Aquacal H-AT100R, H-AT120R User Manual

and

AQ Tech, 9/24/04

Pool and Spa

Heat Pump

&7

Owner’ s Manual

and

Models:

H/AT100R

Installation Guide

PN: L TP0010

01/30/04

A TTENTION INST ALLER:

THIS DOCUMENT IS PURCHASER’S PROPERTY AND IS TO REMAIN WITH THE HEAT PUMP OWNER

H/AT120R

Also Applies to:

XL100R

XL120R

1/7/04

1

1-800-786-7751

NOTES

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2

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----------------------------------------------------------- 1 0

Specifications ----------------------------------------------------------------------- 11

Data Plate Nomenclature----------------------------------------------------------- 11

INSTALLATION ---------------------------------------------------------------------- 12

Placement of Heater----------------------------------------------------------------- 12

Plumbing Requirements ------------------------------------------------------------ 13

Electrical Requirements------------------------------------------------------------- 16
Connecting External Controllers------------------------------------------ 16

START-UP & OPERATION --------------------------------------------------------- 17

Control Panel Features ------------------------------------------------------------- 17

Overview of Controls--------------------------------------------------------------- 18

Initial Start-up and Basic Operation----------------------------------------------- 1 8

Heating T ips-------------------------------------------------------------------------- 20

Calculating Initial Heating Time --------------------------------------------------- 21

3

TABLE OF CONTENTS, continued

MAINTENANCE---------------------------------------------------------------------- 22

Planned Maintenance Program---------------------------------------------------- 2 2

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

W interizing (Hard Freeze Conditions) ------------------------------------------- 25

TROUBLESHOOTING-------------------------------------------------------------- 28

Common Troubleshooting Issues------------------------------------------------- 28

Troubleshooting Flow Charts------------------------------------------------------ 29

Adjusting Water Flow (Pressure) Switch ---------------------------------------- 33

Defrost System: Description & Troubleshooting ------------------------------ 35

T roubleshooting Problems in the Refrigerant Circuit -------------------------- 37

Refrigerant Circuit Performance (T-P) Charts ---------------------------------- 38

REPLACEMENT PARTS ----------------------------------------------------------- 41

CONTACTING THE FACTORY -------------------------------------------------- 42

4

Welcome

to the

T

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

C

only a great investment, but also the most cost effective method available for heating
pools and spas. For example, your heat pump is up to 400% more efficient than gas,
and, when compared to electric resistance
heat, your heat pump is nearly 600% more
effective. You can rest assured that your new
heat pump is of the highest quality and
efficiency , and is designed and built to provide
years of trouble-free operation.

Moreover, should you decide you would like
AquaCal to provide regular inspection and
maintenance of your heat pump—which we
do recommend—you will find that AquaCal’ s
factory-trained service staff is the largest and
most-qualified in the pool & spa heat pump
industry.

manufacture of swimming pool & spa heat pumps. Your new heat pump is not

eam

“You can rest assured

that your new heat
pump is of the highest
quality and efficiency,

and is designed and

built to provide years of

trouble-free

operation.”

5

Important Features of Your New

Icebreaker Heat Pump

ThermoLink

Heat Exchanger

The heart of your heat
pump is the patented
ThermoLink heat ex­changer. The primary
cause 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. The
ThermoLink heat ex­changer tube is made from
titanium, and is virtually im­pervious to water chemis­try damage.

D
D

D
D

D

ThermoLink

Heat Exchanger

Electronic Controller

Corrosion-Resistant

Cabinet

Scroll Compressor

Heat & Cool + Hot Gas

Defrost

Electronic

Controller

State-of-the-art, solid­state electronic controller,
maintains water tempera­ture within 1ºF of set point.
Controller also permits user
to predefine different Pool
and Spa water temperature
set points.

Corrosion-Proof

Cabinet

The cabinet, being made
from resilient, UV-Pro­tected ABS material, can
never rust, fade, or cor­rode. You can expect the
cabinet to retain a like­new appearance with only
an occasional wash down
and—if so desired— a

quick waxing.

