Instruction/ maintenance manual of the product 100 Aquacal
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1 1/7/04 A TTENTION INST ALLER: T HIS D OCUMENT IS P URCHASER ’ S P ROPER TY AND IS TO REMAIN WITH THE H EA T P UMP O WNER Pool and Spa Heat Pump Owner ’ s Manual and Installation Guide PN: L TP00.
2 1-800-786-7751 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ __________.
3 TABLE OF CONTENTS WELCOME TO THE TEAM ---------------------------------------------- 5 IMPOR T ANT FEA TURES OF YOUR NEW HEA T PUMP ------------------ 6 HOW A HEA T PUMP WORKS ----------------------.
4 TABLE OF CONTENTS (CONTINUED) MAINTENANCE AND GENERAL OPERA TION...CONTINUED: Heating Ti ps -------------------------------------------------------- 21 - Heating in Cooler W eather -----------------.
5 W elcome eam T to the Dear Owner: C 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.
6 Corrosion-Proof Cabinet The cabinet, being made from resilient, UV-Protected ABS material, can never rust, fade or corrode. Y ou can expect the cabinet to retain a like-new appear ance with only an occasional wash down and—if so desired—a quick waxing.
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 .
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.
9 Refrigerant Circuit Service Only by Qualified, EP A Certified T echnician Notice: Heater NOT Rep airable by Owner W ater Chemistry Safety Improper water chemistry can present a serious health hazard. T o avoid possible hazards, maintain Pool/S pa water per standards detailed later in this manual.
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.
11 N OTE : T HE HEA T CONTROLLER INCORPORA TES AN ANTI - SHORT CYCLE TIME DELA Y . S HOULD OPERA TION BE INTERRUPTED , 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.
12 HEA TER CONTROLS Control Buttons, Indicator Light s, & Display ( AS INDICA TED BY CIRCLED N UMBERS ) Control Panel Layout (A PPEARANCE V ARIES BY M ODEL ) 1 ) POOL / SPA SELECTOR – Selects either pool or spa thermostat. 2 ) COOLING INDICATOR LIGHT – Indicates unit is cooling.
13 T HE FOLLOWING CODES WILL BE DISPLA YED AS PA R T OF THE NORMAL OPERA TION 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 .
14 HEA TER CONTROLS...continued S t art 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 (owner) .
15 4 . Selecting Pool/Spa Thermostat Settings: A . Depress the [POOL/SP A] key to toggle between the pool and the spa temperature set points. B. The pool/sp a LED indicator lights, located to the left of the temperature display , will confirm the selected set point.
16 HEA TER CONTROLS...continued S tart Up & Setting Operating Controls (ULC Continued on Next Page) 8. User Lock Code Option [ULC]...continued: A. Selecting UCL Option: 1) Depress either the UP or DOWN ARROW keys; if “LOC” is momentarily displayed flowed by “0”, the ULC feature is enabled.
17 HEA TER CONTROLS...continued S tart Up & Setting Operating Controls 9. Selecting Call-Flex Pump Options [CFO]: General Information: The Call-Flex option automatically adjusts the run time of the water circulator pump, and heater , based upon changing weather conditions.
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.
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 basket can reduce water flow .
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.
21 Pool and Sp a Combination Heating... Everything stated for heating a pool applies for heating a spa— only the volume of water being heated is different. All AquaCal heat pumps come equipped with two thermostat s. One thermostat is for the pool and the other is for the spa.
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.
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.
24 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 .
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—while also protecting your investment—potentially extending the useful life of your heat pump far beyond the warranty period.
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.
27 TROUBLESHOOTING FLOWCHART Heat Pump Fails to Operate I s t he heater operati ng c orrec t ly ? I s t he heat er operat ing c orrec t ly ? I s t he heater operat ing c orrec t l y ? I s t he heat er operat ing c orrec t l y ? T he heater is equipped w it h a f iv e m inut e delay .
28 TROUBLESHOOTING FLOWCHART STA RT I s t he ai r being dis c har ged out of t he t op of t he heat er 9-12 degrees c ooler t han t he out s ide air? ST A RT I s t he ai r being dis c harged out of t .
29 TROUBLESHOOTING FLOWCHART W ater Coming from Heat Pump ST A R T H as t he "H eating" lamp been illuminated? ST A RT H as t he "Heat ing" lamp been illuminated? S hut off W ater .
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31 Models 100, 120, & 155 HEATING ONLY and HEATING - COOLING DEALER-SPECIFIC INFORMA TION FOLLOWS Installation Specifications Controls Configur ation &.
32 DEALER-SPECIFIC TABLE of CONTENTS GENERAL SAFETY INFORMA TION ------------------------------------ 34 DA T A PLA TE NOMENCLA TURE ----------------------------------------- 34 HEA TER SPECIFICA TION.
