Summary of Contents for Aquacal Great Big Bopper BB500
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NOTE - If planning for a purchase, it is strongly recommended that a questionaire be used for purchasing advise - https://www.aquacal.com/gbb-questionnaire/ Important Read this document before operating / installing this product For additional product manuals and operation / installation procedures, please visit www.AquaCal.com LTM1122 REL B - (project rel 8.00)
Table of Contents Contacting AquaCal AutoPilot, Inc. Safety 1 - Installation 1.1 Positioning Equipment 1.2 Electrical 1.2.A Electrical Requirements 1.2.B Access Panels 1.2.C Verifying Transformer Setting (Select Units) 1.2.D Schematic Location 1.3 Plumbing 1.3.A Plumbing Requirements 1.3.B Plumbing Diagrams 1.3.C Maintaining Ability to Winterize 1.3.D Water Connections to Heat Pump...
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2.4.F ICM Digital 3-Phase Monitor 2.4.G Initial Cooling Recommendations 2.4.H Initial Heating Recommendations 2.4.I Saving Installer Settings to USB 2.4.J Use Installer Settings from USB 2.4.K Site Configuration Presets (Optional) 2.4.L Standards 2.4.M Schematics 2.4.N Winterizing 2.5 System Information 2.5.A Identifying Model Specifications 2.5.B Viewing System Information 2.5.C Weights 3 - Troubleshooting...
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. SAFETY SIGNALS Throughout this document, safety signals have been placed where particular attention is required.
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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.
Heat Pumps require unobstructed airflow for proper operation. Heat Pumps should never be installed indoors or in a location where airflow is restricted. If an indoor installation is being considered, the installer and dealer are strongly urged to contact the AquaCal Application Department, or a local Professional Engineer prior to proceeding.
Approved mounting (hurricane) brackets are included in a box inside the unit. They should be used to anchor the heat pump to the pad. See "Anchoring (Hurricane) Brackets". If needed, contact AquaCal ® to obtain anchoring kit information. Please have the heat pump model number and serial number when requesting support.
Additional Adjustments Additional information on electrical adjustments have been provided in the appendix of this document including: 1.2.A Electrical Requirements Grounding and Bonding Follow local code requirements for proper grounding and bonding of heat pump equipment. A bonding lug has been provided on the lower left hand corner of the electrical access panel. Surge Suppression The use of approved commercial surge protectors is strongly recommended.
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.
® Great Big Bopper BB500 1.2.C Verifying Transformer Setting (Select Units) 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.
1.2.D 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 52. Page - 8...
Install a bypass valve whenever water-flow may exceed the maximum rating. See "Bypass Valve Kit (# STK0135)" For additional guidance testing water flow rates, please contact AquaCal ® Temperature ports with PVC tees and a test thermometer are also provided in selected models. These ports must be installed between the unions and the bypass valves.
Plumbing diagrams are provided in this section as a planning guide to the sequence of equipment, valves, and fittings. 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.
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Good Plumbing Examples: ® Great Big Bopper Single Unit - Example 1 ® Great Big Bopper Single Unit - Example 2 Page - 11...
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 ® Page - 12...
A strap wrench is used to tighten and ® Great Big Bopper BB500 loosen 4 inch unions 1.3.E In-Line Chlorine Feeders Place in-line chlorinators downstream from the heat pump and as low in elevation as possible. If an erosion type feeder is used, it is recommended that a Hartford Loop be installed to protect internal heat pump components.
FLOW RATES HEAT EXCHANGER MODEL TYPE MINIMUM MAXIMUM 120 GPM (454 280 GPM (1060 ® BB500 60 Hz 460 V Titanium ThermoLink L/min) L/min) * Head Loss - 30 GPM = 1.5 PSI, 70 GPM = 8.2 PSI PLEASE NOTE - If minimum flow rates are not met, heat pump output is reduced and performance will suffer.
1.4 Programming IN THIS SECTION: 1.4.A Setting Date and Time 1.4.B Setting Date and Time Format 1.4.C Selecting Celsius or Fahrenheit 1.4.D Activate HEAT Mode, COOL Mode, AUTO Mode, or Deactivate Equipment 1.4.E Set a desired temperature (setpoint) for the Heat Pump to activate 1.4.F Using Shortcuts 1.4.A Setting Date and Time The date and time are required in order to allow schedules to operate properly.
PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SYSTEM" USE ARROWS TO MENU ENTER TO EDIT USE ARROWS "TIME FORMAT" TO CHANGE ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS Customize Date The date can be displayed as Day-Month-Year (the default is Month-Day-Year). PRESS MENU USE ARROWS TO PRESS "ENTER"...
PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SYSTEM" USE ARROWS TO ENTER TO EDIT USE ARROWS TO "TEMPERATURE UNITS" CHANGE ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS 1.4.D Activate HEAT Mode, COOL Mode, AUTO Mode, or Deactivate Equipment Press "Mode / Enter"...
1.4.E Set a desired temperature (setpoint) for the Heat Pump to activate Press the up or down arrow to set the desired temperature (setpoint) for the water. The heating indicator will illuminate when heating the water. The cooling indicator will illuminate when cooling the water. PLEASE NOTE: The maximum temperature the Heat Pump can be set to is 104°...
1.4.F Using Shortcuts The shortcuts menu provides quick access to model specific options and features. The following outlines some of these options. Service Mode This mode will deactivate the heat pump as well as all equipment connected to the heat pump. (See "...
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Using a Group Shortcut In this example, a user activates a group that was previously created called "FILTRATION". PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SHORTCUTS" ARROWS TO ENTER TO ENTER TO START SHORTCUT TO USE SELECT SHORTCUT ARROWS TO MAXIMUM ENTER TO ACTIVATE MENU TO EXIT, PRESS TIME TO OPERATE...
Circulation Pumps Connect and control compatible circulation pumps to the heat pump. External Controllers To support a direct connection to an external controller, AquaCal® heat pumps are equipped with removable terminal blocks on the control board. Using Multiple Heat Pumps Up to 16 heat pumps can be connected and controlled from a primary heat pump.
1.6 Optional Programming IN THIS SECTION: 1.6.A Freeze Protection 1.6.B Setting Entry Code Option 1.6.C Disabling Entry Code Option 1.6.D Schedule and Program Modes 1.6.A Freeze Protection Failure to heed the following may result in damage to equipment. NOTICE By default (from the factory) the Freeze Protection feature WILL NOT protect the heat pump. The Freeze Protection feature is dependent on equipment controlled by properly configured groups.
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PRESS "MENU" USE ARROWS TO PRESS "ENTER" BUTTON "GROUPS" USE ARROWS TO PRESS "ENTER" ARROWS TO "FREEZE PROTECT ENABLED" GROUP TO EDIT TO EDIT PRESS "ENTER" USE ARROWS TO MENU TO EXIT, PRESS TO EDIT CHANGE TO "ON" & HOLD TO STATUS Adjusting Freeze Protection Options Failure to heed the following may result in damage to equipment.
USE ARROWS TO MENU PRESS "ENTER" ENTER & ARROWS TO "PROTECT ON SETPOINT" "FREEZE PROTECT" TO EDIT ENTER & ARROWS TO ENTER & ARROWS TO ENTER & ARROWS TO "PROTECT OFF SETPOINT" "CYCLE TIME" "ACTIVE TIME" MENU TO EXIT, PRESS &...
ENTER TO SAVE USE ARROWS TO MENU ENTER TO EDIT "USER CODE ENABLED" USE ARROWS TO ENTER TO SAVE MENU TO EXIT, PRESS CHANGE & HOLD TO STATUS 1.6.C Disabling Entry Code Option PLEASE NOTE - If an entry code has already been activated, the code must be entered before proceeding to disable.
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ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS Page - 26...
1.6.D Schedule and Program Modes If the heat pump uses groups and schedules, the schedules can be deactivated temporarily as needed. Either globally through a schedule mode, or individually by setting a group's program mode. NOTE The standard (from the factory) heat pump does not have a group or schedule. These can be created as needed depending on if a heat pump option has been utilized.
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Set Schedule Mode to "AUTO" PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SHORTCUTS" ARROWS TO ENTER TO EDIT ARROWS TO "SCHEDULE MODE" "AUTO" ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS Set Schedule Mode to "AWAY" PRESS MENU USE ARROWS TO PRESS "ENTER"...
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Set Schedule Mode to "OFF" PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SHORTCUTS" ARROWS TO ENTER TO EDIT ARROWS TO "SCHEDULE MODE" "OFF" ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS Set Group Programs to "ON" In the following example, a "Pool"...
