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Aquacal H/AT100R Owner's Manual And Installation Manual

Pool and spa heat pump
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&7
and
Pool and Spa

Heat Pump

Owner's Manual
Models:
and
H/AT100R
Installation Guide
H/AT120R
Also Applies to:
XL100R
XL120R
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
AQ Tech, 9/24/04

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  Summary of Contents for Aquacal H/AT100R

  • Page 1: Heat Pump

    &7 Pool and Spa Heat Pump Owner’s Manual Models: H/AT100R Installation Guide H/AT120R Also Applies to: XL100R XL120R ATTENTION INSTALLER: ’ OCUMENT IS URCHASER ROPERTY AND IS TO REMAIN WITH THE WNER 1/7/04 AQ Tech, 9/24/04...
  • Page 2 1-800-786-7751 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ ________________________________________________________________________________________ ___________________________________________________________________________________ ____________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________...
  • Page 3: Table Of Contents

    WELCOME TO THE TEAM ------------------------------------------------------- 5 IMPORTANT FEATURES OF YOUR NEW HEAT PUMP ------------------- 6 SAFTEY INFORMATION ---------------------------------------------------------- 7 QUICK START & STOP ------------------------------------------------------------ 9 PHYSICAL CHARACTERISTICS & SPECIFICATIONS -------------------- 10 Dimensional Information----------------------------------------------------------- 10 Specifications ----------------------------------------------------------------------- 11 Data Plate Nomenclature----------------------------------------------------------- 11 INSTALLATION ---------------------------------------------------------------------- 12 Placement of Heater ----------------------------------------------------------------- 12 Plumbing Requirements ------------------------------------------------------------ 13...
  • Page 4 TABLE OF CONTENTS, continued MAINTENANCE ---------------------------------------------------------------------- 22 Planned Maintenance Program ---------------------------------------------------- 22 General Maintenance --------------------------------------------------------------- 23 Maintaining Proper Water Flow --------------------------------------------------- 24 Maintaining Proper Clearances --------------------------------------------------- 24 SEASONAL USE & SHUT DOWN ----------------------------------------------- 24 During the Swim Season ----------------------------------------------------------- 24 Freeze protection / Extended Shut Downs--------------------------------------- 24 Winterizing (Hard Freeze Conditions) ------------------------------------------- 25 TROUBLESHOOTING -------------------------------------------------------------- 28...
  • 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 New Icebreaker Heat Pump ThermoLink Heat Exchanger The heart of your heat pump is the patented ThermoLink heat ex- changer. The primary cause of premature heat pump demise is the failure of the heat exchanger. Ordinary heat exchangers are made from a cupron- ickel alloy.
  • Page 7: Safety Information

    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. Warranties may be voided if the heater has been used, maintained, or repaired improperly.
  • Page 8 WARNING ! 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. WARNING ! Heater contains refrigerant under high pressure. Repairs to the refrigerant circuit must not be attempted by untrained and/or unqualified individuals.
  • Page 9: Quick Start & Stop

    If uncertain about any instructions given herein, AquaCal Customer Support (800-786-7751) should be contacted for additional information. Note: The terms “Heat Pump” and “Heater” are used synonymously.
  • Page 10: Physical Characteristics & Specifications

    PHYSICAL CHARACTERISTICS & SPECIFICATIONS Dimensional Information - Heat Wave/AeroTemp 100-120 Series (All Reversing Models)
  • Page 11: Specifications

    Specifications — H/AT100R & 120R Models 100-SERIES: BTU - 80%RH Air ºF / Air ºF… 80/50 BTU - 63% RH Air ºF / Air ºF… 80/50 Kilowatt Input (80% RH) Voltage/Hz/Phase Min. Circuit Ampacity Rec. Fuse or Breaker Size Max. Fuse or Breaker Size...
  • Page 12: Installation

    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 AquaCal Engineering or Technical departments (800-786-7751) for assistance prior to proceeding.
  • Page 13: Plumbing Requirements

    AquaCal Technical Support for advice and guidance: (800) 786-7751. Parts and Materials: Industry technology changes much too rapidly for AquaCal to specify, with exactness, any items outside and beyond the heat pump. What is specified is that the heater must be installed in accordance with all applicable local, state, or national codes &...
  • Page 14 Failure to heed the following may result in damage to equipment. Use of an incorrect bypass valve may compromise the heat pump’s efficiency, reliability, and may void the factory warranty. When using a bypass valve, order and install only an AquaCal PN: 2556 spring- check bypass valve.
  • Page 15 Plumbing Schematics–Flow 70-GPM and Below (continued) Water IN & OUT Connections: For proper operation and maximum efficiency, piping coming from the pump and filter MUST be connected to the "IN" port of the heater. Likewise, connect piping returning to the pool/spa to the "OUT" port of the heater. See drawing below.
  • Page 16: Electrical Requirements

