Aquacal GBB Installation Manual
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Aquacal GBB Installation Manual

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AquaCal
Installation Manual
Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
LTM0934 REV 1.04
- (project rel 7.02)

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  • Page 1 ® AquaCal Installation Manual Important Read this document before operating / installing this product For additional product manuals and operation / installation procedures, please visit www.AquaCal.com LTM0934 REV 1.04 - (project rel 7.02)

  • Page 3: Table Of Contents

    Table of Contents Contacting AquaCal AutoPilot, Inc. Safety Instructions 1 - Installation 1.1 Positioning Equipment 1.2 Clearances 1.3 Dimensions 1.4 Plumbing 1.4.a Plumbing Requirements 1.4.b Plumbing Diagrams 1.4.c Water Connections to Heat Pump 1.4.d In-Line Chlorine Feeders 1.4.e Water Flow Rates 1.4.f Adjusting Water Flow Using ΔT (Delta-T)
  • Page 4 3.6 Available Accessories 3.7 ICM Digital 3-Phase Monitor 3.8 Schematics Schematic LTM0949...

  • Page 5: Contacting Aquacal Autopilot, Inc

    Repair and service of heat pump must be performed by an authorized service center. Warranties may be voided if the equipment has been improperly installed, maintained or serviced. If service is deemed necessary, please contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." above. SAFETY SIGNALS Throughout this document, safety signals have been placed where particular attention is required.
  • Page 6 Failure to heed the following may result in injury or death. WARNING Installation and repairs must be performed by a qualified technician. The 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.

  • Page 7: Installation

    1 - Installation Failure to heed the following may result in injury or death. WARNING 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 installation technicians familiar with the swimming Pool/Spa safety standards.

  • Page 8: Positioning Equipment

    They should be used to anchor the heat pump to the pad. ® If 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 66.

  • Page 9: Clearances

    1.2 Clearances Proper 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. Avoid storing chemical containers near the heat pump. The chemicals can cause equipment damage. Avoid placing objects near or on top of the heat pump.

  • Page 10: Plumbing

    1.4 Plumbing 1.4.a Plumbing Requirements Failure to heed the following may result in damage to equipment. NOTICE Do 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. The heat pump must receive water flow within the specified minimum ranges under worst-case conditions such as a fouled water filter.

  • Page 11: Plumbing Diagrams

    The basic plumbing configurations for typical installations are shown. ® If the installation does not closely follow any of the supplied plumbing diagrams, AquaCal Technical Support is available for installation advice and guidance. Confirm water provided to the heat pump is clean and filtered.
  • Page 12 Good Plumbing Examples: ® Great Big Bopper Single Unit - Example 1 ® Great Big Bopper Single Unit - Example 2 Page - 8...
  • Page 13 ® While multiple Great Big Bopper heat pumps are shown in the following diagrams, it is not a requirement. Sizing requirements will determine the number of required heat pumps. ® Great Big Bopper Multiple Units - Z-Flow Plumbing Design ® Great Big Bopper Multiple Units - U-Flow Plumbing Design Page - 9...

  • Page 14: Water Connections To Heat Pump

    Connections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions. Unions are to be tightened on heat pump using a strap wrench. Do not use metal wrench on unions. ® Plumbing unions are available from AquaCal Failure to heed the following may result in damage to equipment. NOTICE Do not use glue on the threaded portion of the equipment’s unions.

  • Page 15: Water Flow Rates

    1.4.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. Failure to heed the following may result in damage to equipment. NOTICE Water flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may damage the heat pump.

  • Page 16: Adjusting Water Flow Using Δt (Delta-T)

    1.4.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. The adjustment procedure must be completed with the unit in heating mode.

  • Page 17: Maintaining Ability To Winterize

    PLEASE NOTE - Temperature differences are based on pool water temperatures of 69° to 75° F. (20.5° to 23.8° C) ® For water temperatures outside this range, contact AquaCal . See "Contacting AquaCal AutoPilot, Inc." on page 1. 1.4.g Maintaining Ability to Winterize Do not glue the threaded portion of the unions.

  • Page 18: Electrical

    Therefore 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 68. ® 9. If the heat pump continues to operate without water flow, contact AquaCal 1.5 Electrical 1.5.a Electrical Requirements Failure to heed the following will result in injury or death.
  • Page 19 Electrical Standards Standards Title The electrical installation must conform to the current NFPA 70, Nat'l Elec. version of the National Electric Code (NEC), and all Code 2017 applicable local and state codes IEC 60335-1 Household and similar electrical appliances - Safety - General Requirements Household and similar electrical appliances - Safety –...
  • Page 20 Minimum and Maximum Operating Voltage The heat pump must operate within specified voltages. Failure to heed the following may result in damage to equipment. NOTICE Operating equipment under higher or lower voltage conditions may result in damage to your compressor, motors or other electrical components.

