Aquacal Heatwave Superquiet TropiCal User manual

Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
AquaCal®
Installation Manual
LTP0098 REV 2e

Table of Contents
Contacting AquaCalAutoPilot, Inc. 1
Safety Instructions 1
1 - Installation 3
1.1 Positioning Equipment 3
1.2 Clearances 4
1.3 Plumbing 4
1.3.a Plumbing Requirements 4
1.3.b Plumbing Diagrams 5
1.3.c Water Connections to Heat Pump 7
1.3.d In-Line Chlorine Feeders 8
1.3.e Water Flow Rates 9
1.3.f Adjusting Water Flow Using ΔT (Delta-T) 10
1.3.g Maintaining Ability to Winterize 11
1.3.h Adjusting Water Pressure Switch 11
1.4 Electrical 12
1.4.a Electrical Requirements 12
1.4.b Incoming Power Access Holes 15
1.4.c Access Panels 16
1.4.d Verifying Transformer Setting 16
1.4.e Three-Phase Adjustment 17
1.4.f Connecting an External Controller 18
1.4.g Programming for an External Controller 19
1.5 Service Level Programming 21
1.5.a Service Level Factory Defaults 22
1.5.b Enter Service Level Programming 23
1.6 Cleaning Equipment After Installation 24
2 - Appendix 26
2.1 Identifying Model Specifications 26
2.2 Weights 27
2.3 Heating Recommendations 27
2.4 Cooling Recommendations 27
2.5 Available Accessories 28
3 - Troubleshooting 31
3.1 Fault Codes 31
3.2 Issues and Resolutions 34
i

Page - 1
Contacting AquaCalAutoPilot, Inc.
For further assistance, please contact the distributor or installer of this product.
If unavailable, please contact AquaCal®for a partner in your area. To better assist you, please have the heat
pump model and serial number available.
lSee "Identifying Model Specifications" on page 26.
Product Information:
Website www.AquaCal.com
Phone [phone]
Hours 8-5 pm, Eastern M-F
SAFETY INSTRUCTIONS
lFor personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the equipment
and within this manual. Repair and service of heat pump must be performed by an authorized service center.
lWarranties may be voided if the equipment has been improperly installed, maintained or serviced.
lIf service is deemed necessary, please see "Contacting AquaCalAutoPilot, Inc." on page 1.
SAFETY SIGNALS
Throughout this document, safety signals have been placed where particular attention is
required.
DANGER Failure to heed the following will result in injury or death.
WARNING Failure to heed the following may result in injury or death.
NOTICE
Failure to heed the following may result in damage to equipment.
When installing and using your heat pump basic safety precautions must always be followed, including the
following:
DANGER Failure to heed the following will result in injury or death.
lThe heat pump utilizes high voltage and rotating equipment. Use caution when servicing.

Page - 2
WARNING Failure to heed the following may result in injury or death.
lInstallation and repairs must be performed by a qualified technician.
lThe heat pump contains refrigerant under 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 before opening the system.
lImproper water chemistry can present a serious health hazard. To avoid possible hazards, maintain pool / spa water
per standards detailed in this document.
lProlonged immersion in water warmer than normal body temperature may cause a condition known as
Hyperthermia. 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 elderly should be supervised by
a responsible adult.
lProlonged immersion in water colder than normal body temperature may cause a condition known as Hypothermia.
The symptoms of Hypothermia include shivering (although as hypothermia worsens, shivering stops), clumsiness
or lack of coordination, slurred speech or mumbling, confusion and poor decision-making, drowsiness or low
energy, lack of concern about personal welfare, progressive loss of consciousness, weak pulse and slow or shallow
breathing. In addition, persons having an adverse medical history, or pregnant women, should consult a physician
before immersing in a cold body of water. Children and the elderly should be supervised by a responsible adult.
NOTICE
Failure to heed the following may result in damage to equipment.
lMaintain proper water chemistry in order to avoid damage to pump, filter, pool shell, etc.
lWater flow exceeding maximum flow rate requires a bypass. Damage due to excessive water flow will void
warranty.
SAVE THESE INSTRUCTIONS

