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Aquacal 120 Owner's Manual And Installation Manual

Pool and spa heat pump
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Table of Contents
&7
and
Pool and Spa

Heat Pump

Owner's Manual
Models:
-and-
100, 120, & 155
Installation Guide
HEATING ONLY
and
HEATING - COOLING
With HP7 Programming
Instructions Attached
Additional Labels:
APS
Fox Smart
South Beach
Tropez
ATTENTION INSTALLER:
T
D
P
'
P
H
P
O
HIS
OCUMENT IS
URCHASER
S
ROPERTY AND IS TO REMAIN WITH THE
EAT
UMP
WNER
1/7/04
1

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  Summary of Contents for Aquacal 120

  • Page 1: Heat Pump

    &7 Pool and Spa Heat Pump Owner’s Manual Models: -and- 100, 120, & 155 Installation Guide HEATING ONLY HEATING - COOLING With HP7 Programming Instructions Attached Additional Labels: Fox Smart South Beach Tropez ATTENTION INSTALLER: ’ OCUMENT IS URCHASER ROPERTY AND IS TO REMAIN WITH THE...
  • Page 2 1-800-786-7751 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ ________________________________________________________________________________________ ___________________________________________________________________________________ ____________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________...
  • Page 3: Table Of Contents

    TABLE OF CONTENTS WELCOME TO THE TEAM ---------------------------------------------- 5 IMPORTANT FEATURES OF YOUR NEW HEAT PUMP ------------------ 6 HOW A HEAT PUMP WORKS ------------------------------------------ 7 SAFETY INFORMATION------------------------------------------------ 8 QUICK START & STOP ------------------------------------------------- 10 HEATER CONTROLS --------------------------------------------------- 12 Control Panel Layout ----------------------------------------------- 12 Buttons, Lights, and Display -------------------------------------- 12 Operational &...
  • Page 4 (Use) During the Swim Season -------------------------------- 23 Freeze Protection and Winterizing Requirements -------------- 23 Winterizing Procedure ------------------------------------------ 24 AquaCal Preventive Maintenance Program ------------------------ 25 TROUBLESHOOTING (No Op, No heat, Water from Unit) ------------ 26 Troubleshooting Flowcharts ----------------------------------------27 DEALER-SPECIFIC INFORMATION (Installation & Set Up) --------- 31...
  • Page 5: Welcome To The Team

    Welcome Dear Owner: ongratulations on your wise decision to make an AquaCal heat pump part of your home. Since 1981, AquaCal has maintained the worldwide lead in the manufacture of swimming pool & spa heat pumps. Your new heat pump is not only a great investment, but also the most cost effective method available for heating pools and spas.
  • Page 6: Important Features Of Your New Heat Pump

    Important Features of Your The heart of your heat pump is the patented ThermoLink cause of premature heat pump demise is the failure of the heat exchanger. Ordinary heat exchangers are made from a cupronickel alloy. This cupronickel material is susceptible to attack from the sanitizers used in pools and spas, and from other related water chemistry conditions.
  • Page 7: How A Heat Pump Works

    HOW A HEAT PUMP WORKS HE FOLLOWING EXPLANATION IS PROVIDED TO HELP YOU IN UNDERSTANDING … WHAT TO EXPECT FROM YOUR HEAT PUMP A Heat Pump Does Not Make Heat… Heat pumps are so extraordinarily efficient because they do not need to produce heat in order to warm pool or spa water.
  • Page 8: Safety Information

    Your installer can be one source of service, or AquaCal Customer Support personnel stand ready to assist you at: (800) 786-7751. For questions concerning installation, modifications, operation, service and upkeep, please contact your installer or AquaCal Customer Support.
  • Page 9 Heat pumps contain no owner-repairable components. Repairs must not be attempted by untrained and/or unqualified individuals. If service is deemed necessary, contact installing dealer or AquaCal Customer Support at (800) 786-7751. Refrigerant Circuit Service Only by Qualified, EPA Certified Technician WARNING ! Heater contains refrigerant under pressure.
  • Page 10: Quick Start & Stop

    If unsuccessful using the following instructions, see: "Programming an HP7 Controller," attached following this Manual. HEATING- QUICK START & STOP This brief information is provided as an aide to installers, service personnel, and owners. The intent of this section is to provide rapid access to very basic operational information. Individuals who will be routinely using, installing, maintaining, and servicing this heat pump, are strongly encouraged to read this entire manual.
  • Page 11 HEATING-QUICK START & STOP (continued): 3. To Begin Heating: A. Verify MODE is set to: HEAT (HEA); then, depending on which body of water is to be heated, use the POOL / SPA selector key to select POOL or SPA. B.
  • Page 12: Heater Controls