33 INST ALLA TION INSTRUCTIONS (continued): Electrical Requirements ------------------------------------------- 44 General Requirements ------------------------------------------ 44 Code-Specific Requ.
34 Notice: Heater NOT Rep airable by Owner Refrigerant Circuit Service Only by Qualified, EP A Certified T echnician 1 2 3456 7 8 9 1 0 1 1 1 2 AT 1 2 0 A R A E W N A CURRENT RELEASED REVISION A - INI.
35 SPECIFICA TIONS Physical Characteristics 100 & 120 M ODELS 155 M ODELS.
36 SPECIFICA TIONS -Performance/Size/Weight- -W ater/Electrical Requirement s- 1 0 0 - H e a tin g O n ly M o de ls 100A HDE 100BH DE 10 0DHD T 100HH DT BTU - 80 %RH A i r º F / W ater ºF… 80/80 90,000 90,000 73,000 73,000 CO P 5.8 5.8 5.5 5.5 Volt age/H z/ Phase 2 08- 230/60/1 208-230/60/3 380-415/50/3 200-240/50/1 M i n.
37 SPECIFICA TIONS -Performance/Size/Weight- -W ater/Electrical Requirement s- * All A-V oltage 120 heaters with model numbers ending in “B”, MCA = 33 1 2 0 - H e a tin g O n ly M o d e ls 120A HDE 120BH DE 120DH DT 120HHD T BTU - 8 0%RH Air º F / Wa ter ºF… 80 /80 109 , 000 109,000 95,000 95,000 CO P 5.
38 SPECIFICA TIONS -Performance/Size/Weight- -W ater/Electrical Requirement s- 155 - He a t i ng On l y M odel s 155AH DE 155BH DE 155DH DT 155G HDE BT U - 80% R H Air ºF / Water ºF… 80/80 127,000 127,000 110, 000 127, 000 C OP 6. 3 6.3 6. 3 6.3 Volt age/Hz / Phase 2 08- 230 / 60/ 1 200-230 / 60/ 3 380-415/50/3 460/ 60/ 3 M in.
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.
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 directly onto the heat pump.
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 installations are diagrammed.
42 Plumbing Schematic–Flow Exceeding 70-GPM Plumbing Requirement s (continued) INST ALLA TION Plumbing Schematics–Flow 20 to 70-GPM T YPICAL P OOL - F LOW LESS THAN 70- GPM P OOL /S PILL O VER S P.
43 Plumbing Schematics–Flow 20 to 70-GPM (continued) For proper operation and maximum ef ficiency , piping coming from the pump and filter MUST be con- nected to the "IN" port of the heater . Likewise, connect piping returning to the pool/spa to the "OUT" port of the heater .
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 .
45 • 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 .
46 1. Entering Service Menu: A . T o enter the service menu, Simultaneously depress 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.
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 .
48 4. W ater Sensor Calibration...continued: C . Follow the steps 1a . through 1d . above to enter the service menu. Once [dEL] is displayed, press the [POOL/SP A] key until the display shows [tSC] (Water T emperature Calibration).
49 Controls Configuration & Adjustments... Level-2 Microprocessor Programming...continued: 5. Defrost Sensor Calibration...continued: H . Once the correct temperature value has been selected not pressing depressing any buttons for 15 seconds will allow the controller to save the selection and return to the normal operating mode.
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 depressing any buttons for 15-seconds will allow the controller to save the selection and return to the normal operating mode.
51 Controls Configuration & Adjustments... Microprocessor Factory Default Settings Level –1 and Level-2 Default Settings Menu Cod e Descrip tio n Def ault Value Range Level-1 [CF1 ] C elsius/Fah.
52 M essage Er ror D escrip tion Possi ble caus e [dPO] D efrost Sensor Open Cut or l oose sen sor wiring [PO] W ater Tempera ture Sensor Open Cut or l oose sen sor wiring [dPC] Defrost Sen sor Shorted Short cir cuit in de frost s ensor wiri ng or de fective sensor.
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].
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.
56 W ater Flow (Pressure) Switch Adjustment Occasionally , plumbing system design features will create a situation whereas the heater will abnormally cycle on the water flow circuit.
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 of f and the “FLO” code will display .
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 Numbe.
59 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ________________________.
60 2737 24th St. North St. Petersburg, FL 33713 1-800-786-7751.
An important point after buying a device Aquacal 100 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Aquacal 100 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Aquacal 100 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Aquacal 100 you will learn all the available features of the product, as well as information on its operation. The information that you get Aquacal 100 will certainly help you make a decision on the purchase.
If you already are a holder of Aquacal 100, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Aquacal 100.
However, one of the most important roles played by the user manual is to help in solving problems with Aquacal 100. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Aquacal 100 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
