AquaCal AutoPilot Pool & Spa Heat Pump Owner’s Manual MODEL / and Installation Guide SERIAL NUMBER Attention Installer: This manual is purchaser’s property; leave with heat pump owner! 1 PN: LTP0048 REV 2 01/07/10
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TABLE OF CONTENTS WELCOME TO THE TEAM ---------------------------------------------- 5 HEAT PUMP OPTIONS ------------------------------------------------- 6 HOW A HEAT PUMP WORKS ------------------------------------------ 7 SAFETY INFORMATION------------------------------------------------ 8 QUICK START & STOP ------------------------------------------------- 10 HEATER CONTROLS --------------------------------------------------- 12 Control Panel Layout -----------------------------------------------12 Butto
TABLE OF CONTENTS (CONTINUED) MAINTENANCE AND GENERAL OPERATION...
Welcome to the Team 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. Your new heat pump is not only a great investment, but also the most cost efficient method available for heating pools and spas.
Heat Pump Options ThermoLink® Heat Exchanger The heart of your heat pump is the patented ThermoLink® heat exchanger. One of the primary causes 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. Once the heat exchanger fails, the heat pump is ruined.
HOW A HEAT PUMP WORKS THE 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. Rather, heat pumps simply transfer heat from the outside air into the water.
SAFETY INFORMATION 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.
Notice: Heater NOT Repairable by Owner WARNING ! 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 unqualified individuals. If service is deemed necessary, contact installing dealer or AquaCal Customer Support at (727) 823-5642. Refrigerant Circuit Service Only by Qualified, EPA Certified Technician WARNING ! Failure to heed the following may result in permanent injury or death.
Getting Started HEATING- QUICK START & STOP This brief information is provided as an aid 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. Herein, the terms: Heat Pump, Heater, and Unit are used synonymously.
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. Position water valves to flow water from the pool or spa, through the heater, and back to the pool or spa. C. Start the water pump; the fan will start, and after 4-minute time delay the unit will begin heating.
HEATER CONTROLS Control Panel Layout (APPEARANCE VARIES BY MODEL) Control Buttons, Indicator Lights, & Display (AS INDICATED 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 ARROW – Increases temperature setting. (Maximum setting is 104 oF) 4) DOWN ARROW – Decreases temperature setting.
HEATER CONTROLS...continued Operational & Programming Codes THE FOLLOWING CODES WILL BE DISPLAYED AS PART OF THE NORMAL OPERATION OR PROGRAMMING OF THE HEATER: FLO..... No Water 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 heater has been turned off via the mode selector button, or when the temperature set point has been lowered below 45 oF. CFI......
HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions 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 flow, waiting to start the water pump as the last step in the set up and run process. 1. Applying Power to The Controller: A.
HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions... continued: 3. Turning The Heat Pump Off... continued: B. Method 2: using the DOWN key, press the key until the desired water temperature reaches 45oF (minimum setting); then, press the DOWN key one more time, causing the display to read “OFF”. 4. Selecting Pool/Spa Thermostat Settings: A. Press the [POOL/SPA] key to toggle between the pool and the spa temperature set points. B.
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 followed by “0”, the ULC feature is enabled. If “0” displays proceed to “6)” of this section; otherwise, see number “2,” below.
HEATER CONTROLS...continued Start Up & Setting Operating Controls Owner-Level Programming Instructions... continued: C. User Lock Code is Activated, but Pass Number is Not Known (“Back Door Entry”): Note: Should the ULC option be enabled, and a lock code number other than the factory default (0) be installed but is unknown, the following procedure may be followed to regain controller programming access: 1) Simultaneously press and hold the [POOL/SPA] and [UP ARROW] keys until the display shows “888”.
MAINTENANCE & OPERATIONAL RECOMMENDATIONS The information in this section is written primarily for the Home Owner, but may also apply to servicing dealers or HVAC service centers. This section contains information concerning planned maintenance, proper water flow, maintaining proper clearances, as well as other vital information. Please read this section now, and before calling AquaCal Customer Support (727-823-5642).