Scroll Compressor

50% fewer moving parts than standard piston-type compressors. This equates to much improved reliability and
improved efficiency . Scroll compressors are also much quieter in operation than piston-type compressors.

Heat & Cool Capability

Puts you in full control, year round ...W arms your pool or spa with the reliability and efficiency of our other heat
pumps, but, with the flip of a switch, can also cool your pool or spa to refreshing temperatures during the hot
summer months. For cooler climates, Icebreaker heat pumps offer unique advantages over passive defrost
models. Please read more below...

Hot Gas, Icebreaker Defrost

Your Icebreaker heat pump is uniquely equipped for active defrost. Active defrost involves directing hot refrig­erant gas to the heat collector, melting accumulated ice away in a matter of a few minutes—then right back to
heating. Standard heat pumps may remain “off in defrost” for extended periods during very cold weather.
Because of its ability to continue to operate even during freezing weather, your Icebreaker extends the swim-
ming season longer than any other heat pump.

PLEASE SPEND A FEW MINUTES READING FURTHER TO BECOME

FAMILIAR WITH ALL THE FEATURES, THE SAFE OPERATION, AND THE

6

CARE OF YOUR NEW HEAT PUMP.

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.

Likewise, excepting a few minor owner-capable maintenance items (explained later in this manual), repair and
service of your heat pump must be performed only by experienced service personnel. Should you, the owner,
suspect your heat pump is not performing properly, by referring to the section in this manual entitled:
"Troubleshooting", you will be able to determine if a call for service is required. Y our installer can be one
source of service, or AquaCal Customer Support personnel stand ready to assist you at: [phone].
For questions concerning installation, modifications, operation, service and upkeep, please contact your installer
or AquaCal Customer Support. W arranties may be voided if the heater has been used, maintained, or repaired
improperly .

In addition to possible voiding of warranties: unapproved installation methods, nonstandard modifications,
poor or incorrect maintenance, service by unqualified personnel, or improper use of this unit, may result in
personal injury and/or property damage. For personal safety and to avoid damage to equipment, it is important
that safety instructions displayed on the heat pump, and within this manual, are read, understood, and followed.

Throughout this manual the following two safety signals are placed where particular care is required. Please
note "W ARNING" relates to personal safety , while "CAUTION" signals promote avoiding damage to equipment.

Failure to heed the following may result in permanent injury or

WARNING !

This “W arning” symbol appears in this manual where special attention is required for personal safety .

Specific instructions will appear in this box.

CAUTION !

This “Caution” symbol appears in this manual where special care is required to avoid equipment damage.

Specific instructions will appear in this box.

death.

Failure to heed the following may result in damage to equipment.

Water Temperature Safety

Failure to heed the following may result in permanent injury or

WARNING !

Prolonged immersion in water warmer than normal body temperature may cause a condition known as
HYPER THERMIA. The symptoms of hyperthermia include: unawareness of impending hazard, failure
to perceive heat, failure to recognize the need to exit the spa, and unconsciousness. The use of alcohol,
drugs, or medication can greatly increase the risk of fatal hyperthermia. In addition, persons having an
adverse medical history , or pregnant women, should consult a physician before using a hot tub or spa.
Children and the extreme elderly should be supervised by a responsible adult.

death.

7

Heater NOT Repairable by Owner

Failure to heed the following may result in permanent injury

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 [phone].

or death.

Refrigerant Circuit Service Only by
Qualified, EP A Certified T echnician

Failure to heed the following may result in permanent injury

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. Recover refrigerant to relieve pressure before opening system.

or death.

W ater Chemistry Safety

Failure to heed the following may result in permanent injury or

WARNING !

Improper water chemistry can present a serious health hazard. T o avoid possible hazards, maintain
Pool/Spa water per standards below .

CAUTION !

