Aquacal AUTOPILOT 110 User manual

Important
Read This Guide Before Installing or Operating Heat Pump LTP0074 Rev 2 12/27/2011
Heat Pump
Quick Start Guide
Models: 035, 055, 075,115, 110, 120, 121, 155, 156, & 175
For product manuals and further installation / operation procedures
visit www.AquaCal.com

Page 1
SECTION 1 - GENERAL INFORMATION
CONTACTING AQUACAL AUTOPILOT
Web
www.AquaCal.com
Phone
[phone]
8:00 a.m. to 5:00 p.m. Eastern time, Monday through Friday
Fax
[phone]
Please have your model and serial numbers available when contacting AquaCal AutoPilot for questions, service, or
parts.
SAFETY
For personal safety, and to avoid damage to equipment, follow all safety instructions displayed in this guide. Repair
and service of your heat pump must be performed by qualified service personnel. Failure to properly install, operate,
maintain, or repair the heat pump will void factory warranty. Please note "WARNING" signals relate to personal
safety, while "CAUTION” signals promote avoiding damage to equipment.
Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. When installing and using your
heat pump, basic safety precautions must always be followed, including the following:
WARNING - Failure to heed the following may result in injury or death.
Heat pumps contain no owner-repairable components.
Electrical Installation should be by Licensed Electrician only.
Service to the refrigerant circuit must be performed only by qualified HVAC Technicians.
Heat pumps utilize high voltage and rotating equipment. Use caution when servicing.
Heater contains refrigerant under pressure. Recover refrigerant before opening system.
Prolonged immersion in water warmer than normal body temperature can cause fatal Hyperthermia.
The use of alcohol, drugs, or medication can greatly increase the risk of fatal Hyperthermia.
Persons having an adverse medical history, or pregnant women, should consult a physician before
using a hot tub or spa. In addition, children and the extreme elderly should be supervised by a
responsible adult.
CAUTION - Failure to heed the following may result in equipment damage.
Improper water chemistry can cause damage to pump, filter, pool shell, etc. To avoid equipment
damage, maintain Pool/Spa water per standards detailed later in this manual.
Water flow exceeding max flow requires a bypass. Damage due to excessive water flow will void
warranty. SAVE THESE INSTRUCTIONS
SPECIFICATIONS
Specification
Description
Electrical Service
See data plate attached to front cover or behind front access panel on equipment.
Water Flow
Requirements
30 - 55 gallons per minute (gpm) ideal range. A heater bypass is required for water flow greater than 70 GPM flow.
Exception: 035, 055, and 075 with a revision letter of B or higher have a 20-45 GPM range, with a max of 45 GPM.
Table 1
STANDARDS
Standards*
Title
Article 440
Standard for Safety for Electric Spas, Equipment Assemblies, and Associated Equipment.
Article 680
Standard for Safety for Swimming Pool Pumps, Filters and Chlorinators.
IEC 60335-1-2001
Household and similar electrical appliances - Safety - General requirements
IEC 60335-2-40
2006
Household and similar electrical appliances - Safety –Particular requirements for electrical heat pumps, air-
conditioners and dehumidifiers.
NFPA 70
The electrical installation must conform to the current version of the NEC, and all applicable local and state codes.
UL1995
Heating and cooling equipment.
*Not all standards are applicable in all installations. Follow all local applicable codes. Table 2

Page 2
SECTION 2 - INSTALLATION
For commercial or complete installation instructions please, visit www.AquaCal.com for equipment manual.
EQUIPMENT CLEARANCES
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 properly through the heater, and will result in
inefficient operation and/or damage to the heat pump.
Figure 1
Figure 2
PLUMBING SCHEMATIC
3 = Three-Way Valve
B = Bypass Check Valve (5lb) for Water Flow
Over Max Flow (see Specifications for details)
C = Chlorinator
D = Main Drain
F = Filter
H = Heat Pump
P = Water Pump
R = Return
S = Skimmer
Figure 3
ELECTRICAL REQUIREMENTS
1) Locate the equipment power disconnect within 6-feet of the heater’s electrical enclosure.
2) Never mount power disconnects directly to heat pump.
3) Only use copper conductors.
4) Use sequencing controllers when multiple heaters are installed on site.
5) Local codes and regulations may require the use of a ground fault interruption device (GFI Circuit Breaker).
Nuisance tripping of these devices is common and not covered under the terms of the Manufacturer’s warranty.
6) Review online product manual when connecting external controller devices to heat pump.
Overhang with
Gutter
5 feet Minimum Clearance
Overhead
Rain Run-Off Must Be
Directed Away From
Heater
(Front)
30” Minimum
Clearance
(Rear)
12” Clearance for all
IceBreaker / Heat &
Cool Models
12” Clearance for All
Tropical Models
6” Clearance for SQ
“Heat Only” Models
(Rear)
12” Clearance for All IceBreaker / Heat &
Cool Models
12” Clearance for All TropiCal Models
6” Clearance for SQ “Heat Only” Models
(Side)
12”
(Side)
12”
(Front)
30”
F
P
3
S
D
POOL
R
C
B
H