  • Page 21: Access Panels

    1.5.b Access Panels Failure to heed the following will result in injury or death. DANGER Deactivate power while routing wiring to control board. Follow all National Electric Codes (NEC) and/or State and Local guidelines. ® (Great Big Bopper 1.5.c Verifying Transformer Setting Transformer voltage must be confirmed and set correctly depending on the measured voltage found on the site.

  • Page 22: Three-Phase Adjustment

    3. When heat pump starts, disconnect power and verify off. Then confirm all line voltage connections are securely tightened. Reconnect power. ® If the heat pump does not start, contact AquaCal for further assistance. See "Contacting AquaCal AutoPilot, Inc." on page 1.

  • Page 23: Schematic Location

    1.5.e Schematic Location Schematics are located on the inside of the electrical panel. Some schematics have been provided in the appendix of this manual. See "Schematics" on page 71. Page - 19...

  • Page 24: External Equipment

    1.6 External Equipment 1.6.a Connecting a Call Flex To support a direct connection to a call flex accessory, AquaCal ® heat pumps are equipped with optional terminal blocks on the microprocessor. The microprocessor is located on the low-voltage side of the electrical enclosure.
  • Page 25 Configure Call Flex Enter "Installer Menus", then proceed Page - 21...

  • Page 26: Connecting External Controllers To Heat Pump

    1.6.b Connecting External Controllers to Heat Pump To support a direct connection to an external controller, AquaCal ® heat pumps are equipped with optional removable terminal blocks on the microprocessor. The microprocessor is located on the low-voltage side of the electrical enclosure.

  • Page 27: Connecting Smart Bus Controllers

    b.1 Connecting Smart Bus Controllers Wire Connections External Controller 1. Deactivate power to heat pump and external controller. Communication Port 2. Remove electrical access panels on the heat pump and external controller. 3. Route 22-gauge, 2-conductor, low-voltage wires from the external controller communication port (com port) to the low voltage side of the heat pump's electrical enclosure.
  • Page 28 5. If dip-switch settings are required, configure them on the external controller now. Failure to heed the following will result in injury or death. DANGER Deactivate power to the external controller while setting dip-switches ® Example - Jandy AquaLink This external controller has dip switches. Confirm they are properly positioned to operate a heat pump.
  • Page 29 Page - 25...

  • Page 30: Connecting Two-Wire Controllers (With Internal Thermostat)

    SMART COMM FAULT 10. If after 45 seconds, the heat pump displays a " ": A. Confirm dip switches - If external controller uses dip switches, confirm switches are in the correct position. Otherwise, proceed to confirm wiring. a. Deactivate power to the external controller. b.
  • Page 31 Failure to heed the following may result in injury or death. WARNING This section is only for qualified installers who are familiar with the swimming pool and spa safety standards. The installer must be familiar with service industry techniques. 1. Deactivate power to heat pump. 2.
  • Page 32 Page - 28...

  • Page 33: Connecting Gas Backup Heater To Heat Pump

    1.6.c Connecting Gas Backup Heater to Heat Pump ® To support a direct connection to a gas backup heater, AquaCal heat pumps are equipped with optional terminal blocks on the microprocessor. The microprocessor is located on the low-voltage side of the electrical enclosure.
  • Page 34 Connections 1. Deactivate power to heat pump and gas heater. 2. Remove heat pump and gas heater's electrical access panels. Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. 3. Route 22-gauge (minimum), 2-conductor, low-voltage wires from the gas heater to the low voltage side of the heat pump's electrical enclosure.
  • Page 35 Configuring Gas Backup There are two different ways the gas backup heater can be configured. 24-hour mode - commonly used for commercial applications The circulation pump operates continuously. The gas heater will activate if the water temperature falls two degrees below the set temperature. When the set temperature is reached, the gas heater will be deactivated.
  • Page 36 Page - 32...
  • Page 37 Configure for Scheduled Mode Enter "Installer Menus", then proceed Page - 33...

  • Page 38: Connecting Multiple Heat Pumps (Master / Slaved)

    1.6.d Connecting Multiple Heat Pumps (Master / Slaved) Up to 16 heat pumps can be connected and controlled from a primary heat pump. There are two reasons for using a multiple heat pump configuration: 1. Controlling multiple heat pumps from one location; the master heat pump. 2.
  • Page 39 Failure to heed the following may result in damage to equipment. NOTICE The wire size connecting the heat pumps must be 22-gauge, 2-conductor, DO NOT CONNECT low-voltage wire. Be sure that the size of the wire will allow at least two HP7 or HP7R boards wires per connection point.
  • Page 40 Configuring Multiple Heat Pumps Master (Primary) Heat Pump Confirm the first connected heat pump is designated as the master (primary) unit. Enter "Installer Menus", then proceed Page - 36...
  • Page 41 Page - 37...
  • Page 42 Slaved (Secondary) Heat Pumps Go to the next connected heat pump and configure it as a slaved unit with a heat pump address of "01". Each additionally connected heat pump will require a unique heat pump address ("02", "03", etc.) Enter "Installer Menus", then proceed Page - 38...
  • Page 43 Page - 39...