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MENU TO EXIT, PRESS & HOLD TO STATUS Set Group Programs to "PAUSED" In the following example, a "Pool" group's set of scheduled programs will be paused. This will continue until the programs are set back to "ON". PRESS MENU USE ARROWS TO PRESS "ENTER"...
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Set Group Programs to "OFF" In the following example, a "Pool" group's set of scheduled programs will be set from "ON" to "OFF". The schedules will not resume until the programs are set back to "ON". PRESS MENU USE ARROWS TO PRESS "ENTER"...
ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS When service is complete, repeat above steps setting SERVICE MODE to "OFF". 2.2 Adjustments IN THIS SECTION: 2.2.A Adjusting Water Flow Using ΔT (Delta-T) 2.2.B Three-Phase Adjustment 2.2.A Adjusting Water Flow Using ΔT (Delta-T) The Delta-T is the temperature difference between the water temperatures entering and leaving the heat pump.
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Table 1 - Temperature Chart 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.
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Re-connect power and attempt to restart the unit. 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."...
2.3 Defaults IN THIS SECTION: 2.3.A Equipment Parameters 2.3.B Factory Reset 2.3.C Menu Trees 2.3.A Equipment Parameters This section describes all the possible parameters for equipment that can be connected to the heat pump. Pumps Parameter Description A set of names are provided for easy identification of the Name circulation pump.
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2.3.B Factory Reset A factory reset of all settings can be performed if needed. This will reset all settings to factory defaults. PLEASE NOTE: This action will wipe all previously set configurations such as external controller settings, optional device settings, groups, equipment, schedules, and site specific settings and return the heat pump to its default firmware settings from the factory.
2.4.K Site Configuration Presets (Optional) 2.4.L Standards 2.4.M Schematics 2.4.N Winterizing 2.4.A Additional Options Additional product option advice is available online in the options manuals. https://www.aquacal.com/hp11-options-manuals/ This includes the following: Circulation pump control, Solar control, Using External Controllers, Installing expansion boards, Connecting relays and actuators, using installation presets, and setting up groups and schedules.
2.4.B Anchoring (Hurricane) Brackets The heat pump must be properly anchored to the pad. (See " " below Anchoring Bracket Installation Diagram for more information.) These anchoring brackets are supplied with the new heat pump and are located in a box placed inside the electrical panel.
Formula 409 ® Cascade ® All Power Plain Detergent (3% Solution) Table 2 - Cleaning Agents • The trademarks used in approved cleaning agents are the property of their owners and are not related to AquaCal ® Page - 42...
Table 3 - Polishing Agents • The trademarks used in approved polishing agents are the property of their owners and are not related to AquaCal ® 2.4.D 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.
2.4.E Irrigation and Storm Run-Off Irrigation water may damage heat pump components. Direct irrigation water away from the heat pump. The 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.
2.4.G Initial Cooling Recommendations The following recommendations will reduce the amount of time required to cool a pool or cold plunge application. If unsure of equipment cooling capability, review equipment data plate. See "Identifying Model Specifications" on page 55. 1. Confirm the valves are turned to the correct body of water. 2.
Steps to save configuration to a thumb drive: 1. Deactivate power to heat pump. 2. Remove heat pump's electrical access panel. 3. Plug USB thumb drive into port as indicated. See Figure 1. 4. Activate power to heat pump. Do not touch thumb drive or electrical components inside heat pump.
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PLEASE NOTE: This file will take advantage of any custom configurations entered by the installer on prior installations. The file will contain the equipment, group, and schedule settings. Other settings such as multi-unit installations, etc. will still need to be configured. Failure to heed the following will result in injury or death.
7. After heat pump has successfully loaded file and restarted, deactivate heat pump at power breaker. 8. Remove thumb drive. 9. Reinstall heat pump's access panel. 2.4.K Site Configuration Presets (Optional) A list of site configurations (presets) can be used to easily configure equipment directly connected to the heat pump.
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Select the appropriate preset for the site conditions. NOTE Variable speed circulation pump presets will not show on this document. Look for the "Options Manual (Circulation Pumps)" for those options. See https://www.aquacal.com/heatpump-manuals/. PRESET OPTIONS: Pool / Spa, No Pump Pool Only, No Pump...
2.4.M Schematics Some schematics have been provided in the appendix of this manual. 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.