Page 3
SECTION 3 - OPERATION
Figure 4
INDICATOR LIGHTS
LIGHTS
EXPLANATION
SUPPLEMENTAL INFORMATION
“Pool”
Pool Thermostat Selected
“Spa”
Spa Thermostat Selected
“Cooling”
Actively Cooling Water
Not applicable for Straight Heat models.
“Desired Temp”
Setting Desired Water Temperature
“Water Temp”
Actual Water Temperature
“Heating”
Actively Heating Water
Table 3
BUTTONS
BUTTONS
EXPLANATION
SUPPLEMENTAL INFORMATION
“Pool / Spa”
Select between Pool and Spa
Please note –this does not turn off equipment. It only allows a user to
toggle between the Pool thermostat and the Spa thermostat.
“Up”
Select to raise temperature set
point or move up in a menu choice
“Down”
Select to lower temperature set
point or move down in a menu
choice
“Mode”
Select a mode
Modes available are “ACH”, “COOL”, “HEAT”, and “OFF”.
Please note –“ACH” and “COOL” only available on some models.
Table 4
DISPLAY
MESSAGE
EXPLANATION
SUPPLEMENTAL INFORMATION
“000”
A user lockout code has been
activated.
A numeric code is required before any temperature adjustment can
be entered. Use the “UP” or “DOWN” arrow to enter code, then select
“MODE” to temporarily unlock Heat Pump. If code is unknown, a re-
set option is available in product manual. Manuals can be
downloaded from www.AquaCal.com.
“ACH”
Auto-Change Over Mode
When this mode is active, the heat pump will automatically switch
between heating and cooling modes to maintain a set temperature
point within 3 degrees. Feature available for Heat & Cool units.
“COOL”
Cooling Mode
Heat Pump is set to cool the water. Feature available for Heat & Cool
units.
“HEAT”
Heating Mode
Heat Pump is set to heat water.
“OFF”
Unit off
Heat Pump can be turned off by using “MODE” button or setting
temperature below 45 degrees. Heat Pump will not allow a set
temperature to be programmed until turned on again.
“xx°”
Current Water Temperature
(Example 78°)
Temperature can be set from 45° F to 104° F. This can be displayed
in Fahrenheit or Celsius depending on programming.
FLO
No water flow through Heat Pump
This can be a normal display depending on system settings. See
“Troubleshooting” if needed.
Table 5
POOL
SPA
78°
Pool
Spa
Cooling
Desired Temp
Water Temp
Heating
UP
DOWN
MODE