Page - 3
1 - Installation
WARNING Failure to heed the following may result in injury or death.
lInstallation of this equipment by anyone other than a qualified installer can result in a safety hazard.
lThe information contained throughout the "Installation" section is intended for use by qualified installation
technicians familiar with the swimming Pool / Spa safety standards.
NOTICE
Failure to heed the following may result in damage to equipment.
lFailure to protect equipment against corrosive conditions will adversely affect the life of the equipment and will
void equipment warranty.
1.1 Positioning Equipment
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not install equipment inside of a building.
Outdoor Use Only
Do not install equipment inside of a room or building.
lHeat Pumps require unobstructed air flow for proper operation. Heat Pumps should never be installed indoors or
in a location where air flow is restricted. See "Clearances" on page 4.
Controlling Irrigation and Rainwater Runoff
lIrrigation water may damage heat pump components. Direct irrigation water away from the heat pump.
lThe heat pump will withstand normal rainfall. Do not allow a roof slope to direct rainwater onto the heat pump.
Have a gutter installed on the roof edge to direct this water away from the heat pump. Or install the heat pump in
another location.
Planning for Condensation
The heat pump can produce a large amount of condensation. The amount of water depends on air temperature
and humidity.
lInstall the heat pump with enough height to allow for water drainage.
lPlan for water drainage as needed.
nSee "Condensation Drain Kit (# STK0202)" on page 28.
Mounting Pad Requirements
lThe heat pump's base must be installed on a flat and level surface that completely supports the entire base.
lBuild the heat pump pad out of concrete or other code-approved material.
lConfirm the pad can support the weight of the heat pump. See "Weights" on page 27.
lElevate the pad enough to allow for drainage.
lMake sure the pad is flat and level.
lHave the pad extend at least 6 inches from the heat pump base in all directions.
lDo not install the heat pump on soil or grass.
lDo not allow the heat pump base to touch the building's foundation.
lDo not place the heat pump directly on a concrete floor. This can case noise to be transmitted to an occupied
space. If necessary install vibration dampers between the heat pump base and floor.
lEquipment pad must meet all requirements of authorities having code-related jurisdiction.

Page - 4
Anchoring to Pad
lFollow all applicable local, state, and national requirements regarding wind load anchoring.
lThe shipping brackets used to secure the heat pump to the pallet are approved mounting (hurricane) brackets.
They should be used to anchor the heat pump to the pad.
lIf needed, contact AquaCal®to obtain anchoring kit information. Please have the heat pump model number and
serial number when requesting support. See "Identifying Model Specifications" on page 26.
1.2 Clearances
lProper air circulation is required for the heat pump to operate efficiently. The following diagrams show the
minimum clearances required for the proper operation of the heat pump.
lAvoid storing chemical containers near the heat pump. The chemicals can cause equipment damage.
lAvoid placing objects near or on top of the heat pump. This includes shrubbery and lawn furniture. These objects
will reduce performance and efficiency and hinder maintenance access.
(Overhead Clearance) (Top View)
1.3 Plumbing
1.3.a Plumbing Requirements
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will prevent the
equipment from being properly winterized.
lThe heat pump must receive water flow within the specified minimum ranges under worst-case conditions such as a
fouled water filter.
lFailure to provide clean filtered water to the heat pump can void product warranty.
lWater flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may
damage the heat pump. This will not be covered under equipment warranty. See "Water Flow Rates" on page 9.
lInstall a bypass valve whenever water-flow may exceed maximum rating.
lSee "Bypass Valve Kit (# STK0135)" on page 28.
lFor additional guidance testing water flow rates, please contact AquaCal®.
lA safety enhancing "Over Temperature Alarm"kit is strongly recommended for all spa applications. See "Over
Temperature Alarm Kit" on page 29.

Page - 5
1.3.b Plumbing Diagrams
Plumbing diagrams are provided in this section as a planning guide to the sequence of equipment, valves, and
fittings.
lThe basic plumbing configurations for typical installations are shown.
lIf the installation does not closely follow any of the supplied plumbing diagrams, AquaCal®Technical Support is
available for installation advice and guidance.
lConfirm water provided to heat pump is clean and filtered.
Heat Pump with water flows equal or less than maximum listed flow rate
See "Water Flow Rates" on page 9.
Heat Pump with water flows greater than maximum listed flow rate
See "Water Flow Rates" on page 9.

