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Aquacal 120 - page 1
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 TP0051 8/10/05 &7 and Models: 100, 120, & 155 Additional Labels: APS Fox Smart South Beach T r opez HEA TING ONL Y and HEA TING - COOLING With H ...
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Aquacal 120 - page 2
2 1-800-786-7751 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ ____________________________________________________________________________ ...
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Aquacal 120 - page 3
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 ------------------------------------------ 7 SAFETY INFORMA TION ------------------------------------------------ 8 QUICK ST AR T & STOP ------------------------------- ...
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Aquacal 120 - page 4
4 TABLE OF CONTENTS (CONTINUED) MAINTENANCE AND GENERAL OPERA TION...CONTINUED: Heating Ti ps -------------------------------------------------------- 21 - Heating in Cooler W eather -------------------------------------- 21 Pool/Spa Blankets ----------------------------------------------- 21 Pool & Spa Combination Heating --------------------- ...
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Aquacal 120 - page 5
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. Y our new heat pump is not only a great investment, but also the most cost effective method available for heating p ...
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Aquacal 120 - page 6
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 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, THE SAFE OPERA TION, AND T ...
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Aquacal 120 - page 7
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 ...
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Aquacal 120 - page 8
8 Used and maintained properly , your heat pump will provide year-upon-y ear 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 ...
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Aquacal 120 - page 9
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.. Failure to heed the following may result in perma ...
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Aquacal 120 - page 10
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 ...
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Aquacal 120 - page 11
11 N OTE : T HE HEA TER 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. T o Stop the Heat Pump: A . Select: OFF via the MODE selector . This method of shut down p ...
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Aquacal 120 - page 12
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 ...
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Aquacal 120 - page 13
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 of f, or when the heater is not receiving correct water flow . OFF ..... System is Off. This code appears whenever heater has been tu ...
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Aquacal 120 - page 14
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 (the owner). These features reside at the Level-1 access point within the micropro ...
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Aquacal 120 - page 15
15 4 . Selecting Pool/Spa Thermostat Settings: A . Press 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. 5. Changing The Pool T emperature Set Point: A . Using the [POOL/SP A] key , select t ...
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Aquacal 120 - page 16
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 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 s ...
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Aquacal 120 - page 17
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. Without Call-Flex, as weather conditions grow progressively cooler durin ...
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Aquacal 120 - page 18
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 contains information concerning planned maintenance, proper water flow , maintaining proper clearances, as well as other vital information. Please ...
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Aquacal 120 - page 19
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 . K ...
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Aquacal 120 - page 20
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 ...
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Aquacal 120 - page 21
21 S pa Heating & S p a Setback Option... Air blowing into your spa while it is being heated 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 off the air blower . Air indu ...
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Aquacal 120 - page 22
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 ...
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Aquacal 120 - page 23
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 ...
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Aquacal 120 - page 24
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 . See Figure-3 (position may vary between models). Remove plug. 4. Permit all of the water to drai ...
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Aquacal 120 - page 25
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 ...
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Aquacal 120 - page 26
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 ...
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Aquacal 120 - page 27
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 . W ait at least f iv e m inut es t o allow th e ti me r to r es et ...
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Aquacal 120 - page 28
28 TROUBLESHOOTING FLOWCHART STA RT I s t he air 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 the 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 allow ex t ended operat i on of t he heat er ...
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Aquacal 120 - page 29
29 TROUBLESHOOTING FLOWCHART W ater Coming from Heat Pump ST A RT H as t he "H eating" lamp been illuminated? ST A RT H as t he "H eating" lamp been illuminated? S hut off W ater P um p a n d Ca l l Aq u a Ca l f o r A ssistance: 800-786-7751 S hut off W ater P um p a n d Ca l l Aq u a Ca l f o r A ssistance: 80 0-7 86 -77 51 W ...
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Aquacal 120 - page 30
30 ...
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Aquacal 120 - page 31
31 Models 100, 120, & 155 HEATING ONLY and HEATING - COOLING DEALER-SPECIFIC INFORMA TION FOLLOWS Installation Specifications Controls Configur ation & ...
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Aquacal 120 - page 32
32 DEALER-SPECIFIC TABLE of CONTENTS GENERAL SAFETY INFORMA TION ------------------------------------ 34 DA T A PLA TE NOMENCLA TURE ----------------------------------------- 34 HEA TER SPECIFICA TIONS -------------------------------------------- 35 Physical Characteristics (dimensional drawings) ----------------- 35 P erformance, Size, W eight, El ...
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Aquacal 120 - page 33
33 INST ALLA TION INSTRUCTIONS (continued): Electrical Requirements ------------------------------------------- 44 General Requirements ------------------------------------------ 44 Code-Specific Requirements ----------------------------------- 44 Connecting External Controllers -------------------------------- 44 Sizing the Electrical Service ---- ...
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Aquacal 120 - page 34
34 Notice: Heater NOT Rep airable by Owner Refrigerant Circuit Service Only by Qualified, EP A Certified T echnician 1 2 3456 7 891 0 1 1 1 2 AT 1 2 0 A R A E W N A CURRENT RELEASED REVISION A - INI TIAL RELEASE BRAND H = HeatW ave OPTI ONS AT= AeroTe mp N-NO NE SB = S o uthB ea ch TZ = Tropez CABINET COLOR W - CRÈME B - BLACK CAPACI T Y REFR IGE ...
