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Aquacal AutoPilot WS03 Operation And Installation Manual

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AquaCal AutoPilot
Water Source
Operation and Installation Manual
LTM0266 rev 3

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  Summary of Contents for Aquacal AutoPilot WS03

  • Page 1 AquaCal AutoPilot Water Source Operation and Installation Manual LTM0266 rev 3...
  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 - GENERAL INFORMATION 1.1 Contacting AquaCal AutoPilot ....................1 1.2 Safety ............................ 1 SECTION 2 - OPERATION 2.1 Control Panel ........................2 2.1.a Indicator Lights ........................ 2 2.1.b Control Buttons (Inactive if unit under external control) ............ 2 2.1.c LED Display........................
  • Page 3 TABLE OF CONTENTS 4.4 Wiring ..........................23 4.4.a Standards ........................23 4.4.b General Requirements ....................23 4.4.c Grounding and Bonding ....................23 4.4.d Surge Suppression ....................... 23 4.4.e Sizing the Electrical Service ..................23 4.4.f Verify Transformer Tap ....................24 4.4.g Three Phase Monitor Adjustment ..................
  • Page 4 TABLE OF CONTENTS “CEr” Indicator ......................38 SECTION 6 - APPENDIX 6.1 Available Accessories ......................39 6.2 Schematics ......................... 39...
  • Page 5: Section 1 - General Information

    Phone 8-5 pm, Eastern M-F (727) 821-7471 Please have your model and serial numbers available when contacting AquaCal AutoPilot for questions, service, or parts. 1.2 Safety For personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the equipment and within this manual.
  • Page 6: Section 2 - Operation

    Page 2 SECTION 2 - OPERATION 2.1 Control Panel The following information outlines the operation for a standard installation. Control Buttons will operate differently for custom installations; such as a heat pump connected to an external controller. Please see “External Controls / Equipment” on page 23 for more information.
  • Page 7: User Level Programs

    Page 3 2.1.d User Level Programs The heat pump features two levels of programming; User-level programming designed for the end user and Service-level programming designed for the product installer. This section describes User-level programming. STEPS EXPLANATION Turning Heat Pump On ...
  • Page 8: Enabling User Lock Option

    Page 4 STEPS EXPLANATION Enabling User Lock Option Press and hold “Up” and If “LOC” is briefly displayed, followed by a “0”, the heat pump is already locked. “Down” buttons simultaneously A numerical password is required to proceed. See “Unlocking Heat Pump” on until “CF1”...
  • Page 9: Section 3 - Maintenance

    Page 5 SECTION 3 - MAINTENANCE 3.1 Cleaning Equipment Clean and polish heat pump frequently to prevent damage to equipment. More frequent service is required for heat pumps located in sandy or coastal areas where sand and salt spray can become detrimental factors to equipment.
  • Page 10: Pool Chemistry

    Maintain water flow rates as shown below. Please note, these specifications relate to the heat pump only. Code-specified whole system turnover rates must be satisfied. Contact AquaCal AutoPilot Technical Support for guidance regarding testing for water flow rates.
  • Page 11: Adjusting Water Flow Using ∆T (Delta-T)

    (measured with supplied temperature pressure probe). See Table 9 for correct temperatures. Temperature differences are based on source water temperatures of 72° (+ or – 3° F). For source temps outside this range contact AquaCal AutoPilot Customer Support.
  • Page 12: Irrigation And Storm Run-Off

    Page 8 11) Mark valves at this position for future reference. Water Temperature Range Chart TEMPERATURE (HEA MODE ONLY) HEAT MODEL EXCHANGER * SOURCE-SIDE POOL-SIDE Titanium 3° to 5° F 1.5° to 3° F WS03 Cupro-Nickel 6° to 9° F Titanium 3°...
  • Page 13 Page 9 heat exchanger with Figures 4 through 7. Follow appropriate winterizing instructions for heat exchanger type. 4) When ready to use heat pump again, hand-tighten connection unions. Re-connect electrical power, and set operating mode on heat pump. Turn “ON” circulation pump. Heat Pump with External Drain Plug Heat Pump a) Remove external drain plug.
  • Page 14: Planned Maintenance

    An annual inspection and maintenance program is strongly recommended starting one (1) year after installation of heat pump. See Figure 6 for recommended inspection checklist. AquaCal AutoPilot can perform this service in limited areas. Contact Customer Support for more information.
  • Page 15: Section 4 - Installation

    Page 11 SECTION 4 - INSTALLATION WARNING - Failure to heed the following may result in injury or death. Installation of this equipment by anyone other than a qualified installer can result in a safety hazard. The information contained throughout the “Installation” section is intended for use by qualified heat pump installation technicians, familiar with the swimming pool/spa service industry safety standards and methods.
  • Page 16: Access Panels