Page - 6
Heat Pump with Spillover Spa (One filter Pump)
Heat Pump with Spillover Spa (Two filter Pumps)
Heat Pump with Solar Panels in Plumbing Circuit

Page - 7
Heat Pump with Gas Heater backup
Multiple Air Source Heat Pumps
1.3.c Water Connections to Heat Pump
lHeat Pump union sizes are specified on diagrams.
lConnections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions.
lPlumbing unions are available from AquaCal®.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will prevent the
equipment from being properly winterized.

Page - 8
HeatWave SuperQuiet®SQ120R, SQ125, SQ145,
SQ166R, SQ225
TropiCal®T035, T055, T075 TropiCal®T090, T115, T135
1.3.d In-Line Chlorine Feeders
Place in-line chlorinators downstream from the heat pump and as low in elevation as possible.
lIf an erosion type feeder is used, it is recommended that a Hartford Loop be installed to protect internal heat
pump components.
lA Hartford Loop is not necessary with a Salt Chlorine Generator.
Heat Pump with Hartford Loop

Page - 9
1.3.e Water Flow Rates
Maintain water flow rates as indicated. Please note, these specifications relate to the heat pump only. Code-
specified whole system turnover rates must be satisfied.
NOTICE
Failure to heed the following may result in damage to equipment.
lWater flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may
damage the heat pump. This will not be covered under equipment warranty.
MODEL HEAT EXCHANGER TYPE FLOW RATES
MINIMUM MAXIMUM
SQ120R Titanium ThermoLink®30 GPM 70 GPM
SQ125 Titanium ThermoLink®30 GPM 70 GPM
SQ145 Titanium ThermoLink®30 GPM 70 GPM
SQ166R Titanium ThermoLink®30 GPM 70 GPM
SQ225 Titanium ThermoLink®30 GPM 70 GPM
T035 Titanium Tube-in-Tube 20 GPM 45 GPM
T055 Titanium Tube-in-Tube 20 GPM 45 GPM
T075 Titanium Tube-in-Tube 20 GPM 45 GPM
T090 Titanium ThermoLink®30 GPM 70 GPM
T115 Titanium ThermoLink®30 GPM 70 GPM
T135 Titanium ThermoLink®30 GPM 70 GPM
PLEASE NOTE -
If minimum flow rates are not met, heat pump performance is reduced and performance will
suffer. Internal safety devices may deactivate the heat pump with the following errors:
lHP and HP5
lor (if equipped) error codes of LP and LP5
lOperate water filtration devices per manufacturer's specifications. Dirty filters can cause a reduction of water flow
to the heat pump. An increase of 7-10 psi higher than the clean filter pressure typically reduces flow rates. This
requires the filter to be cleaned or back-washed.
lKeep baskets free of debris. A large quantity of debris in the pump and skimmer baskets can reduce water flow.
lCheck for improper valve settings. A partially closed valve after the filter, or a full-open bypass around the heat
pump, will cause insufficient water flow through the heat pump.
lThe maximum static pressure (or operating pressure) is 50 pounds-per-square-inch (PSI). These specifications
relate to the heat pump only.
lCode-specified whole system turnover rates must be satisfied.

Page - 10
1.3.f Adjusting Water Flow Using ΔT (Delta-T)
The Delta-T is the temperature difference between the water temperatures entering and leaving the heat pump.
The equipment can be fine-tuned for maximum performance by balancing water flow rates to maintain an
ideal ∆T.
lInstalled temperature ports are required to perform the following procedures.
lThese ports are typically located on the pool in and pool out water lines approximately six inches away from the
heat pump.
lThe adjustment procedure must be completed with the unit in heating mode.
PLEASE NOTE -
lThe installation of temperature ports are required for all commercial applications.
lThe installation of temperature ports are strongly recommended for residential installations.
nSee "Temperature Port Kit (# STK0096)" on page 29.
Temperature Port
(Shown with Probe)
1. Adjust thermostat to its lowest setting with unit in heating
mode.
2. Deactivate the water filtration pump.
3. Confirm that the filters leading to the heat pump are clean.
4. Adjust the valves controlling water headed towards the heat
pump to the half open position.
5. Adjust the valves controlling water leading away from the
heat pump to a fully open position.
6. Activate the pool water filtration pump.
7. Slowly raise the thermostat temperature until the heat pump
activates.
lAfter a four-minute delay, the heat pump's compressor
will start.
8. With the heat pump running, confirm water filtration pump is operating properly with adequate flow and no short
cycling.
9. Wait for water temperatures to stabilize (approximately 5 minutes).
10. Adjust valves in the following order using the temperature chart provided:
a. Adjust the valve that controls water exiting the heat pump. Match the temperature measured with a
temperature probe to the chart.
b. Wait for water temperatures to stabilize. Then check temperature again. Re-adjust the valve as needed.
11. Mark valves at these positions for future reference.
MODEL TEMPERATURE
SQ120R 3° to 7° F
SQ125 3° to 7° F
SQ145 3° to 7° F
SQ166R 3° to 8° F
SQ225 4° to 9° F