  • Page 44: Connecting A Pool/Spa Switching Relay

    1.6.e Connecting a Pool/Spa Switching Relay A direct connection to an external flow relay switch has been provided on the terminal microprocessor. A pool/spa relay switch will automatically change between the pool and spa thermostat depending on the position of the plumbing valves. When water flows to the pool, the pool thermostat will be used.
  • Page 45 Connecting Switch 1. Deactivate power to heat pump. Dry Contact Connection Points to the 2. Plumb the switch as indicated in accessories installation Microprocessor instructions. 3. Remove heat pump electrical access panel. 4. Using two of the three wires from the installed switch, route wires to the low voltage side of the electrical enclosure.
  • Page 46 Page - 42...

  • Page 47: Program Heat Pump For The Customer

    1.7 Program Heat Pump for the Customer 1.7.a Setting Date and Time Set the heat pump's time and date using the following steps. Page - 43...

  • Page 48: Setting Time And Date Format

    1.7.b Setting Time and Date Format The heat pump's time and date format can be customized. Customize Time The time can be displayed in 24-hour military time (the default display is 12 hour). Enter "Installer Menus", then proceed Page - 44...
  • Page 49 Customize Date The date can be displayed as Day-Month-Year (the default is Month-Day-Year). Enter "Installer Menus", then proceed Page - 45...
  • Page 50 Page - 46...

  • Page 51: Selecting Celsius Or Fahrenheit

    1.7.c Selecting Celsius or Fahrenheit Set the water temperature to show in either Fahrenheit (default) or Celsius. Enter "Installer Menus", then proceed Page - 47...

  • Page 52: Setting Entry Code Option

    1.7.d Setting Entry Code Option The entry code feature can prevent unauthorized temperature adjustments. This feature initiates after the heat pump goes into the sleep mode for the first time. Failure to heed the following may result in damage to equipment. NOTICE Before enabling the entry code feature, be sure to record the code.
  • Page 53 Page - 49...

  • Page 54: Using Entry Code To Access Heat Pump

    1.7.e Using Entry Code to Access Heat Pump If a user entry code has been enabled in the user menu, an entry code will be required to access heat pump options. PLEASE NOTE - If the entry code has been misplaced, the heat pump will need to be reset to factory defaults. After three minutes of inactivity, the heat pump's sleep mode will activate.
  • Page 55 Page - 51...

  • Page 56: Cleaning Equipment After Installation

    Formula 409 ® Cascade ® All Power Plain Detergent (3% Solution) Table 3 - Cleaning Agents • The trademarks used in approved cleaning agents are the property of their owners and are not related to AquaCal ® Page - 52...
  • Page 57 APPROVED POLISHING AGENTS ® Simoniz ® Glo-Coat Armor All ® Protectant Table 4 - Polishing Agents • The trademarks used in approved polishing agents are the property of their owners and are not related to ® AquaCal Page - 53...

  • Page 58: Troubleshooting

    2 - Troubleshooting IN THIS SECTION: Fault Codes AIR TEMP SENSOR OPEN or AIR TEMP SENSOR SHORT CLOCK LOW BATTERY DEFROST1 SENSOR OPEN or DEFROST2 SENSOR OPEN DEFROST1 SENSOR SHORT or DEFROST2 SENSOR SHORT ERROR AT MASTER UNIT HIGH PRESSURE FAULT HIGH WATER TEMPERATURE HP5 SYSTEM LOCKOUT LOW PRESSURE FAULT...

  • Page 59: Fault Codes

    A fault code indicates a specific issue or condition that will require action before the equipment can resume operating. Please perform the following troubleshooting. If the issue reoccurs, please contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." on page 1. Failure to heed the following will result in injury or death.

  • Page 60: Defrost1 Sensor Short Or Defrost2 Sensor Short

    DEFROST1 SENSOR SHORT DEFROST2 SENSOR SHORT ISSUE Shorted defrost sensor. RESOLUTION A qualified technician should replace the defrost sensor. ERROR AT MASTER UNIT ISSUE The heat pump is slaved to a master heat pump that is displaying a fault code. RESOLUTION The error at the master heat pump must be corrected before the slaved unit will resume operation.

  • Page 61: Hp5 System Lockout

    Heat and Cool Units (Reversing) Place heat pump in heating mode and perform the following troubleshooting. ® 1. Check for proper fan operation. If the fan is not operating, contact AquaCal Technical Support. 2. Check for obstructed airflow around the heat pump.

