Aquacal H/AT100R Programming manual

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ATTENTIONINSTALLER:
THIS DOCUMENT IS PURCHASER’SPROPERTY AND IS TO REMAIN WITH THE HEAT PUMP OWNER
Models:
H/AT100R
H/AT120R
Pool and Spa
Heat Pump
Owner’s Manual
and
InstallationGuide
PN:LTP0010
01/30/04
1/7/04
&7
Also Applies to:
XL100R
XL120R
and

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1-800-786-7751 NOTES
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TABLEOFCONTENTS
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----------------------------------------------------------- 10
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----------------------------------------------- 18
Heating Tips-------------------------------------------------------------------------- 20
Calculating Initial HeatingTime --------------------------------------------------- 21

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MAINTENANCE---------------------------------------------------------------------- 22
Planned Maintenance Program---------------------------------------------------- 22
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
Winterizing (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
Troubleshooting Problems in the Refrigerant Circuit -------------------------- 37
Refrigerant Circuit Performance (T-P) Charts ---------------------------------- 38
REPLACEMENT PARTS ----------------------------------------------------------- 41
CONTACTING THE FACTORY -------------------------------------------------- 42
TABLEOFCONTENTS, continued

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Welcome
eam
T
“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.”
to the
Dear Owner:
Congratulations on your wise decision to make anAquaCal heat pump part of
your home. Since 1981,AquaCal has maintained the worldwide lead in the
manufacture of swimming pool & spa heat pumps. Your new heat pump is not
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,andisdesignedandbuilttoprovide
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 thatAquaCal’s
factory-trained service staff is the largest and
most-qualified in the pool & spa heat pump
industry.

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ThermoLink
HeatExchanger
The heart of your heat
pump is the patented
ThermoLink heat ex-
changer. The primary
cause of premature heat
pumpdemise is the failure
of the heat exchanger.
Ordinary heat exchangers
are made from a cupron-
ickel alloy. This cupron-
ickel material is suscep-
tible to attack from the
sanitizersusedinpools and
spas, and from other re-
latedwater chemistry con-
ditions. Once the heat ex-
changer fails, the heat
pump is ruined. The
ThermoLink heat ex-
changer tube is made from
titanium,andisvirtuallyim-
pervious to water chemis-
try damage.
Electronic
Controller
State-of-the-art, solid-
state electronic controller,
maintains water tempera-
turewithin 1ºFof setpoint.
Controlleralsopermitsuser
to predefine different Pool
andSpa water temperature
set points.
Corrosion-Proof
Cabinet
The cabinet, being made
from resilient, UV-Pro-
tected ABS material, can
never rust, fade, or cor-
rode. You can expect the
cabinet to retain a like-
new appearance with only
an occasional wash down
and—if so desired— a
quickwaxing.
PLEASE SPEND A FEW MINUTES READING FURTHER TO BECOME
FAMILIAR WITH ALL THE FEATURES, THE SAFE OPERATION, AND THE
CARE OF YOUR NEW HEAT PUMP.
Important Features of Your New
Icebreaker Heat Pump
Heat & Cool Capability
Puts you in full control, year round ...Warms 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 refrig-
erant 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.
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.
ThermoLink
Heat Exchanger
Electronic Controller
Corrosion-Resistant
Cabinet
Scroll Compressor
Heat & Cool + Hot Gas
Defrost
D
D
D
D
D