While your heat pump’s titanium-based heat exchanger provides nearly impervious protection against
poor water chemistry , improper water chemistry may cause expensive damage to pump, filter, pool
shell, etc. T o avoid equipment damage, maintain Pool/Spa water per standards below .

death.

Failure to heed the following can result in damage to equipment.

RECOMMENDED W A TER CHEMISTRY ST ANDARDS

Chlorine . . . . . . . . . . . . . . .:

Bromine . . . . . . . . . . . . . . .:

pH . . . . . . . . . . . . . . . . . . .:

T otal Alkalinity . . . . . . . . . .:

Calcium Hardness . . . . . . . .:

T otal Dissolved Solids . . . . .:

1.0 – 3.0 ppm in pools, 1.5 – 3.0 ppm in spas

2.0 – 4.0 ppm in pools, 3.0 – 5.0 ppm in spas

7.4 – 7.6 ppm in pools, 7.2 – 7.8 ppm in spas
80 – 140 ppm in pools, 80 – 120 ppm in spas
200 – 400 ppm in pools and spas
1,000 – 2,000 ppm in pools,
1,500 ppm above start-up TDS in spas

8

HEATING-QUICK START & STOP

his brief information is provided as an aide to installers, service personnel, and owners. The intent of this
section is to provide rapid access to (only) very basic operational information. Individuals who will be

T

routinely using, installing, maintaining, and servicing this heat pump, are strongly encouraged to read this
entire manual. 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 .

S tart Up

1. With water pump OFF , position water valves to heat the POOL or SP A.

2. Set water pump controls to allow for temporary , continuous operation.

3. Rotate both thermostats counterclockwise to lowest temperature settings.

4. Depending on valve settings (per #1, above), position the POOL/OFF/SP A toggle switch to point at
either the POOL or SP A thermostat knob. Set HEAT/COOL toggle switch to HEAT position.

5. Ensure power is supplied to the heater, then start the water pump; the POWER and FLOW lights
should now both be lit. Permit the water pump to operate for five (5) minutes before proceeding.

Setting the Temperature Controls - Pool or Spa

1. Turn the selected pool or spa thermostat dial clockwise to its highest setting.

2. The heat pump will start and begin to warm the pool or spa.

NOTE: The heat pump utilizes a short-cycle time delay device. If heat pump does not
start, wait five (5) minutes; the time delay may be preventing the heat pump from starting.

3. Initially , the typical spa may take several hours to heat, while a pool may take several days. Heating
time will depend on the volume of water, beginning water temperature, and the weather conditions at
the time of start-up. (Also see T able of Contents item: Calculating Initial Heating T ime.)

4. When the pool or spa reaches the desired temperature, slowly rotate the thermostat knob

counterclockwise until the heat pump (just) stops. The thermostat is now positioned to automatically
maintain the set temperature.

Once the heat pump has brought the pool or spa up to temperature, it will be necessary to reset the
pump run-time controls. Be sure to allow enough running time for the heat pump to replace lost heat.
Required run time will vary depending upon the time of year . Colder months require longer running
times–generally eight to twelve hours/day .

Switching Controls from Pool to Spa

NOTE: It is best to stop the water pump while repositioning valves.

1. Open spa valves and close pool valves.

2. With the spa water circulation pump operating for at least five minutes, move the POOL/OFF/SP A
toggle switch from the POOL setting to the SP A setting.

3. Turn the Spa thermostat fully clockwise (104º F). Heat pump should start (also see time delay note,
above).

4. Initially, the typical spa may take several hours to heat. Heating time will depend on the volume of
water, beginning water temperature, and the weather conditions at the time of start-up.

5. When the spa reaches the desired temperature (104º F is maximum), slowly rotate the SP A
thermostat knob counterclockwise until the heat pump (just) stops. The spa thermostat is now
positioned to automatically maintain the set temperature.

The heat pump can be stopped by interrupting the electrical power supply , or by setting the desired temperature
lower than the actual water temperature. However, please note, if electrical power and water flow are present
to the heat pump, and the water temperature falls below 60ºF (with thermostat set to minimum), the heat pump
will operate to maintain the water temperature at 60ºF .