    HEATER CONTROLS Control Buttons, Indicator Lights, & Display 1) POOL / SPA SELECTOR – Selects either pool or spa thermostat. 2) COOLING INDICATOR LIGHT – Indicates unit is cooling. (Note: this light nonfunctional with heat-only models.) 3) UP ARROW – Increases temperature setting. (Maximum setting is 104 4) DOWN ARROW –...
  • Page 13: Operational & Programming Codes

    CFO... Call Flex Options. This is a programming entry point; when used in conjunction with an AquaCal Call/Flex add on kit, permits the use of CALL or FLEX options. FS... Heater in Defrost Mode (Applicable to Heat-Only Units, only). This code appears as a normal display during periods of lower air temperatures.
  • Page 14: Owner-Level Programming (Complete)

    If unsuccessful using the following instructions, see: "Programming an HP7 Controller," attached following this Manual. HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions (Complete) Covered within this section are features and settings typically accessed first by the installer, and then remaining accessible by the end user (the owner).
  • Page 15 HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions... continued: . Selecting Pool/Spa Thermostat Settings: A. Press the [POOL/SPA] key to toggle between the pool and the spa temperature set points. B. The pool/spa LED indicator lights, located to the left of the temperature display, will confirm the selected set point.
  • Page 16 HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions... continued: 8. User Lock Code Option [ULC]...continued: A. Selecting ULC Option: 1) Press either the UP or DOWN ARROW keys; if “LOC” is momentarily displayed flowed by “0”, the ULC feature is enabled. If “0” displays proceed to “6)” of this section; otherwise, see number “2,”...
  • Page 17 [ELC] is reset to “0.” 3) In addition, all other settings are returned to the factory defaults. If an external controller is in use, contact AquaCal Technical Support Group (800-786-7751); ask for assistance with re-configuring the controller for use with an external controller.
  • Page 18: Maintenance And General Operation

    Should you as the owner desire to perform the coil rinsing and other cosmetic care of the heat pump, please contact AquaCal Customer Support: 1-800-786-7751; request the document titled: “Appearance Care for Air-Source Heat Pumps: Approved Method for Home Owners.”...
  • Page 19: Maintaining Proper Water Flow

    2.0 – 4.0 ppm in pools, 3.0 – 5.0 ppm in spas 7.4 – 7.6 ppm in pools, 7.2 – 7.8 ppm in spas 80 – 140 ppm in pools, 80 – 120 ppm in spas 200 – 400 ppm in pools and spas 1,000 –...
  • Page 20: Controlling Irrigation And Storm Water Run Off

    Please see diagrams, below, for specific clearance requirements. VERHANG WITH GUTTER AIN RUN MUST BE DIRECTED AWAY FROM UNIT 30” MINIMUM CLEARANCE MINIMUM CLEARANCE 100 & 120 M ODELS 155 M ODELS CALE (continued) 100 & 120 M 12-I ODELS NCHES 155 M 24-I...
  • Page 21: Heating Tips

    3 - 4° of heat per night versus 8 - 10° overnight with an un-blanketed pool. Reductions of 40-60% on heating bills can be achieved by using blankets. (Idea...Contact AquaCal Customer Support (800-786-7751) to learn about Liquid Blanket innovations.) WARNING ! Improperly used, Pool-Spa blankets can become a drowning risk to people and pets.
  • Page 22: Calculating Initial Heating Time

    MAINTENANCE & OPERATION The time it takes to initially warm your pool or spa depends on several factors. First, determine how many gallons of water are to be heated. Knowing this, you can then compute the equivalent pounds of water involved, and the BTU's necessary to heat the volume of water to the desired temperature.
  • Page 23: Seasonal Use & Shut Down

    MAINTENANCE & OPERATION Seasonal Use & Shut Down During the Swim Season: • During the swim season, even if the pool or spa is not in use, allow water to flow through the heater. Doing so eliminates the need to reposition valves when you do wish to heat the pool or spa.
  • Page 24: Winterizing Procedure

    MAINTENANCE & OPERATION Winterizing Procedure: 1. Disconnect all electrical power to the heater; turn OFF circulating pump. 2. At the two (2) connection unions, disconnect the plumbing to the heater (removal is counter- clockwise). 3. Locate the hand drain plug at lower, front corner of heater. See Figure-3 (position may vary between models).
  • Page 25: Aquacal Preventive Maintenance Program