Page - 11
MODEL TEMPERATURE
T035 1° to 4° F
T055 2° to 5° F
T075 3° to 7° F
T090 3° to 6° F
T115 3° to 7° F
T135 4° to 8° F
Table 1 - Temperature Chart
PLEASE NOTE -
lTemperature differences are based on pool water temperatures of 69° to 75° F.
lFor water temperatures outside this range, contact AquaCal®.See "Contacting
AquaCalAutoPilot, Inc." on page 1.
1.3.g Maintaining Ability to Winterize
Do not glue the threaded portion of the unions. The unions are used to decouple the heat pump from the
plumbing system during hard freeze conditions.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will prevent the heat
pump from being properly winterized.
1.3.h Adjusting Water Pressure Switch
Adjust water pressure switch when heat pump attempts to operate without water flow.
Before attempting any adjustments confirm the following :
lThe filter is clean.
lFilter pump is operating.
lThe valves are set to direct the appropriate amount of water through the
heat pump. See "Water Flow Rates" on page 9.
lFLO is displayed (or displays intermittently).
WARNING Failure to heed the following may result in injury or death.
lWater Pressure Switch adjustment procedure to be performed by experienced service personnel only; procedure
must not be attempted by individuals lacking adequate electrical and mechanical experience.
NOTICE
Failure to heed the following may result in damage to equipment.
lIf the heat pump continues to operate after a water pressure switch adjustment, deactivate equipment and perform
additional troubleshooting.

Page - 12
1. Remove heat pump access panel.
2. Locate the water pressure switch. It will be outside and along
the bottom edge of the electrical enclosure. Exact location
varies by model.
3. Activate filter pump.
4. Apply power to heat pump.
5. Slowly rotate the adjustment wheel on the switch. Keep
turning the wheel until the heat pump indicates it is receiving
water. The display will no longer display the FLO code.
6. Deactivate filter pump. If correctly adjusted, theheat pump
will deactivate and the display will show the FLO code.
7. Re-install heat pump access panel.
8. If the heat pump continues to operate without water flow, the installation of a grid flow switch may be required.
lThis can become necessary if the heat pump is installed below the elevation of the body of water to be heated
or cooled. The standing pressure from the water can cause the water pressure switch to activate when the
circulation pump is off. Therefor a water flow switch must be used in place of a water pressure switch to
determine if incoming water is being sent to the heat pump. See "Grid Flow Switch (# 0040S)" on page 29.
9. If heat pump continues to operate without water flow, contact AquaCal®.
1.4 Electrical
1.4.a Electrical Requirements
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified electricians familiar with electrical
service-industry safety standards and methods.
lLocate the equipment disconnect as near to the heat pump as possible. Always satisfy applicable codes and
standards.
lNever mount power-disconnects directly to the heat pump.
lIn sizing power wiring, be especially aware of up-sizing requirements necessary due to wiring distances. Always
satisfy applicable codes and standards.
lAquaCal®heat pumps are designed to use copper conductors, only. Do not use aluminum wire.
lMultiple heat pumps installed at the same site may benefit from automatic sequencing controllers (ASC) to avoid
excessive power drops at start-up. See "Available Accessories" on page 28.