  • Page 62: Ota System Lockout

    OTA SYSTEM LOCKOUT ISSUE A malfunction has occurred that could allow the water temperature to surpass a safe level. An installed "Over Temperature Alarm" kit has disabled the system. See "Over Temperature Alarm Kit" on page 69 for more information. RESOLUTION Call for service.

  • Page 63: Issues And Resolutions

    Failure to heed the following may result in damage to equipment. NOTICE Service by unauthorized personnel will void the factory warranty. Please perform the following troubleshooting. For further assistance, please contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." on page 1. A Front Panel Warning Indicator is Red (Select Units) ISSUE The Heat Pump is experiencing an incoming power fluctuation.

  • Page 64: Displays "Defrosting

    Displays Defrosting Displays "DEFROSTING" ISSUE The heat pump has sensed the coil is icing up. See "Ice Forming on the Heat Pump" on page 63. No action is required. RESOLUTION Heat and Cool Units - Active Defrost Hot refrigerant gas will be sent through the coil to rapidly remove ice or frost. During this process, the melting of the ice may appear as steam coming off the heat pump.

  • Page 65: Displays "Set Unit Model Number

    RESOLUTION The model number and serial number will need to be re-entered into the system. The system will then operate as normal. ® If the issue reoccurs, please contact AquaCal Technical Support. Heat Pump Not Running ISSUE The heat pump will not run.

  • Page 66: Heat Pump Won't Shut Off

    Heat Pump Won’t Shut Off ISSUE The heat pump will not deactivate. RESOLUTION PLEASE NOTE When the heat pump is set to off, the display will show the current water temperature or no water flow indicator. 1. Confirm the correct mode has been set on the heat pump. 2.

  • Page 67: Heat Pump Is Running, Not Cooling

    Heat Pump Is Running, Not Cooling ISSUE The heat pump is running. But the water is not cooling. RESOLUTION 1. If the heat pump is using an external controller, confirm the heat pump is programmed properly to allow for cooling. 2.

  • Page 68: Pool / Spa" Button Will Not Work

    "Pool / Spa" Button Will Not Work ISSUE The "Pool / Spa" button is disabled if the following devices have been configured on the heat pump. RESOLUTION A 2-wire external controller. A 3-wire external controller. An external flow switch. Water Coming From Heat Pump ISSUE The water may be normal condensation produced as a by-product of the heat pump's refrigeration process.

  • Page 69: Appendix

    3 - Appendix IN THIS SECTION: 3.1 Factory Defaults 3.2 Identifying Model Specifications 3.3 Weights 3.4 Heating Recommendations 3.5 Cooling Recommendations 3.6 Available Accessories 3.7 ICM Digital 3-Phase Monitor 3.8 Schematics 3.1 Factory Defaults Certain programming options have been preset at the factory. These options can be overwritten for site- specific conditions.

  • Page 70: Identifying Model Specifications

    Installer Menus MENUS DEFAULT OPTIONS 12 Hour SET TIME FORMAT 12 Hour 24 Hour SET DATE FORMAT Fahrenheit SET TEMPERATURE UNITS Fahrenheit Celsius SET BACKUP HEAT MODE SCHEDULED 24HR SET ENTRY CODE ENABLED SET USER ENTRY CODE SET CALL-FLEX INSTALLED SET CALL-FLEX MODE CALL FLEX...

  • Page 71: Weights

    Model Number Example 3.3 Weights NOTE: Specifications subject to change. Model Type Model Number Install Weight ® Great Big Bopper 1540 Pounds BB500 (698.5 kg) 3.4 Heating Recommendations The following recommendations will reduce the amount of time required to heat a pool. If unsure of equipment heating capability, review equipment data plate.

  • Page 72: Cooling Recommendations

    This will allow the Heat Pump the time required to cool the water at start-up. After the water has reached the desired temperature, reset the filter pump to normal operating time-frames. 3.6 Available Accessories Accessories may be purchased through an authorized dealer of AquaCal ® products.
  • Page 73 Liquid Blankets An invisible liquid heat barrier designed to retain heat and extend the swimming season. ® ® AquaCal recommends Lo-Chlor Aqua Blanket ™ Over Temperature Alarm Kit This kit is an additional safety device. It disables the heat pump if any malfunction occurs that allows the water temperature to surpass a safe level.
  • Page 74 Follow all National Electric Codes (NEC) and/or State and Local guidelines. Page - 70...
  • Page 75 3.8 Schematics Some schematics have been provided in the appendix of this manual. Page - 71...
  • Page 76 PLEASE NOTE: Specifications are subject to change without notice. ® Schematics are available by calling AquaCal Customer Support. See "Contacting AquaCal AutoPilot, Inc." on page 1. Please have the complete model and serial number available. See "Identifying Model Specifications" on page 66. Schematic Document Numbers Chart...

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