    Just as you would have yearly service performed on your air-conditioning system, regular inspection and maintenance of your AquaCal heat pump will insure highest operating efficiencies. A regularly maintained heater will protect your investment, and will potentially extend the useful life of your heat pump far beyond the warranty period.
  • Page 26: Troubleshooting (No Op, No Heat, Water From Unit)

    Is the air blowing out of the top of the unit noticeably cooler than the surrounding air? (A 9°F to 12°F difference is typical.) If not, contact AquaCal for service at: 800-786-7751. But first, be sure all air coil surfaces are free from obstructions– low roof overhangs, landscaping, walls, fences, etc., can restrict air flow.
  • Page 27: Troubleshooting Flowcharts

    . Wait at least the timer to reset. f iv e minutes to allow the timer to reset. Is the unit operating Is the unit operating correctly ? correctly ? Contact Contact AquaCal AquaCal for Assistance at for Assistance at 800-786-7751 800-786-7751...
  • Page 28 .)? of f .)? heater. heater. operation. operation. Problem Problem Solved. Solved. Call AquaCal Call AquaCal for Assistance: for Assistance: 800-786-7751. 800-786-7751. Is the pool pump timer Is the pool pump timer set to allow extended operation of the heater?
  • Page 29 Shut off Water Pump Shut off Water Pump and Call AquaCal for Y es and Call AquaCal for START START Has the "Heating" lamp been Has the "Heating" lamp been...
  • Page 31: Dealer-Specific Information (Installation & Set Up)

    Models 100, 120, & 155 HEATING ONLY HEATING - COOLING Installation Specifications & Controls Configuration...
  • Page 32: Dealer-Specific Table Of Contents

    DEALER-SPECIFIC TABLE of CONTENTS GENERAL SAFETY INFORMATION ------------------------------------ 34 DATA PLATE NOMENCLATURE ----------------------------------------- 34 HEATER SPECIFICATIONS -------------------------------------------- 35 Physical Characteristics (dimensional drawings) ----------------- 35 Performance, Size, Weight, Electrical/Water Needs -------------- 36 INSTALLATION INSTRUCTIONS -------------------------------------- 39 Placement of Heater ----------------------------------------------- 39 Indoor Installations --------------------------------------------- 39 Outdoor Installations ------------------------------------------ 39 Required Clearances -------------------------------------------- 39...
  • Page 33 DEALER-SPECIFIC TABLE of CONTENTS INSTALLATION INSTRUCTIONS (continued): Electrical Requirements ------------------------------------------- 44 General Requirements ------------------------------------------ 44 Code-Specific Requirements ----------------------------------- 44 Connecting External Controllers -------------------------------- 44 Sizing the Electrical Service ------------------------------------ 45 Ground Fault Protection (not recommended) ------------------ 45 CONTROLS CONFIGURATION & ADJUSTMENTS ---------------------- 46 Level-2 (dealer-service) Programming ---------------------------- 46 1.
  • Page 34: General Safety Information

    Heat pumps contain no owner-repairable components. Repairs must not be attempted by untrained and/or unqualified individuals. If service is deemed necessary, contact installing dealer or AquaCal Customer Support at (800) 786-7751. Refrigerant Circuit Service Only by Qualified, EPA Certified Technician WARNING ! Heater contains refrigerant under high pressure.
  • Page 35: Heater Specifications

    SPECIFICATIONS Physical Characteristics 100 & 120 M ODELS 155 M ODELS...
  • Page 36: Performance, Size, Weight, Electrical/Water Needs

    -Performance/Size/Weight- -Water/Electrical Requirements- BTU - 80%RH Air ºF / Water ºF…80/80 Voltage/Hz/Phase Min. Circuit Ampacity Max. Fuse or Breaker Rec. Fuse or Breaker Min-Max Water Flow (gpm) Shipping weight (lbs) Shipping Size (l x w x h) Uncrated Weight (lbs) Uncrated Size (l x w x h) 100 –...
  • Page 37 Shipping Size (l x w x h) 40" X 36" X 44" Uncrated Weight (lbs) Uncrated Size (l x w x h) 34” X 31” X 39” All A-Voltage 120 heaters with model numbers ending in “B”, MCA = 33 120AHDE 120BHDE 109,000 109,000...
  • Page 38 40” x 37” x 47” 40” x 37” x 47” 40” x 37” x 47” 37” x 33” x 41” 37” x 33” x 41” 37” x 33” x 41” 155ARDE 155BRDE 120,000 120,000 208-230/60/1 208-230/60/3 20-70 20-70 40” x 37” x 47”...
  • Page 39: Installation Instructions