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Aquacal 120 - page 35
35 SPECIFICA TIONS Physical Characteristics 100 & 120 M ODELS 155 M ODELS ...
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Aquacal 120 - page 36
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. Cir cui t Am paci t y ...
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Aquacal 120 - page 37
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 5.6 5.6 5. 5 5.5 Volt age/Hz / Pha se 20 ...
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Aquacal 120 - page 38
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. C ir cui t Am pa ...
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Aquacal 120 - page 39
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 ...
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Aquacal 120 - page 40
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. • Do not locate t ...
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Aquacal 120 - page 41
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 ...
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Aquacal 120 - page 42
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 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 Bypass Check V alve T YPICAL P OOL - F LOW G REA ...
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Aquacal 120 - page 43
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 . See drawing below . PLUMBI NG CONNECTION D ETAIL Fr ...
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Aquacal 120 - page 44
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 . • In sizing power wiring, be especially aware of up-sizing requirements ne ...
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Aquacal 120 - page 45
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 . • Refer to either equipment data plate for unit-specific electrical power supply requirements. ? ...
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Aquacal 120 - page 46
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: ? ...
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Aquacal 120 - page 47
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 ...
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Aquacal 120 - page 48
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] (Water T emperature Calibration). Using either the [UP] or [DOWN] arrow keys, calibrate the water temperature sensor by increasing or decreasing the numeric ...
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Aquacal 120 - page 49
49 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/SP A ...
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Aquacal 120 - page 50
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 ...
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Aquacal 120 - page 51
51 Controls Configuration & Adjustments... Microprocessor Factory Default Settings Level –1 and Level-2 Default Settings Microprocessor Level-2 Set Up & Calibration Codes Service Adjust able Parameters Code Descr iption Facto ry Set ting Ran ge [LO C] Ser vi ce Lock Co de 50 00-9 9 [dEL] 4-minute D elay on Make 1 0 / 1 [JAO ] Ex tern al C ...
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Aquacal 120 - page 52
52 M essage Er ror D escrip tion Possi ble caus e [dPO] Defrost Sen sor 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 wiring or defective sensor. [P C] W ater Tempera ture Sensor Shorted Short cir cuit in w ater te m peratur e sen ...
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Aquacal 120 - page 53
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 ...
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Aquacal 120 - page 54
54 Controls Configuration & Adjustment s... Microprocessor Mode Jumper Positioning... continued: ...
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Aquacal 120 - page 55
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 af fect the heater ’s performance ...
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Aquacal 120 - page 56
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 ...
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Aquacal 120 - page 57
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 . CAUTION: If the heater continues ...
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Aquacal 120 - page 58
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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Aquacal 120 - page 59
59 NOTES ___________________________________________________________________________________ __________________________________________________________________________________ ___________________________________________________________________________________ _________________________________________________________________________________ ________ ...
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Aquacal 120 - page 60
60 2737 24th St. North St. Petersburg, FL 33713 1-800-786-7751 ...
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Aquacal 120 - page 61
Identifying an HP 7 -Equipped Hea ter To program , HP7 controllers require water flow. In addition, H P7-equipped heaters w i ll NOT be equipped with a “ Mo de ” button on the programm in g pad. 50 HEAT PUMP OWNER ’ S INSTRUCTIONS -for- PROGRAMM ING AN HP7 CONTROLLE R N O T E : T H I S M A N U A L A L S O A P P L I E S T O X L 1 0 0 , X L 1 2 ...
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Aquacal 120 - page 62
8 GETTING F AMILIAR WITH CONTROLS DIGITAL CONT ROLLER – PA NEL LAYOUT Control Buttons ( AS INDICATED BY CIRCLED LETTERS ) A. Down Arrow – Pressing this key decreases the tem per ature setting. Setting the temperature below 60°F turns the heat pu mp off. B. Pool / Spa Selector – Pressing this key selects either the pool or spa mode. Also used ...
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Aquacal 120 - page 63
9 DIGITAL CONT ROLLER - OPER ATIONAL DIS PLAYS T HE FOLLOWIN G C ODES WILL BE DISPLAYED AS PAR T OF THE NORMAL OPERATI ON OF THE HEATER : OPERATIONAL CODES o FLO —No water flow detected. Code m es sage will appear any tim e th e circulating pump is off, or when the hea t er is not receiving correct water flow. o OFF —System is off. System is of ...
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Aquacal 120 - page 64
10 GETTING YO UR HEAT P UMP STARTED & STOPP ED ATTENTION : THIS IS A QUICK-START GUIDE …For m ore complete information concerning the digital controller features a nd programming, see: Owner’s Instructions for HP7 Digital Heat Pump Controller, locate d in the appendix of this manual. INITIAL START UP 1. Start the water circulator pum p. NOT ...
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Aquacal 120 - page 65
11 GETTING YOUR HEAT PUMP STARTED & STO PPED (Continued) 8. In operation, whenever the actua l (displayed) water tem p erature falls below the desired set point, the unit will start heat i ng after an initial tim e d elay of 3-4 minutes. NOTE: T HE HEA T PUMP INCORPORA TES AN ANTI - SHOR T CYCLE TIME DELAY . S HOULD OPERATION BE INTERRUPTED , R ...
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