MAINTENANCE & OPERATION (continued) Maintain Proper Water Flow • 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 water flow. Keep baskets free of debris. • Check for improper valve settings.
MAINTENANCE & OPERATION (continued) Control Irrigation and Storm Run Off • Control Irrigation: Irrigation water spray can damage heater components. Regardless of water quality, it is important that irrigation be directed away from the heat pump. • Prevent rain water runoff from pouring directly into the heater. The heater is designed to withstand normal rainfall, but solid streams of water from roof drip-lines may eventually damage heat pump components.
MAINTENANCE & OPERATION (continued) Heating Tips Heating in Cooler Weather... Late night and early morning, generally being the coolest times of the day, are least efficient for heating. For most efficient heating operation, heat pumps should be timed to operate during the warmest, daylight portions of the day. Conversely, if cooling a pool, it is best to run the equipment at night. Please set water pump and heat pump controls accordingly. Pool/Spa Blankets...
MAINTENANCE & OPERATION (continued) 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 the approximate BTU output of your heat pump at the current ambient air temperature; see product literature at: www.aquacal.
MAINTENANCE & OPERATION (continued) 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 position. Important !!! Information Critical to the Survival of Your Heater Follows...
MAINTENANCE & OPERATION (continued) Winterizing Procedure 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 counterclockwise). 3. If your unit has an external drain plug, remove plug. This plug would be located at lower, front corner of heater. (position may vary between models). Allow water to drain out of the condensor. DO NOT replace plug until final winterizing step.
MAINTENANCE & OPERATION (continued) 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 the warranty period.
TROUBLESHOOTING Heat Pump Fails to Operate... Is the display illuminated? .. 51. e pag es” e e d o s or Co s l A r “Er 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 positioned incorrectly allowing water to bypass the heat pump.
TROUBLESHOOTING FLOWCHART Heat Pump Fails to Operate START START Y es No Is theDisplay Illuminated?, Is theDisplay Illuminated?, Display is illuminated. If Display is illuminated. "FLO" is display ed, If "FLO" is display ed, check to be sure the check to be sure circulating pump is the circulating pump is operating and the f ilter andmay the f ilter isoperating clean. There is clean. also be a vThere alv e may also incorrectly be a v alv e . positioned positioned incorrectly .
TROUBLESHOOTING FLOWCHART Heat Pump Running...
TROUBLESHOOTING FLOWCHART Water Coming from Heat Pump START START Has the "Heating" lamp been illuminated? Has the "Heating" lamp been illuminated? Y es When the heater is operating, thetoheater is operating, it isWhen normal produce up to 8 itgallons is normal to produce up to 8 of condensation gallons condensation (water) per of hour. If water (water)seems per hour. If water drainage excessiv e, proceed seems to TESTING. drainage excessiv e, proceed to TESTING.
AquaCal AutoPilot Pool & Spa Heat Pump Installation Specifications & Controls Configuration C I F I C E P S R E L N L O A I T T A INS M R O F S IN W O L L FO 30
INSTALLER-SPECIFIC TABLE of CONTENTS GENERAL SAFETY INFORMATION ------------------------------------ 33 DATA PLATE NOMENCLATURE ----------------------------------------- 33 HEATER SPECIFICATIONS -------------------------------------------- 34 Physical Characteristics (dimensional drawings) ----------------- 34 INSTALLATION INSTRUCTIONS -------------------------------------- 39 Placement of Heater ----------------------------------------------- 39 Indoor Installations ---------------------------------------
INSTALLER-SPECIFIC TABLE of CONTENTS (CONTINUED) 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 CONFIGURA
SAFETY INFORMATION Notice: Heater NOT Repairable by Owner WARNING ! 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 unqualified individuals. If service is deemed necessary, contact installing dealer or AquaCal Customer Support at (727) 823-5642.
SPECIFICATIONS Physical Characteristics 100 & 120 34
SPECIFICATIONS Physical Characteristics 35
SPECIFICATIONS Physical Characteristics 36
SPECIFICATIONS 135, 155, & 175 Physical Characteristics 37
SPECIFICATIONS Physical Characteristics 38
INSTALLATION Placement of Heater -Indoor InstallationIndoor installations can be problematic, and for that reason are discouraged. However, if no viable alternative exists, indoor installations may be successfully accomplished provided very exacting criteria is addressed. Every indoor installation is unique; therefore, there are no specific guidelines for this type of installation.