Time Clock Programming

To Stop the Heat Pump

9

PHYSICAL CHARACTERISTICS

&

SPECIFICATIONS

Dimensional Information - Heat Wave/AeroTemp

100-120 Series (All Reversing Models)

10

Specifications — H/AT100R & 120R Models

SERIES:

SERIES:

100 -

H100AR

AT100AR

H100BR

AT100BR

H100DR

AT100DR

H100HR

AT100HR

BTU - 80%RH

Air ºF / Air ºF… 80/50

88,000/63,000

COP 5.6/4.1

BTU - 63% RH

Air ºF / Air ºF… 80/50

COP

Kilowatt Input (80% RH )

83,000/57,000

5.3/3.9

4.6

(DATA PENDING)

Voltage/Hz/Phase 208-230/60/1 208-230/60/3 380-415/50/3 220-240/50/1

Min. Circuit Ampacity 38.16 22.13 11.62 26.14
Rec. Fuse or Breaker Size
Max. Fuse or Breaker Size

40 30 15 30
60 35 20 40

Min-Max Water Flow (gpm) 20-70 20-70 20-70 20-70

Shipping weight (lbs) 320 320 320 320

Shipping Size (LXWXH)

Uncrated Weight

12 0-

BTU - 80%RH

Air ºF / Air ºF… 80/50

36” X 40” X 43" 36” X 40” X 43" 36” X 40” X 43" 36” X 40” X 43"

293 293 293 293

H120AR

AT120AR

H120BR

AT120BR

H120DR

AT120DR

H120HR

AT120HR

103,000/70,000

(DATA PENDING)

COP 5.4/4.1

BTU - 63% RH

Air ºF / Air ºF… 80/50

99,000/68,000

COP 5/3.8

Kilowatt Input (80% RH ) 5.6

Voltage/Hz/Phase

Min. Circuit Ampacity

208-230/60/1 208-230/60/3 380-415/50/3 220-240/50/1

38.16 26.14 12.82 36.56

Rec. Fuse or Breaker Size 40 30 15 40
Max. Fuse or Breaker Size 60 40 20 60

Min-Max Water Flow (gpm) 20-70 20-70 20-70 20-70

Shipping weight (lbs)

Shipping Size (LXWXH)

330 330 330 330

36” X 40” X 43" 36” X 40” X 43" 36” X 40” X 43" 36” X 40” X 43"

Uncrated Weight 303 303 303 303

Data Plate Nomenclature

1234567891011 12
AT120ARAEW N A

CURRENT RELEASED REVISION

BRAND

H = HeatWave OPTIONS
AT= AeroTemp N-NONE
SB = SouthBeach
TZ = Tropez

CAPACITY

100 = 90000 Btus/hr
120 = 109000 Btus/hr E - R22
155 = 120000 Btus/hr T - R407C

VOLTAGE

A - 1/60/208-230 D - DIGITAL
B - 3/60/208 - 230
D - 3/50/380
H - 1/50/200-220

RFRG CONTROL

H - HEAT
R - REVERSING

A - INITIAL RELEASE

CABINET COLOR

W - CRÈME
B - BLACK

REFRIGERANT

Z - R410A

CONTROLS

A - ANALOG

11

INSTALLATION

GU

R

Placement of Heater

Indoor Installation

Indoor 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. If
considering an indoor installation, you are strongly urged to contact AquaCal Engineering or T echnical
departments (800-786-7751) for assistance prior to proceeding.

Outdoor Installation

Service and Operational Clearances:

♦ T o operate correctly , heat pumps require large volumes of air moving over the heat collector. Allow

adequate clearance between the heat pump and walls, fences, shrubs, or other objects. Refer to
recommended clearance drawings below .

♦ Allow five (5) feet of vertical clearance between the top of the heat pump and any roof overhang or other

obstruction. This clearance prevents cold discharge air from recirculating back into the heat pump
(recirculation would reduce the overall performance of the heat pump).