    Page 12 WS10 Source Pool FRONT RIGHT 39.4 in [100.2 cm] 60.5 in 34.5 in [153.7 cm] [87.6 cm] Figure 8 4.1.c Access Panels WS03, WS05 and SP05 WS10 (Back Panel) (Back Panel) Plumbing Plumbing Access Access (Front Panels) (Front Panels) Controller and Controller and Service Access...
  • Page 17: Electrical Cutouts

    Page 13 4.1.d Electrical Cutouts WS03, WS05 and SP05 BOTTOM 1-3/8 in [3.5 cm] 7/8 in [2.2 cm] Figure 10 WS10 BOTTOM 1-3/8 in [3.5 cm] Figure 11 4.2 Placing Heat Pump 4.2.a Positioning Clearances  Confirm adequate clearance is provided above and around heat pump to permit access panel removal during equipment maintenance and service.
  • Page 18: Controlling Irrigation And Rainwater Runoff

     Equipment pad and racks must meet all requirements of authorities having code-related jurisdiction. 4.2.e Anchoring Heat Pump to Pad Follow all relevant local, state, or national requirements regarding wind load anchoring. Contact AquaCal AutoPilot to obtain the correct anchoring kit information. Please have the heat pump model number ready when contacting AquaCal AutoPilot.
  • Page 19: Plumbing Diagrams

    Page 15  Using an open (or raw) body of salt water as the heat pumps source water is not recommended. o Raw salt water promotes the growth of crustaceans, which can eventually clog a heat pump’s heat exchanger. These types of applications are highly problematic and require additional maintenance.
  • Page 20 Page 16 SOURCE WATER FROM WELL LEGEND = Hose Spigot = Check Valve = Indicates Direction of Water flow = Clean Out Port with Threaded Cap = Butterfly or Ball Valve = Temperature / Pressure Port Figure 13 TYPICAL DEEP WELL CONSTRUCTION Size and Depth may vary.
  • Page 21 Page 17 SOURCE WATER FROM SURFACE WATER LEGEND = Hose Spigot = Check Valve = Indicates Direction of Water flow = Clean Out Port with Threaded Cap = Butterfly or Ball Valve = Temperature / Pressure Port Figure 15 TYPICAL LAKE CONSTRUCTION 45°...
  • Page 22 Page 18 SOURCE WATER FROM POOL (SUNPOWER HEATING SPA) LEGEND = Indicates Direction of Water flow = Butterfly or Ball Valve = Temperature / Pressure Port Figure 17 WATER SOURCE AND SUN POWER COMBO Please note –  Insert additional heat pumps using same plumbing configuration.
  • Page 23 Page 19 WATER SOURCE HEAT PUMP CONNECTIONS (TOWER) LEGEND = Indicates Direction of Water flow = Butterfly or Ball Valve Thicker path lines indicate metal pipe. Thinner path lines indicate PVC pipe. = Temperature / Pressure Port = Brass Temperature / Pressure Port Note: High pressure heat pumps have copper source piping.
  • Page 24: In-Line Chlorine Feeders

    Page 20 4.3.b In-Line Chlorine Feeders Place in-line chlorinators as far downstream from the heat pump and as low in elevation as possible. If an erosion type feeder is used, always install a Hartford Loop to protect internal heat pump components. 4.3.c Water Connections to Heat Pump Connection to site plumbing is made via PVC solvent cement to the female slip socket of the plumbing unions.
  • Page 25: Maintaining Ability To Winterize

    Figure 24 and Figure 25. Follow the adjustment procedure for the appropriate switch.  Should adjustment of water pressure switch prove unsuccessful, contact AquaCal AutoPilot Technical Support; site-specific factors may require the installation of an external flow switch.
  • Page 26 Page 22 “Len Gordon” Switch: 1) Locate black rectangular plastic tab, located Len Gordon Switch on forward-facing side of the switch. See Figure 24. The black rectangle is a wheel lock tab. In this orientation rotate top of adjustment 2) Slide tab left to unlock the adjustment wheel TOWARD you to decrease water pressure required to start heat pump.
  • Page 27: Wiring

     Locate the equipment disconnect as close to the heat pump as possible. Always satisfy applicable codes and standards.  AquaCal AutoPilot heat pumps are designed for copper conductors, only. Do not use aluminum wire.  Never mount a power-disconnect directly to the heat pump.
  • Page 28: Verify Transformer Tap

