.

4. Electric cutout switch that will interrupt all power to the unit. This switch must be within line of sight of the

heat pump.

5. Watertight conduit to run the electrical supply line.

Note: We recommend installing isolation valves on the inlet and outlet water connections for ease
of serviceability.

ThermalFlo Installation and User’s Guide

4

ThermalFlo Heat Pump Dimensions

38.7"

PART NUMBER
SERIAL NO.

CONTAINER ID

PRODUCT SPEC
LABEL

WATER

REMOTE

PRESSURE

THERMOSTAT

POOL

SPA

HEATING

POWER/
MODE

COOLING

TEMPERATURE SETTING

AUTO-HEAT/COOL

POOL SPA

PRESS ANY ARROW ONCE TO
CHECK SET TEMPERATURE

ETL LISTED

CONFORMS TO
UL STD 1995

C US

CERTIFIED TO

3044065

CAN/CSA STD C2 2.2 NO. 236

A

ThermalFlo™ HP

30.7"

11.25"

9.25"

4.5"

18.0"

32.0"

Figure 1.

REBMUNLEDOM

0050070090021C0021C/HR0021

6.5"
.5"

"A"noisnemiD”5.33”5.33”5.14”5.14”5.14”5.14

Correct installation is required to assure safe operation. The requirements for Pentair Water heat pumps
include the following:

• Dimensions for critical connections.

• Field assembly (if required).

• Appropriate site location and clearances. (See pages 4-5.)

• Proper electrical wiring. (See pages vi and 11-13.)

• Adequate water flow. (See page vi.)

This manual provides the information needed to meet these requirements. Review all application and installation
procedures completely before continuing the installation.

Location

CAUTION — When pool equipment is located below the pool surface, a leak from any component can cause

large scale water loss or flooding. Pentair Water Pool and Spa, Inc. cannot be responsible for such
water loss or flooding which may cause damage to the product.

Avoid placing the heat pump in locations where it can cause damage by water or condensate
leakage. If this is not possible, provide a suitable drain pan to catch and divert any leakage.

ThermalFlo Installation and User’s Guide