Aquacal Heat Pump manual

1 Attention Installer: This manual is purchaser’s property; leave with heat pump owner! PN: L TP0048 REV 2 01/07/10 AquaCal AutoPilot Pool & Spa Heat Pump Owner ’ s Manual and Installation Guide MODEL / SERIAL NUMBER[...]

NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ ___________[...]

3 TABLE OF CONTENTS WELCOME TO THE TEAM ---------------------------------------------- 5 HEA T PUMP OPTI ONS ------------------------------------------------- 6 HOW A HEA T PU MP WORKS ------------------------------------------ 7 SAFETY INFORMA TION ------------------------------------------------ 8 QUICK ST ART & ST OP ------------------------[...]

4 TABLE OF CONTENTS (CONTINUED) MAINTENANCE AND GENERAL OPERA TION...CONTINUED: Heating Tips -------------------------------------------------------- 21 - Heating in Cooler W eather -------------------------------------- 21 Pool/Spa Blankets ----------------------------------------------- 21 Pool & Spa Combination Heating ----------------------[...]

5 Dear Owner: C ongratulations on your wise decision to make an AquaCal heat pump part of your home. Since 1981, AquaCal has has been recognized as the worldwide leader in the manufacture of swimming pool & spa heat pumps. Y our new heat pump is not only a great investment, but also the most cost efficient method avail- able for heating pools a[...]

6 Corrosion-Proof Cabinet The cabinet, being made from resilient, UV-Protected ABS material, has superior fade resistance and can never rust or corrode. Y ou can expect the cabinet to retain a like- new appearance with only an occasional wash down and—if so desired—a quick waxing. PLEASE READ FUR THER T O BECOME F AMILIAR WITH ALL THE FEA TURES[...]

7 HOW A HEA T PUMP WORKS T HE FOLLOWING EXPLANA TION IS PROVIDED TO HELP YOU IN UNDERST ANDING WHA T TO EXPECT FROM YOUR HEA T 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 . Rather , heat pumps simply transfer heat from the outside [...]

8 Used and maintained properly , your heat pump will provide year-upon- year of safe and economical service. However , as with any mechanical or electrical device, to get the most from your heat pump–while insuring personal safety for you and others–certain operational and maintenance factors must be observed. Likewise, excepting a few minor ow[...]

9 Refrigerant Circuit Service Only by Qualified, EP A Certified T echnician Notice: Heater NOT Rep airable by Owner W ater Chemistry Safety W ater T emperature Safety W ARNING ! Failure to heed the following may result in permanent injury or death. Heat pumps contain no owner-repairable components. Repairs must not be attempted by untrained and/or [...]

10 HEA TING- QUICK ST ART & ST OP Getting Started (Quick-Start & Stop Continued Next Page) 1. V erify Electrical Power is Present at Heater: A . Ensure that the unit has electrical power connected; the heater controller display should be illuminated. B. If the display is blank, be certain the electrical breaker , and heater disconnect, are [...]

11 N OTE : T HE HEA TER CONTROLLER INCORPORA TES AN ANTI - SHORT CYCLE TIME DELA Y . S HOULD OPERA TION BE INTERRUPTED , COMPRESSOR REST ART WILL BE DELA YED BY APPROXIMA TEL Y 4- MINUTES . HEA TING-QUICK ST ART & ST OP (continued): (End...Quick-Start & Stop) 6. T o Stop the Heat Pump: A . Select: OFF via the MODE selector . This method of [...]

12 HEA TER CONTROLS Control Panel Layout (A PPEARANCE V ARIES BY M ODEL ) Control Buttons, Indicator Light s, & Display ( AS INDICA TED BY CIRCLED NUMBERS ) 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 [...]

13 T HE FOLLOWING CODES WILL BE DISPLA YED AS PA R T OF THE NORMAL OPERA TION OR PROGRAMMING OF THE HEA TER : Operational & Programming Codes FLO ..... No W ater Flow Detected. This code appears whenever the circulating pump is off, or when the heater is not receiving correct water flow . OFF ..... System is Off. This code appears whenever heat[...]

14 HEA TER CONTROLS...continued S tart Up & Setting Operating Controls This section covers features and settings topically accessed first by the installer , and also accessible to the owner/operator . These features reside at the Level-1 access point within the microprocessor . Note: if preferred, all programming may be performed without water [...]

15 4 . Selecting Pool/Spa Thermostat Settings: A . Press the [POOL/SP A] key to toggle between the pool and the spa temperature set point s. B. The pool/spa LED indicator light s, located to the lef t of the temperature display , will confirm the selected set point. 5. Changing The Pool T emperature Set Point: A . Using the [POOL/SP A] key , select[...]

16 S tart Up & Setting Operating Controls (ULC Continued on Next Page) 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 followed by “0”, the ULC feature is enabled. If “0” displays proceed to “6)” of this section; otherwise, see numb[...]

17 S tart Up & Setting Operating Controls 9. Selecting Call-Flex Pump Options [CFO]: General Information: The Call-Flex option automatically extends or overrides the run time of the water circulator pump, and heater , based upon changing weather conditions. Without Call-Flex, as weather conditions grow progressively cooler during winter months,[...]