    Page 24 4.4.f Verify Transformer Tap Voltage settings must be confirmed and set correctly on the heat pump depending on the measured voltage found at the installation site. If an incorrect voltage is set on the heat pump, it may not start or it could possible cause damage to heat pump components.
  • Page 29 Page 25 1. Attempt to turn heat pump on by adjusting thermostat to call for heat. If more than one heat pump is onsite, turn them all on. Final adjustments must be made with all heat pumps running. 2. Locate the phase rotation monitor in the electrical box of heat pump. a) If a standard phase monitor is found (Figure 28), adjustment is not needed.
  • Page 30: External Controls / Equipment

    Page 26 ADDITIONAL DIGITAL MONITOR SETTINGS OPTION DEFAULT SETTING Delay on Break Delay on Fault Percent over volt Percent phase unbal Reset mode CNTRL mode Table 13 3. If heat pump(s) do not start, perform the following procedure: A. Confirm heat pump’s transformer is set for correct voltage. See section entitled "Verify Transformer Tap”...
  • Page 31: Positioning Mode Jumper

    The installer must insure the programming is compatible with any external controllers and confirm heat pump starts and operates per manufacturer’s specifications. Unless instructed by AquaCal AutoPilot Technical Support Group, the installer should not adjust sensor calibration or dead-band values.
  • Page 32: Program Displays

    - Failure to heed the following may result in equipment damage.  Service Level Programming must only be attempted by authorized service centers. If adjustments are deemed necessary, contact installing dealer or AquaCal AutoPilot Customer Support. Un-authorized adjustments in the Service Menu (beyond the “LOC”...
  • Page 33: Configuring For External Controller

    Page 29 STEPS EXPLANATION Press “Up” or “Down” button to Select “0” to disable time delay. select “0” or “1”. Select “1” to allow time delay to remain active. Wait 15 seconds to allow heat pump to exit programming Configuration is complete. mode.
  • Page 34: Calibrating Defrost Sensor

    The dead-band differential determines the number of degrees the water temperature must rise or fall below the set point before calling for heating or cooling. The installer should not adjust sensor calibration or dead-band values unless instructed by an AquaCal AutoPilot Technician. If needed, see “Entering Service Menu” in this chart.
  • Page 35: Resetting Heat Pump ("Back Door" Entry)

    Page 31 STEPS EXPLANATION Resetting Heat Pump ("Back Door” Entry) The factory "Back Door Entry" will reset the service lock code back to the factory setting “50”. CAUTION - Using this option will RESET ALL SETTINGS TO THE FACTORY Simultaneously Press “Pool / DEFAULTS.
  • Page 36: Section 5 - Troubleshooting

    WARNING - Failure to heed the following may result in injury or death. Repairs must not be attempted by untrained unqualified individuals. If service is deemed necessary, contact installing dealer or AquaCal AutoPilot Customer Support. WARNING - Failure to heed the following may result in injury or death.
  • Page 37: Heat Pump Running, Not Heating

    STEP 7: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. Heat Pump Running, Not Heating STEP 1: Confirm heat pump mode is set to either “HEA” OR Incorrect mode “ACH”.
  • Page 38: Heat Pump Tripping Breaker

    “Heatsavr ”, can also compensate for excessive heat loss. STEP 9: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. Heat Pump Tripping Breaker STEP 1: If breakers do not trip immediately, the issue is most Weak breaker likely a weak breaker.
  • Page 39: Heat Pump Running, Not Cooling

    Confirm that water pump is not being set with low runtimes. STEP 8: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. Water Coming From Heat Pump STEP 1: If using chlorine or bromine as a pool / spa sanitizer, use a test strip in water at heat pump to determine if sanitizer is present.
  • Page 40: Fault Code Definitions

    See heat pump charge. data plate for correct charge and verify charge. Please note – improperly charging the system can void manufacturer’s warranty. STEP 6: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance.
  • Page 41: Hp5" Indicator

    Please note – improperly charging the system can void manufacturer’s warranty. STEP 5: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. “LP5” Indicator Heat Pump has locked out due to...
  • Page 42: Flo" Indicator

    See section entitled “Water Flow (Pressure) Switch incorrectly Adjustment” on page 21. calibrated STEP 4: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. “CSE” Indicator Control system error. STEP 1: Disconnect then reconnect power to reset control. If error recurs, proceed to next step.
  • Page 43 Page 39 SECTION 6 - APPENDIX 6.1 Available Accessories NAME PART # DESCRIPTION  Used for automatic pool / spa thermostat switching.  Use when the pool / spa elevation is higher than the EXTERNAL FLOW heat pump. SWITCH KIT ...
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This manual is also suitable for:

Autopilot ws05Autopilot ws10Autopilot sp05