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Usedand maintained properly,yourheatpumpwillprovideyear-upon-yearofsafeandeconomicalservice.
However, aswith any mechanical or electricaldevice, to get themost from your heat pump–whileinsuring
personalsafety for you and others–certain operational andmaintenancefactorsmustbeobserved.
Likewise,exceptingafewminorowner-capablemaintenanceitems(explainedlaterinthismanual),repairand
serviceofyourheatpump mustbeperformed onlybyexperienced servicepersonnel. Shouldyou, theowner,
suspect your heat pump is not performing properly, by referring to the section in this manual entitled:
"Troubleshooting",you will be ableto determineif acall forserviceis required. Your installer can beone
source of service, orAquaCal Customer Support personnel stand ready to assist you at: [phone].
Forquestionsconcerninginstallation,modifications,operation,serviceandupkeep,pleasecontactyourinstaller
orAquaCalCustomerSupport. Warranties maybevoided iftheheater hasbeenused,maintained,orrepaired
improperly.
Inadditiontopossiblevoidingofwarranties:unapprovedinstallationmethods,nonstandardmodifications,
poororincorrect maintenance, service by unqualifiedpersonnel, or improper useof this unit,may result in
personalinjuryand/orpropertydamage. Forpersonalsafetyandtoavoiddamagetoequipment,itisimportant
thatsafetyinstructionsdisplayedontheheatpump,andwithinthismanual,areread,understood,andfollowed.
Throughoutthis manual thefollowingtwosafetysignals are placed whereparticularcareisrequired. Please
note "WARNING"relatestopersonalsafety,while"CAUTION"signalspromoteavoidingdamagetoequipment.
SAFETY INFORMATION
Specific instructions will appear in this box.
Water Temperature Safety
This“Warning”symbol appearsinthis manualwherespecial attentionisrequired forpersonalsafety.
Specific instructions will appear in this box.
Failuretoheedthefollowingmayresultinpermanentinjury or
death.
WARNING!
This“Caution” symbolappearsinthis manualwherespecialcare isrequiredtoavoid equipment damage.
Failuretoheedthe followingmayresultindamagetoequipment.
CAUTION !
WARNING! Failureto heedthefollowingmayresultinpermanentinjuryor
death.
Prolongedimmersioninwaterwarmerthannormalbodytemperaturemay causeaconditionknownas
HYPERTHERMIA. Thesymptomsofhyperthermiainclude:unawarenessofimpendinghazard,failure
toperceiveheat,failure torecognizethe needtoexitthespa,andunconsciousness. Theuse ofalcohol,
drugs,ormedicationcan greatlyincreasethe riskoffatalhyperthermia. Inaddition,personshavingan
adversemedical history, or pregnantwomen,shouldconsulta physician beforeusingahot tub orspa.
Childrenand the extreme elderlyshouldbesupervisedby a responsible adult.

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RefrigerantCircuitServiceOnlyby
Qualified,EPACertifiedTechnician
Heater NOT Repairable by Owner
Water Chemistry Safety
Chlorine . . . . . . . . . . . . . . .:
Bromine . . . . . . . . . . . . . . .:
pH . . . . . . . . . . . . . . . . . . .:
TotalAlkalinity . . . . . . . . . .:
Calcium Hardness . . . . . . . .:
Total DissolvedSolids .. . ..:
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
RECOMMENDEDWATERCHEMISTRYSTANDARDS
Improperwater chemistry canpresenta serious healthhazard. Toavoid possiblehazards, maintain
Pool/Spawater per standardsbelow.
Failuretoheedthefollowingmayresultinpermanentinjury or
death.
WARNING!
WARNING! Failuretoheedthefollowingmayresultinpermanentinjury
ordeath.
Heatercontainsrefrigerantunderhighpressure. Repairstotherefrigerantcircuitmustnotbeattempted
by untrained and/or unqualified individuals. Service must be performed only by qualified HVAC
technicians. Recoverrefrigerant torelievepressurebefore openingsystem.
WARNING! Failuretoheedthefollowingmayresultinpermanentinjury
ordeath.
Heatpumpscontainno owner-repairable components. Repairs must not be attemptedby untrained
and/orunqualifiedindividuals. Ifserviceisdeemednecessary, contact installing dealer orAquaCal
Customer Support at [phone].
Whileyour heat pump’stitanium-basedheat exchanger providesnearlyimperviousprotectionagainst
poorwater chemistry, improperwater chemistry may causeexpensive damage to pump,filter,pool
shell,etc. Toavoidequipmentdamage,maintainPool/Spawaterperstandardsbelow.
Failuretoheedthefollowing canresultin damagetoequipment.
CAUTION !