18 MAINTENANCE OPERA TIONAL RECOMMENDA TIONS & The information in this section is written primarily for the Home Owner , but may also apply to servicing dealers or HV AC service centers. This section cont ains information concerning planned maintenance, proper water flow , maintaining proper clearances, as well as other vital information. Pleas[...]

19 • It is important to operate and maintain the filter according to the manufacturer's specifications. As a filter gets dirty , the water flow to the heat pump is reduced. The higher the pressure on the filter gauge, the lower the flow rate. • Similar to a dirty filter , large amounts of debris in the pump and skimmer baskets can reduce w[...]

20 Maint ain Proper Clearances Around Heater • For maximum efficiency , proper air flow clearances around heater must be maintained. • It is important to keep the area immediately adjacent to the heat pump clear of items such as shrubs and bushes, lawn furniture, chemicals containers, etc. These items can prevent air from circulating fully thro[...]

21 S p a Heating & Sp a Setback Option... Air blowing into your spa, while it is being brought to temperature, will very often neutralize or partially counteract the heat being put into the spa by the heater; this added heat loss equates to increased time to bring your spa to desired temperature. When heating a sp a, be sure to turn of f the ai[...]

22 Calculating Initial Heating Time 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. Next, find [...]

23 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. • During periods when heating or cooling is not desired, leave heater controls in the OFF po[...]

24 Winterizing Procedure Continued: Location of External Drain Plug will vary by model MAINTENANCE & OPERA TION (continued) 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. If your unit has an external drain[...]

25 Planned 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 [...]

26 Heat Pump Fails to Operate... Is the display illuminated? If not, ensure the main breaker (located at the power supply panel) and the disconnect switch (located near the heat pump) are both turned ON. Is the code “FLO” displayed? If so, check to be sure that the circulating pump is operating and the filter is clean. There may also be a valve[...]

27 TROUBLESHOOTING FLOWCHART Heat Pump Fails to Operate I s t he heat er operat ing c orrect ly ? I s t he heater operat ing correc t ly ? I s t he heat er operat ing c orrect ly ? I s t he heat er operat ing c orrect ly ? T he heat er is equipped w it h a f iv e minut e delay . W ait at leas t f i v e mi n u te s to a l lo w th e ti mer to r ese t[...]

28 TROUBLESHOOTING FLOWCHART STA RT I s t he air being dis c harged out of t he t op of t he heat er 9-12 degrees c ooler t han t he out s ide air? STA R T I s t he air being dis c harged out of t he t op of t he heat er 9-12 degrees c ooler t han t he out s ide air? I s t he pool pum p t im er s et t o all ow ex t ended operat ion of t he heat er?[...]

29 W ater Coming from Heat Pump STA R T H as t he " H eat ing" lam p been illum inat ed? STA R T H as the "H eat ing" lam p been illum inat ed? Sh u t o f f Wa te r Pu mp a n d Ca ll Aq u a Ca l f o r A ssist ance: 800-786-7751 S hut o ff W ate r P um p a n d Ca ll Aq u a Ca l f o r A ssist ance: 800-786-7751 W hen t he heater i[...]

30 INST ALLER-SPECIFIC INFORMA TION FOLLOWS Installation Specifications Controls Configur ation & AquaCal AutoPilot Pool & Spa Heat Pump[...]

31 INSTALLER-SPECIFIC TABLE of CONTENTS GENERAL SAFETY INFORMA TION ------------------------------------ 33 DA T A PLA TE NOMENCLA TURE ----------------------------------------- 33 HEA TER SPECIFICA TIONS -------------------------------------------- 34 Physical Characteristics (dimensional drawings) ----------------- 34 INST ALLA TION INSTRUCTIONS [...]

32 INST ALLA TION INSTRUCTIONS (continued): Electrical Requirements ------------------------------------------- 44 General Requirements ------------------------------------------ 44 Code-Specific Requirements ----------------------------------- 44 Connecting External Controllers -------------------------------- 44 Sizing the Electrical Service ----[...]

33 Notice: Heater NOT Rep airable by Owner Refrigerant Circuit Service Only by Qualified, EP A Certified T echnician SAFETY INFORMA TION DA T A PLA TE NOMENCLA TURE W ARNING ! Failure to heed the following may result in permanent injury or death. Heat pumps contain no owner-repairable components. Repairs must not be attempted by untrained and/or un[...]

34 100 & 120 SPECIFICA TIONS Physical Characteristics[...]

35 SPECIFICA TIONS Physical Characteristics[...]

36 SPECIFICA TIONS Physical Characteristics[...]

37 SPECIFICA TIONS Physical Characteristics 135, 155, & 175[...]

38 SPECIFICA TIONS Physical Characteristics[...]

39 Required Inst allation Clearances Code Required Clearances: In addition to the previously stated clearance requirements, follow all applicable local, state, and national requirements relative to spacing from other objects or equipment. Placement of Heater Indoor installations can be problematic, and for that reason are discouraged. However , if [...]