    Every indoor installation is unique; therefore, there are no specific guidelines for this type of installation. If considering an indoor installation, you are strongly urged to contact the AquaCal Engineering department (800-786-7751) for assistance prior to proceeding. Service and Operational Clearances: •...
  • Page 40: Irrigation, Rain Runoff, And Landscape Factors

    - AquaCal anchoring kits satisfy, completely, the very stringent Florida Building Code Section 301.13: Wind Anchoring Requirements. -Contact AquaCal Parts Group (800-785-7751) to obtain the correct anchoring kit for the heater being installed. - Please have the heater model number ready when contacting AquaCal Parts Group.
  • Page 41: Plumbing Requirements

    Maximum Operating Pressure: 50-PSI Minimum - Maximum Water Flow Rates • All AquaCal 100, 120, and 155 models are designed to operate successfully at flow rates of 20- to-70 gallons-per-minute (GPM). • Design the plumbing system to maintain at least 20-GPM flow through the heater; the heat pump will not operate correctly, nor reliably, with less than 20-GPM of water flow supplied.
  • Page 42: Plumbing Schematics (Layout Drawings)

    Plumbing Schematic–Flow Exceeding 70-GPM Bypass Check Valve YPICAL (2-HP P Plumbing Schematics–Flow 20 to 70-GPM YPICAL UMP WITH INSTALLATION Plumbing Requirements (continued) REATER THAN LOW LESS THAN OLAR ANELS PILL PILL YSTEM YSTEM...
  • Page 43 INSTALLATION Plumbing Requirements Plumbing Schematics–Flow 20 to 70-GPM (continued) ULTIPLE NSTALLATION UMP WITH EATER 24-I INIUM PACING NCHES Water IN & OUT Connections- Typical (exact location varies by model) For proper operation and maximum efficiency, piping coming from the pump and filter MUST be con- nected to the "IN"...
  • Page 44: Electrical Requirements

    Always satisfy applicable codes and standards. • Multiple heaters installed at same site generally require special sequencing controls (an “ASC” controller will be required). If yours is a multi-heater installation, contact AquaCal Technical Support Group (800-786-7751) for application assistance.
  • Page 45: Sizing The Electrical Service

    Reference the Equipment Data Plate • AquaCal 100, 120, and 155 model heat pumps have two (2) identical data plates affixed: one can be found outside the unit, on right front corner; the second data plate is located behind the front access panel, on the electrical enclosure cover.
  • Page 46: Controls Configuration & Adjustments

    Generally speaking, the installer’s main focus within Level-2 programming will be in configuring for external controller compatibility. And, unless instructed to do otherwise by the AquaCal Technical Support Group, the installer should not adjust sensor calibration or dead-band values.
  • Page 47: Time Delay

    Controls Configuration & Adjustments... Level-2 Microprocessor Programming... continued: 2. Time Delay [dEL]: A. With the [dEL] (4 minute time delay) code message displayed use the [UP] or [DOWN] arrow key to select either “1” to allow the time delay to remain active or “0” to deactivate the time delay.
  • Page 48: Defrost Sensor Calibration

    Controls Configuration & Adjustments... Level-2 Microprocessor Programming... continued: 4. Water Sensor Calibration... continued: C. Follow the steps 1, A through 1, D to enter the service menu. Once [dEL] is displayed, press the [POOL/SPA] key until the display shows [tSC] (Water Temperature Calibration). Using either the [UP] or [DOWN] arrow keys, calibrate the water temperature sensor by increasing or decreasing the numeric value displayed to match the measured water temperature.
  • Page 49: Spa Dead Band Differential (And Adjustment)

    Controls Configuration & Adjustments... Level-2 Microprocessor Programming... continued: 5. Defrost Sensor Calibration... continued: G. Once the correct temperature value has been selected, not pressing any buttons for 15-seconds will allow the controller to save the selection and return to the normal operating mode.
  • Page 50: Changing Service Lock Code & "Back Door" Entry

    Controls Configuration & Adjustments... Level-2 Microprocessor Programming... continued: 7. Pool Dead Band Differential... continued: C. Once the desired dead band value has been selected, not pressing any buttons for 15-seconds will allow the controller to save the selection and return to the normal operating mode.
  • Page 51: Level-2 Set Up & Calibration Codes