Page 4
PROGRAMMING
Activity
Steps
Adjusting
Temperature
Step 1: Select the “POOL / SPA” button to choose the thermostat to adjust.
Step 2: Select the “UP” or “DOWN” button to increase or decrease the desired set temperature.
Step 3: Once set, the current water temperature will be displayed. The Heat Pump will start to operate to meet
the desired temperature. Please note a time delay will be experienced if Heat Pump has just been
initialized. This delay is between 4 to 5 minutes.
Turning Heat Pump
“ON”
Step 1: Confirm Heat Pump has power.
Step 2: Select the “MODE” button.
Step 2: Using the “UP” or “DOWN” arrow, select “ACH”, “COOL”, “HEAT”, or “OFF”. See section on Display
for “MODE” usage.
Turning Heat Pump
“OFF”
Step 1: Select the “MODE” button.
Step 2: Using the “UP” or “DOWN” arrow, select “OFF”
Please note –setting temperature below 45° F will also turn off Heat Pump.
Setting to “Celsius”
or “Fahrenheit”
Step 1: Select and hold down both the “UP” and “DOWN” arrow keys simultaneously until the Celsius /
Fahrenheit code (CF1) appears on the display.
Step 2: Select the “UP” or “DOWN” arrow to select “1” for Fahrenheit or “2” for Celsius.
Step 3: Allow display to time-out.
Switching from Pool
to Spa
Select the “POOL / SPA” button.
Table 6
SECTION 4 - MAINTENANCE
POOL CHEMISTRY
Maintain pool water with the following chemical levels. Commercial applications may vary from depending on locale.
All values show in PPM (Parts Per Million).
Chemical
Pool
Spa
Chlorine
1 to 3 parts per million (PPM)
1.5 to 3 PPM
Bromine
1 to 3 PPM
3 to 5 PPM
pH
7.4 to 7.8 PPM
7.2 to 7.8 PPM
Total Alkalinity
80 to 140 PPM
80 to 120 PPM
Calcium Hardness
200 to 400 PPM
200 to 400 PPM
Total Dissolved
Solids
1,000 to 2,000 PPM
1,500 to 2,000 PPM
Table 7
WINTERIZING
In areas where freezing conditions are a rare occurrence, allow the filtration system to run continuously throughout
the freeze period. Typically, during light freeze conditions, circulating (moving) water will not freeze. In areas where
freezing conditions are prevalent and sustained, the heat pump must be winterized as follows:
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 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 condenser. Replace the
winterizing plug by threading the plug in clockwise until just snug, then apply an additional 1/8 turn.
4) If no drain plug is found, unit is self draining from unions. Check online manuals for appropriate winterizing
procedures on heat pumps older than 2005.
5) To prevent insects and vermin from entering the plumbing during the winterized period, partially reconnect
the two (2) plumbing connection unions: couple each union one or two threads; this will permit condensation
to drain, but will prevent most insects and animals from entering the plumbing circuit.
START UP
To ready a winterized heat pump for use, simply retighten plumbing connection unions. Hand-tight is generally
sufficient.

Page 5
SECTION 5 - TROUBLESHOOTING
ERROR CODES
SYMPTOM
RULE OUT
RESOLUTION
"FLO"
Insufficient water flow
through heater or
circulation pump is off
Insufficient Water Flow
Step 1:
Confirm water pump is on and water valves are in the correct position to allow
water to flow through Heat Pump. If error persists, proceed to next step.
Filtration Dirty
Step 2:
Confirm filtration system is clean. Backwash if needed. If error persists,
proceed to next step.
Possible Water
Pressure Switch
Step 3:
Request Service
“CEr” Error
Communication Fault
N/A
Request Service
“CSE” Error
Control System Error
N/A
Request Service
“dPC” Error
Defrost Sensor Shorted
N/A
Request Service
“dPO” Error
Defrost Sensor Open
N/A
Request Service
“FS” Error
Unit in defrost mode.
Normal defrost mode
Step 1:
If error persists after air temperature is over 50° F, request service.
“HP” Error
High Pressure.
Insufficient Water Flow
Step 1:
Confirm water pump is on and water valves are in the correct position to allow
water to flow through Heat Pump. If error persists, proceed to next step.
Filtration Dirty
Step 2:
Confirm filtration system is clean. Backwash if needed. If error persists,
proceed to next step.
Possible Refrigerant
Issue
Step 3:
Request Service
“HP5” Error
Equipment has
registered high pressure
five times and locked.
Insufficient Water Flow
and/or Filtration Dirty
Step 1:
Follow steps outlined in “HP” error, then reset circuit breaker to clear error. If
error persists, request service.
“LP” Error
Refrigerant Issue
N/A
Request Service
“LP5” Error
Refrigerant Issue
N/A
Request Service
“OTA”
Over Temperature
Alarm
Temperature over
110° F (Unit Locked)
Other heating
equipment
Check if alternate heater (such as a solar heater) is heating water leading to
heat pump. If “yes”, turn off alternate heater and check if error clears. If error
persists, request service.
“PC” Error
Water Temperature
Sensor Shorted
N/A
Request Service
“PO” Error
Water Temperature
Sensor Open
N/A
Request Service
Table 8