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Setting the Temperature Controls - Pool or Spa
1. Turnthe selectedpoolorspathermostatdial clockwise to its highestsetting.
2. The heat pump will startand begin to warm the poolor spa.
NOTE:The heatpumputilizes ashort-cycle timedelaydevice. If heatpump does not
start,wait five(5) minutes;thetime delaymaybe preventingthe heatpumpfrom starting.
3. Initially,thetypicalspamay take several hours to heat, while apoolmaytakeseveraldays. Heating
timewill depend onthevolumeof water,beginningwatertemperature, and theweatherconditionsat
the time of start-up. (Also see Table of Contents item: Calculating Initial Heating Time.)
4.When the pool or spa reaches the desired temperature, slowly rotate the thermostat knob
counterclockwiseuntil theheatpump(just) stops. The thermostatisnowpositioned toautomatically
maintainthesettemperature.
HEATING-QUICK START & STOP
SwitchingControls from PooltoSpa
NOTE: Itis best to stop the water pump while repositioning valves.
1. Open spavalves and closepool valves.
2. Withthespa watercirculation pumpoperatingfor atleast fiveminutes,movethe POOL/OFF/SPA
toggleswitch from the POOLsettingto the SPAsetting.
3. Turnthe Spathermostat fullyclockwise (104ºF). Heat pumpshould start(alsosee timedelay note,
above).
4. Initially, thetypicalspa maytakeseveral hourstoheat. Heatingtime willdependon thevolumeof
water,beginning watertemperature,andtheweatherconditionsat the time of start-up.
5. When the spareaches the desiredtemperature (104º F ismaximum), slowlyrotate the SPA
thermostatknob counterclockwise until the heat pump (just)stops.Thespathermostatisnow
positionedtoautomaticallymaintainthesettemperature.
StartUp
1. Withwater pump OFF, positionwater valvesto heatthe POOLor SPA.
2. Set water pump controls toallowfortemporary,continuousoperation.
3. Rotate both thermostatscounterclockwisetolowesttemperaturesettings.
4. Depending on valve settings(per #1, above),position the POOL/OFF/SPAtoggleswitch topoint at
eitherthePOOLorSPAthermostat knob. Set HEAT/COOLtoggle switch to HEATposition.
5. Ensure power is supplied to the heater, then start the water pump; the POWER and FLOWlights
shouldnowbothbelit. Permitthewaterpumptooperatefor five (5) minutes before proceeding.
To Stop the Heat Pump
Theheatpumpcanbestoppedbyinterruptingtheelectricalpowersupply,orbysettingthedesiredtemperature
lowerthan theactualwater temperature. However,please note,ifelectricalpower andwaterflow arepresent
totheheatpump,andthewatertemperature fallsbelow60ºF(with thermostatsettominimum),theheatpump
willoperatetomaintainthe water temperature at 60ºF.
TimeClockProgramming
Once the heat pump has brought the pool or spa up to temperature, it will be necessary to reset the
pumprun-timecontrols. Besuretoallowenoughrunningtimefortheheatpumptoreplacelostheat.
Requiredruntime will vary depending upon thetime of year. Coldermonths require longer running
times–generallyeighttotwelvehours/day.
Thisbriefinformationisprovidedasanaidetoinstallers,servicepersonnel,andowners. Theintentofthis
sectionis toproviderapid accessto(only)very basicoperationalinformation. Individuals whowillbe
routinelyusing,installing,maintaining,andservicingthisheatpump,arestronglyencouragedtoreadthis
entiremanual. If uncertainaboutanyinstructionsgiven herein,AquaCal Customer Support(800-786-7751)
should be contacted for additional information. Note: The terms “Heat Pump” and “Heater” are used
synonymously.

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Dimensional Information - Heat Wave/AeroTemp
100-120 Series (All Reversing Models)
PHYSICAL CHARACTERISTICS
SPECIFICATIONS
&