    ♦ In sizing power wiring, be especially aware of up-sizing requirements necessary due to wiring distances. Always satisfy applicable codes and standards. ♦ Multiple heaters installed at same site generally require special sequencing controls (AquaCal P.N.: ASC-(+number of heaters)); if yours is a multi-heater installation, contact AquaCal Technical Support (800-786-7751) for application assistance.
  • Page 17: Start-Up & Operation

    START-UP & OPERATION Getting Familiar with Controls Heat Wave/AeroTemp 100R &120R Control Panel Features 1) POWER LIGHT – Indicates electrical power is supplied to the heater. 2) FLOW LIGHT – Indicates water pressure (flow) is present at the heater. 3) DEFROST LIGHT – Indicates heater is in the defrost mode. 4) HIGH REFRIGERANT PRESSURE –...
  • Page 18: Overview Of Controls

    (Please refer to control panel diagram on previous page.) POOL/OFF/SPA (P/O/S) Toggle Switch and Sequence of Operation With the toggle switch in the OFF (O) position, the heater will be prevented from operating (however, there may be power to the unit; see "Power Light On", below). With the toggle switch positioned toward the SPA or POOL thermostat knob, with HEAT selected, and with the following conditions met: 1) water pump in operation, with water flowing through the heater, and, 2) electrical power to the heater, the heater will run if the water temperature drops below the thermostat setting.
  • Page 19 3. Select POOL or SPA & HEAT or COOL, Raise or Lower Associated Thermostat: ♦ Position the POOL/OFF/SPA toggle towards the POOL or SPA thermostat knob (depending on which body of water you are preparing to heat or cool). ♦ For Heating, move HEAT/COOL toggle to HEAT, then turn the selected pool or spa thermostat dial clockwise to its highest setting.
  • Page 20: Heating Tips

    Your system can be automated with the addition of an optional AquaCal Universal Heater Controller (AquaCal part #0097TS). Using this option will save you from having to change the thermostat switch each time you change from pool to spa and back again. For details, contact your installing dealer.
  • Page 21: Calculating Initial Heating Time

    Hrs. of Operation at 60º F O.A. When you start your AquaCal heat pump for the first time, the heat pump must be permitted to operate, continuously, until the desired water temperature is attained. This may take several hours, to several days, depending upon the time of the year and weather conditions.
  • Page 22: Maintenance

    > Check Water Temperature Change Through Condenser We recommend all AquaCal heat pump owners take advantage of this annual service starting one year after the installation of the unit. You will be surprised at the minimal cost of this service– the service is very reasonably priced for what is included.
  • Page 23: General Maintenance

    Additionally, if the heat pump is located on the beach, or at a sea wall where salt spray and sand can become detrimental factors, more frequent service may be necessary. For service plan information, please see: Planned Maintenance Program, on previous page, and then contact AquaCal Customer Support at: 800- 786-7751.
  • Page 24: Maintaining Proper Water Flow

    ♦ If the conditions listed above remain unresolved, the water flow through the heater may be reduced to a point where internal safety devices shut the heater off. Before calling for service, always check the filter, the pump basket, and water valve positions. If the problem persists, call AquaCal Customer Support at: (800) 786-7751.
  • Page 25: Winterizing (Hard Freeze Conditions)

    SEASONAL USE & SHUT DOWN (CONTINUED): Winterizing (Hard Freeze Conditions) WARNING ! To avoid injury from rotating equipment (fan blade), disconnect electrical power from heat pump before proceeding with INTERNAL DRAIN winterizing process. CAUTION ! Failure to properly winterize heat pump may result in serious equipment damage. Freeze damage is not covered under the heat pump warranty.
  • Page 26 Winterizing a Heat Pump Equipped with an Internal Drain Figure 1 On the side Winterizing a Heat Pump Equipped with an External Drain 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 counterclockwise). 3.
  • Page 27 Winterizing a Heat Pump Equipped with an External Drain CAUTION ! While the plumbing connections are in the winterized condition (not fully tightened), it is imperative pool/ spa water not be circulated through the heat pump. Loss of water through loose plumbing connections may result in damage to circulating pump, pool-spa structure, and/or other equipment.
  • Page 28: Troubleshooting

    (5) minute delay. If the heat pump still fails to start, and the unit is not in defrost (defrost light lit), contact AquaCal Customer Support: 800-786-7751.
  • Page 29: Troubleshooting Flow Charts