    Controls Configuration & Adjustments... Microprocessor Level-2 Set Up & Calibration Codes Service Adjustable Parameters Code Description [LOC] Service Lock Code [dEL] 4-minute Delay on Make [JAO] External Controller Interface [FS2] Flow Switch/Auto T-Stat Switching [tSC] Water Sensor Calibration [dSC] Defrost Sensor Calibration [dBS] Spa Dead Band Differential [dBP]...
  • Page 52: Troubleshooting Using Displayed Codes

    Then, if after working through site-related issues the heater is still not functioning correctly, the Service Representative will offer to set up a service visit. As necessary, please Contact AquaCal Customer Support Group (800- 786-7751).
  • Page 53: Mode Jumper And Positioning

    Controls Configuration & Adjustments... Microprocessor Mode Jumper Positioning The HP7R microprocessor is designed to operate as a Heat-Only or a Heating & Cooling controller. The selection between the two choices is made through the positioning of a mode jumper contained on the microprocessor board.
  • Page 54 Controls Configuration & Adjustments... Microprocessor Mode Jumper Positioning... continued:...
  • Page 55: Defrost Systems (Described And Explained)

    Controls Configuration & Adjustments... Defrost Systems- Described DEFROST CYCLE (HEAT ONLY UNITS): The microprocessor controller monitors the heater’s air-coil temperature, minimizing air-coil freeze- up during cooler weather conditions. If the controller senses air-coil temperatures conductive to mak- ing ice, the heater’s compressor operation is interrupted while the fan is allowed to continue in opera- tion.
  • Page 56: Water Flow Pressure Switch Adjustment

    (see photo P-1, on following page). 3. AquaCal heat pumps may come equipped with either of two (2) water pressure switches: “Len Gordon” or “TecMark” brand (see photos P-2 and P-3, on following page, to determine which brand pressure switch is installed).
  • Page 57 Controls Configuration & Adjustments... Water Flow (Pressure) Switch Adjustment... continued: To Complete the Adjustment Procedure– Either Brand Switch: 1. With electrical power remaining ON to the heater and heater operating, shut off the power to the circulating pump. If the switch has been correctly adjusted, when the water pump stops, the heater will shut off and the “FLO”...
  • Page 58: Contacting The Factory

    CONTACTING THE FACTORY What We Need to Know When You Call Us If you should need to call AquaCal for service or parts, please have the follow- ing information ready: Model: ________________________________ Serial Number: __________________________ Installation Date: ________________________ Having the above information ready will speed the service process and allow us to respond more quickly.
  • Page 59 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ ________________________________________________________________________________________ ___________________________________________________________________________________ ____________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________...
  • Page 60 2737 24th St. North St. Petersburg, FL 33713 1-800-786-7751...
  • Page 61 HEAT PUMP OWNER’S INSTRUCTIONS PROGRAMMING AN HP7 CONTROLLER Identifying an HP7-Equipped Heater To program, HP7 controllers require water flow. In addition, HP7-equipped heaters will NOT be equipped with a “Mode” button on the programming pad. H e a t W a v e H 1 0 0 H 1 2 0 H 1 5 5...
  • Page 62: Getting Familiar With Controls

    GETTING FAMILIAR WITH CONTROLS DIGITAL CONTROLLER – PANEL LAYOUT Control Buttons ( A. Down Arrow – Pressing this key decreases the temperature setting. Setting the temperature below 60°F turns the heat pump off. B. Pool / Spa Selector – Pressing this key selects either the pool or spa mode. Also used to accept programming selections.
  • Page 63 DIGITAL CONTROLLER- OPERATIONAL DISPLAYS HE FOLLOWING CODES WILL BE DISPLAYED AS PART OF THE NORMAL OPERATION OF THE HEATER OPERATIONAL CODES o FLO—No water flow detected. Code message will appear any time the circulating pump is off, or when the heater is not receiving correct water flow.
  • Page 64 GETTING YOUR HEAT PUMP STARTED & STOPPED THIS IS A QUICK-START GUIDE…For more complete information concerning the digital controller features and programming, see: Owner’s Instructions for HP7 Digital Heat Pump Controller, located in the appendix of this manual. 1. Start the water circulator pump. NOTE: T ILTER HEATING...
  • Page 65 GETTING YOUR HEAT PUMP STARTED & STOPPED 8. In operation, whenever the actual (displayed) water temperature falls below the desired set point, the unit will start heating after an initial time delay of 3-4 minutes. NOTE: T HE HEAT PUMP INCORPORATES AN ANTI OPERATION BE INTERRUPTED CONTINUOUS USAGE AND WATER AROUND UNIT o If you have followed the directions up to this point, you should be on your way to...