♦ The access panel requires removal during installation and service. Do not place plumbing, or other

items, closer than 30” from the front of the heater.

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.

T ypical Installation Clearances

-

RAIN RUN

OFF MUST BE

DIRECTED

AWAY FROM

.

UNIT

30” M

INIMU M

C

LEARANCE

F

RONT

OVERHANG

WITH

,

TTE

5 FT.

MINIMUM

CLEARANCE

O

VERHEAD

1 FT.

C

LEARANCE

,

MINIMUM

,

24-

I

NCHES

(

SIDE

)

12-I

(R

30-I

(

NCHES

EAR

NCHES

FRONT

)

24-

NCHES

I

SIDE

(

)

)

FRONT-SIDES-REARFRONT-REAR-OVERHEAD

12

Irrigation, Rainwater Runoff, and Landscape Features:

Place the heat pump away from direct rain runoff from roofs. A gutter or rain shield may 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 the heat pump directly adjacent to plants, shrubs, or bushes. Doing so will prevent
proper air circulation into the unit, and may inhibit access to the heater when service is needed. Consult
drawings on previous page (Recommended Installation Clearances) for proper spacing to other objects.

Equipment Pad Requirements:

The equipment pad should be constructed of concrete, pressure treated wood, or other material intended
for the use. The pad shall be elevated and placed to provide adequate drainage and support to the base of
the heat pump. The pad should be essentially level with just enough pitch to drain condensate and any other
water away from the heater. In addition, the pad shall extend–in all directions–(at least) 3" beyond the base
of the heat pump. Under no circumstances shall the heater be installed directly onto the earth.

Anchoring Heater to Pad:

Follow all relevant local, state, or national requirements regarding wind load anchoring. When anchoring is
required, use AquaCal optional Hurricane Anchoring Kit, PN: STK0001. AquaCal anchoring kits satisfy ,
completely , the very stringent Florida Building Code Section 301.13 wind anchoring requirements. As
necessary , contact AquaCal Te chnical Support (800-786-7751) for assistance in determining best method
of compliance.

Plumbing Requirements

Overview:

When planning plumbing system layout, reference the plumbing schematics following 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. Should the system installation under consideration not closely
match any of the schematics, contact AquaCal T echnical Support for advice and guidance: [phone].

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 & standards.

Water Connections to Heat Pump:

All Heat W ave and AeroT emp heat pumps are supplied with 2" PVC plumbing unions. Connection to site
plumbing is made via PVC solvent cement to the female slip socket of the plumbing unions.

Maintain Ability to Winterize:

In regions where hard winters are typical, the unions mentioned above allow for easy disconnection/reconnection
of the heater from/to the plumbing system. Caution: Do not defeat the function of the unions–use no glue on the
threaded portion of the unions.

Maximum Operating Pressure: 50 PSI
Minimum/Maximum Water Flow Rates:

All Heat W ave and AeroT emp models are designed to operate successfully between flow rates of 20-to-70
gallons-per-minute (GPM). Design the plumbing system to maintain at least 20-GPM flow through the heater;
the heat pump will not operate correctly , nor reliably, with less than 20-GPM of water flow supplied. If water
flow rates through the heater will exceed 70-GPM, a 5-lb spring-check bypass valve (AquaCal P .N.: 2556)
will be required; generally speaking, most residential pools and spas will not require a bypass unless a pump of
two (2) horsepower or larger is used (for bypass valve placement details, see plumbing schematic contained
on next page: “…Flow Greater than 70-GPM”).

13

Plumbing Schematic–Flow Exceeding 70-GPM

CAUTION !

Use of an incorrect bypass valve may compromise the heat pump’s ef ficiency, reliability , and may void
the factory warranty . When using a bypass valve, order and install only an AquaCal PN: 2556 spring­check bypass valve.

Bypass Check

Failure to heed the following may result in damage to equipment.

Plumbing Schematics–Flow 70-GPM and Below

14