    Wait at least five minutes to allow the minutes to allow the timer to reset. timer to reset. Is the unit operating Is the unit operating correctly? correctly? Contact Contact AquaCal for AquaCal for Assistance at: Assistance at: 800-786-7751 800-786-7751...
  • Page 30 (defrost light off), and is discharge air now 9-12 degrees cooler than (defrost light off), and is discharge air now 9-12 degrees cooler than the outside air? the outside air? Call AquaCal for Call AquaCal for Assistance: Assistance: 800-786-7751. 800-786-7751.
  • Page 31 Problem Problem Solved. Solved. Call AquaCal for Call AquaCal for Assistance: Assistance: 800-786-7751 800-786-7751 If heater has not run recently, If heater has not run recently, and water is coming...
  • Page 32 Pool/Spa returns. flow at Pool/Spa returns. Be sure the evaporator is clean Be sure the evaporator is clean and free of air restricting and free of air restricting obstructions. obstructions. Call AquaCal for Assistance: Call AquaCal for Assistance: 800-786-7751 800-786-7751...
  • Page 33: Adjusting Water Flow (Pressure) Switch

    2. Reinstall heater front cover. Should adjustment of the water pressure switch prove unsuccessful, contact AquaCal technical support (800-786-7751); site-specific factors may require the installation of an external flow switch.
  • Page 34 Water Pressure Switch Adjustment (continued) P-1, WPS Location P-2, Len Gordon Style Switch P-3, TecMark Style Switch...
  • Page 35: Defrost System: Description & Troubleshooting

    Defrost System: Description and Troubleshooting Heat wave and AeroTemp Icebreaker models incorporate an active, time and temperature, hot-gas defrost system. Basically stated, when an evaporator coil thermostat senses a significant icing condition, the control circuit reverses the flow of refrigerant, sending hot refrigerant vapor to the outdoor coil. The effect is a rapid melting of ice and frost, and a quick return to the normal heating mode.
  • Page 36 WARNING ! 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. The following defrost system troubleshooting procedures to be performed by authorized service personnel only.
  • Page 37: Troubleshooting Problems In The Refrigerant Circuit

    Troubleshooting Refrigerant Circuit Problems NOTICE: Refrigerant Circuit Service by EPA Certified Individuals Only WARNING ! Heater contains refrigerant under high pressure. Repairs to the refrigerant circuit must not be attempted by untrained and/or unqualified individuals. Service must be performed only by qualified HVAC technicians.
  • Page 38: Refrigerant Circuit Performance (T-P) Charts

    Troubleshooting Refrigerant Circuit Problems (Continued) TXV Stuck Open: • Head pressure will be slightly to moderately low; • Suction pressure will be slightly high to very high; • Amperage (not a reliable indicator of this condition); • Liquid subcooling will be lower than normal; •...
  • Page 39 Refrigerant Circuit Performance Charts (continued) Refrigerant Circuit Performance Charts: A & B Voltage Models Spa Condition: Water @ 104ºF & 45 GPM, Ent. Air: 80 ºF - 63% R.H. Model Discharge Suction Pressure Pressure PSIG H/AT100”X”R H/AT120”X”R Standard Condition: Water @ 80ºF & 45 GPM, Ent. Air: 80 ºF - 63% R.H. Model Discharge Suction...
  • Page 40 Refrigerant Circuit Performance Charts (continued) Refrigerant Circuit Performance Charts: D & H Voltage Models Spa Condition: Water @ 104ºF & 45 GPM, Ent. Air: 80 ºF - 63% R.H. Model H/AT100”X”R H/AT120”X”R Standard Condition: Water @ 80ºF & 45 GPM, Ent. Air: 80 ºF - 63% R.H. Model H/AT100”X”R H/AT120”X”R...
  • Page 41: Replacement Parts

    CON. PANEL ASSY. ECA0209 ECA0209 ACCESS PANEL HPA0216 HPA0216 FRONT PANEL HPA0218 HPA0218 ELEC. ENC. COVER HPA0214 HPA0214 To order replacement parts, contact AquaCal Customer Support: (800) 786-7751 H/AT100-120”X”R H100DR H100HR PLA0203 PLA0203 PLA0202 PLA0202 PCP0015 PCP0015 ACP0005 ACP0005 CPA0215...
  • Page 42: Contacting The Factory

    CONTACTING THE FACTORY What We Need to Know When You Call Us If you should need to call AquaCal for service, please have the following information ready: Model: ________________________________ Serial Number: __________________________ Installation Date: ________________________ Having the above information ready will speed up the service process and allow us to respond more quickly.
  • Page 43 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ ________________________________________________________________________________________ ___________________________________________________________________________________ ____________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________________...
  • Page 44 2737 24th St. North St. Petersburg, FL 33713 1-800-786-7751...