INSTALLATION - PLACEMENT OF HEATER (continued) 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 pump directly adjacent to plants, shrubs, or bushes.
INSTALLATION Plumbing Requirements 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 installations are diagrammed. In operation, it is imperative the heat pump receive water flow within the minimum-maximum ranges specified for the particular heat pump.
INSTALLATION Plumbing Requirements (continued) CAUTION ! Failure to heed the following may result in damage to equipment. Water flow exceeding 70-GPM may damage titanium condenser; such damage will NOT be covered under the equipment warranty. Install a bypass check valve (AquaCal P.N.: 2556, or equal to Del Industries P.N.: CO-0103) whenever water flow rate may exceed 70-GPM. Contact AquaCal Technical Support (727-823-5642) for guidance regarding testing for water flow rate.
INSTALLATION Plumbing Requirements General Plumbing Schematics – Flow 30 to 70-GPM (continued) HEAT PUMP WITH GAS HEATER BACK UP MULTIPLE HEAT PUMP INSTALLATION MINIMUM 30 GPM TO EACH HEATER MINIUM SPACING 24-INCHES Water IN & OUT Connections- Typical (exact location varies by model) 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.
INSTALLATION Electrical Requirements WARNING! Failure to heed the following may result in permanent injury or death. Installation made by unqualified persons can result in hazards to the installer and others. The information contained in this Electrical Installation section is intended for use by qualified electrical installation technicians, familiar with electrical service industry safety standards and methods. Electrical installation to be performed by qualified individuals only.
INSTALLATION Electrical Requirements (continued): Sizing the Electrical Service... Reference the Equipment Data Plate • All AquaCal 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. • Refer to either equipment data plate for unit-specific electrical power supply requirements.
Controls Configuration & Adjustments Level-2 (Dealer-Service) Microprocessor Programming (Includes Configuration for External Controllers) Level-2 programming involves configuring the heat pump microprocessor for specific site characteristics. To explain: this programming is where the heat pump microprocessor is set to operate with, or without, an external “pool equipment” controller; where sensor calibrations are performed; and where changes to other factory default parameters are made.
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. Not pressing any buttons for 15 seconds will allow the controller to save the selection and return to the normal operating mode.
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.
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. Pressing the [POOL/SPA] key will also save the selection and step to the next menu parameter: [dBS] (Dead Band for Spa). H. Return system controls to desired mode of operation. 6.
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. Pressing the {POOL/SPA] key will also save the selection and step to the next menu parameter: [LOC] (LOCK CODE). 8. Changing the Service Lock Code and “Back Door” Entry: A.
Controls Configuration & Adjustments...
Controls Configuration & Adjustments... Troubleshooting 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 beneficial to let the factory Service Representative know if any code is being displayed.
Controls Configuration & Adjustments... Microprocessor Mode Jumper Positioning Mode Jumper Explained 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. The position of the jumper is set at the factory, and is dependant upon the design of the heater being controlled.
Controls Configuration & Adjustments... Microprocessor Mode Jumper Positioning...
Controls Configuration & Adjustments... Defrost Systems- Described DEFROST CYCLE (HEAT ONLY UNITS): The microprocessor controller monitors the heater’s air-coil temperature, minimizing air-coil freezeup during cooler weather conditions. If the controller senses air-coil temperatures conductive to making ice, the heater’s compressor operation is interrupted while the fan is allowed to continue in operation. With the compressor off, the air-coil begins to warm to the surrounding air temperature.
Controls Configuration & Adjustments... Water Flow (Pressure) Switch Adjustment Occasionally, plumbing system design features will create a situation whereas the heater will abnormally 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 error code: “FLO” remains displayed (or displays intermittently).
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” code will display.
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 following information ready: Model: ________________________________ } Look for this information on sticker located at top of front cover of this manual; otherwise, see data plate on side of heater. } Refer to installer’s invoice for this information.
2737 24th St. North St.