40 Irrigation, Rainwater Runoff, and Landscape Features • Place the heat pump away from direct rain runoff from roofs. If roof slope directs runoff into the heater , a gutter or rain shield will be required on the roof edge above the heat pump. • Relocate or adjust irrigation to avoid water spray onto the heat pump. • Do not locate the heat p[...]

41 Plumbing Requirement s Overview When planning plumbing system layout, reference the plumbing schematics within this section as a guide to the sequence of equipment, valves, fittings, etc. The plumbing configurations for typical instal- lations are diagrammed. In operation, it is imperative the heat pump receive water flow within the minimum-maxi[...]

42 General Plumbing Schematic–Flow Exceeding 70-GPM Plumbing Requirement s (continued) INST ALLA TION General P lumbing Schematics – Flow 30 to 70-GPM T YPICAL P OOL - F LOW LESS THAN 70- GPM P OOL /S PILL O VER S PA - T WO P UMP S YSTEM H EA T P UMP WITH S OLAR P ANELS P OOL /S PILL O VER S PA - O NE P UMP S YSTEM W ater flow exceeding 70-GPM [...]

43 General P lumbing Schematics – Flow 30 to 70-GPM (continued) For proper operation, 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 . Plumbing Requirement s INST ALLA TION W ater IN[...]

44 General Requirement s • Locate the equipment disconnect means within 3-feet of the heater ’s electrical enclosure, or as close to the heater as possible. Always satisfy applicable codes and standards. • AquaCal heat pumps are designed for copper conductors, only . Never mount disconnect directly to heat pump. • In sizing power wiring, be[...]

45 • All AquaCal heat pumps have two (2) identical data plates af fixed: 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 . • Refer to either equipment data plate for unit-specific electrical power supply requirements. • Based on data pl[...]

46 1. Entering Service Menu: A . T o enter the service menu, Simultaneously press and hold both the [UP ARROW] and [DOWN ARROW] keys until [CF1] (Celsius / Fahrenheit) code appears. (Note: if “000” displays, the User Lock Code is enabled, and the ULC pass code must be entered before proceeding. See Owner-Level Operating Instructions, page-15: ?[...]

47 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 . Not pressing any buttons for 15 seconds will allow the controller to save the selection and return to the normal operatin[...]

48 4. W ater Sensor Calibration... continued: C. Follow the steps 1, A through 1, D to enter the service menu. Once [dEL] is displayed, press the [POOL/SP A] key until the display shows [tSC] (W ater T emperature Calibration). Using either the [UP] or [DOWN] arrow keys, calibrate the water temperature sensor by increasing or decreasing the numeric [...]

49 Controls Configuration & Adjustment s... 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. Pressing the [POOL/SP [...]

50 Controls Configuration & Adjustment s... 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. Pressing the {POOL/SP A][...]

51 Controls Configuration & Adjustment s... Microprocessor Factory Default Settings Level –1 and Level-2 Default Settings Microprocessor Level-2 Set Up & Calibration Codes Service Adjust able Parameters Code Description Factory Setting Range [LOC] Servic e L ock Code 50 00-99 [dEL] 4-minut e Delay on M ake 1 0 / 1 [JAO] External Contro ll[...]

52 T roubleshooting Using Displayed Codes Interpreting Error Codes The HP7R heat pump microprocessor controller is designed to be self-diagnostic through the display of various fault codes. Owners & Operators: If you believe you are experiencing a problem with the heater , and feel a need to call the factory for assistance, it will be beneficia[...]

53 1. Apply electrical power to the heater . 2. Review the available modes by repeatedly pressing the [MODE] key: A. Heat-Only Models: the [MODE] key functions should appear as: [OFF] and [HEA]. B. Heat-Cool Models (Icebreakers): the [MODE] key functions should appear as: [OFF], [HEA], [COO], and [AHC]. 3. If the modes do not display correctly for [...]

54 Controls Configuration & Adjustment s... Microprocessor Mode Jumper Positioning... continued:[...]

55 Defrost Systems- Described DEFROST CYCLE (HEA T & COOL UNITS): The microprocessor controller , in conjunction with the defrost sensor , constantly monitors the heater ’ s evaporator (air-coil) temperature. Should the controller sense ice or frost has formed on the evapora- tor , sufficient in amount as to affect the heater’s performance,[...]

56 W ater Flow (Pressure) Switch Adjustment Occasionally , plumbing system design features will create a situation whereas the heater will abnor- mally cycle on the water flow circuit. This situation will be evident if the circulator pump is operating, the filter is clean, and all water valves are set to flow water through the heater– but the err[...]

57 T o 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” code will display . CAUTION: If the heater continues t[...]

58 What W e Need to Know When Y ou Call Us If you should need to call AquaCal for service or part s, please have the follow- ing information ready: Model: ________________________________ Serial Number: __________________________ Installation Date: ________________________ Having the above information ready will speed the service process and allow [...]

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60 2737 24th St. North St. Petersburg, FL 33713 1-727-823-5642[...]