Page - 13
Electrical Standards
Standards Title
NFPA 70 The electrical installation must conform to the current
version of the NEC, and all applicable local and state
codes
NFPA 70 Article 440 Standard for Safety for Electric Spas, Equipment
Assemblies, and Associated Equipment
NFPA 70 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
UL1995 & CSA C22.2
236-05 Heating and cooling equipment
Table 2 - Standards
Grounding and Bonding
Follow local code requirements for properly grounding and bonding heat pump equipment.
lA bonding lug has been provided on the lower right hand corner of the front access panel.
Surge Suppression
The use of approved commercial surge protectors is strongly recommended.
Sizing the Electrical Service
Refer to equipment data plate for specific information required to size electrical service and over-current
protection of heat pump. Sizing is based on data plate information, wire size, wiring devices, and over-current
protection per applicable local codes and standards. See "Identifying Model Specifications" on page 26.

Page - 14
Minimum and Maximum Operating Voltage
The heat pump must operate within specified voltages.
NOTICE
Failure to heed the following may result in damage to equipment.
lOperating equipment under higher or lower voltage conditions may result in damage to your compressor, motors or
other electrical components. This damage will not be covered by product warranty.
1. Measure site voltage. The site voltage MUST be measured under “FULL LOAD” conditions. Activate all
equipment using the same electrical panel as the heat pump.
2. If measured site voltage is outside listed ranges, immediately deactivate equipment until site conditions have been
corrected. If unsure of heat pump equipment rating, please see "Identifying Model Specifications" on page 26.
Equipment Rating Minimum
Site Voltage
Maximum
Site Voltage
A Voltage
(208 to 230 Volts)
Single Phase 60 hertz
200 Volts 253 Volts
B Voltage
(208 to 230 Volts)
Three Phase 60 hertz
200 Volts 253 Volts
D Voltage
(380 to 420 Volts)
Three Phase 50 hertz
361 Volts 441 Volts
E Voltage
(380 Volts)
Three Phase 60 hertz
361 Volts 399 Volts
G Voltage
(460 Volts)
Three Phase 60 hertz
437 Volts 483 Volts
H Voltage
(200 to 240 Volts)
Single Phase 50 hertz
180 Volts 264 Volts

Page - 15
1.4.b Incoming Power Access Holes
(HeatWave SuperQuiet®
SQ120R, SQ125, SQ145,
SQ166R and SQ225)
(TropiCal®T035, T055
and T075)
(TropiCal®T090, T115
and T135)

Page - 16
1.4.c Access Panels
HeatWave SuperQuiet®
TropiCal®
1.4.d Verifying Transformer Setting
Transformer voltage must be confirmed and set correctly depending on the measured voltage found on the
site. Incorrect settings may cause heat pump damage. The following procedure will allow the installer to set
the heat pump's transformer for the appropriate site voltage.
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified technicians, familiar with electrical
service-industry safety standards and methods.

Page - 17
Example of heat pump
transformer
(Varies between models)
1. Turn heat pump on by adjusting the thermostat to call for heating or cooling.
If more than one heat pump is on site, turn them all on. Allow time for all
heat pump compressors to activate.
2. Measure the running site voltage.
3. Confirm transformer tap is set for the measured site voltage. If more than one
voltage tap is shown, select the voltage nearest to the running site voltage.
PLEASE NOTE -
lIf more than one voltage is shown on the equipment’s data plate, the factory default setting is
usually the higher voltage on the transformer.
lAs an example, a "208/230" voltage will be set to "240" from the factory.
1.4.e Three-Phase Adjustment
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified technicians, familiar with electrical
service-industry safety standards and methods.
If a three-phase unit fails to operate at start up, the orientation of the line voltage "field" wiring may need to be
adjusted.
lThe phase monitor is located inside the electrical panel.
Three-Phase
Monitor
1. Deactivate power to the unit. Confirm that power is off to all three legs using an
electrical test meter set for the correct voltage.
2. Switch position of the incoming power wires at each leg as follows, re-connect power, and
attempt to restart the unit. If the unit fails to start, disconnect power. Verify off and proceed to
next leg.
lSwitch incoming power wires at L1 and L2 on the line side to the contactor.
lSwitch incoming power wires at L1 and L3 on the line side to the contactor.
lSwitch incoming power wires at L2 and L3 on the line side to the contactor.
3. When heat pump starts, disconnect power and verify off. Then confirm all line voltage
connections are securely tightened. Reconnect power.
lIf heat pump does not start, contact AquaCal®for further assistance. See "Contacting AquaCalAutoPilot,
Inc." on page 1.