2.4.N Winterizing Failure to properly winterize the heat pump as needed may result in serious equipment damage. 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. Failure to heed the following may result in injury or death.
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9. Set the operating mode on the heat pump. 10. Activate the filter pump. Page - 54...
2.5 System Information IN THIS SECTION: 2.5.A Identifying Model Specifications 2.5.B Viewing System Information 2.5.C Weights 2.5.A Identifying Model Specifications 1. Find Data Plate - The data plate is usually posted on the Data Plate Example side of the equipment or the inside of the heat pump's access plate.
PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SYSTEM" USE ARROWS TO MENU PRESS ENTER TO VIEW USE ARROWS TO VIEW "UNIT SERIAL NUMBER" "INFORMATION" USE ARROWS TO VIEW USE ARROWS TO VIEW MENU TO EXIT, PRESS "UNIT MODEL NUMBER" "FIRMWARE VERSION"...
3 - Troubleshooting 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. Failure to heed the following may result in injury or death. WARNING Repairs must not be attempted by untrained or unqualified individuals.
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IN THIS SECTION: Fault Codes AQUASTAR VS PUMP FAULT DEFROST1 SENSOR OPEN or DEFROST2 SENSOR OPEN DEFROST1 SENSOR SHORT or DEFROST2 SENSOR SHORT ERROR AT PRIMARY UNIT HAYWARD VS PUMP FAULT HIGH PRESSURE FAULT HIGH WATER TEMP HP5 SYSTEM LOCKOUT HPC TEMP SYSTEM LOCKOUT JANDY VS PUMP FAULT LOW PRESSURE FAULT...
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. AQUASTAR VS PUMP FAULT ISSUE The heat pump has either lost communication with a connected Aquastar circulation pump.
See "Adjusting Water Flow Using ΔT (Delta-T)" on page 33. Cool Only Units Determine if there is a proper air circulation around the equipment. 1. Check for proper fan operation. If the fan is not operating, contact AquaCal ® Technical Support.
HIGH WATER TEMP ISSUE Incoming water temperature has exceeded 108° F (42° C) and the unit has been deactivated. The heat pump will not operate until the incoming water temperature drops to 100° F (38° C) or lower. RESOLUTION 1. Determine if a gas heater is sending water directly to the heat pump. This situation would need to be corrected before continuing.
ISSUE The refrigerant system’s low-pressure switch is showing as open. RESOLUTION Heat Only Units 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.
2. If this does not resolve the issue, a qualified technician should verify the connection between the control board and the display (loose or disconnected cable, crimps in the cable, etc.). 3. If the issue reoccurs, please contact AquaCal. See "Contacting AquaCal AutoPilot, Inc." on page 1. PENTAIR VS PUMP FAULT ISSUE The heat pump has either lost communication with a connected Pentair water pump.
SMART COMM FAULT ISSUE Heat Pump is not receiving a signal from an external controller using a smart connection point. RESOLUTION 1. Confirm a smart external controller is being used. If not, set external controller mode to "none" instead of "SMART". 2.
3.2 Issues and Resolutions 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.
Displays Defrosting Displays "DEFROSTING" ISSUE The heat pump has sensed the coil is icing up. See "Ice Forming on the Heat Pump" on page 71. No action is required. RESOLUTION Heat Only Units - Passive Defrost When ice starts to form on the coil, the compressor will stop operating while the fan continues to operate.
"NO SYSTEM FIRMWARE" Displays ISSUE The heat pump has encountered a software error. RESOLUTION ® 1. If heat pump is using a PoolSync , confirm the device is connecting to the internet. It will ® automatically attempt to load firmware on the heat pump. See PoolSync manual for specifics.
The heat pump has encountered a software error. 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.
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.
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.
Ice Forming on the Heat Pump Ice Forming on the Heat Pump ISSUE When conditions are too cold for proper operation, the heat pump will enter a defrost mode. This prevents ice from building up on the evaporator coil. RESOLUTION Heat Only Units: The heat pump may develop a fine layer of white frost on the outside coil before entering the defrost mode.
"Pool / Spa" Button Isn't Working ISSUE The "Pool / Spa" button is disabled if the following devices have been configured on the heat pump. A 2-wire external controller. A 3-wire external controller. A "SMART" external controller. An external flow switch. RESOLUTION If not used to operate the heat pump, deactivate the external control device.
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