Aquacal WS03 Installation Manual
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Aquacal WS03 Installation Manual

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AquaCal
®
Installation Manual
Five Push Button Display v2.xxx (HP11 control board)
NOTE - If planning for a purchage, it is strongly recommended that a questionaire be used for
purchasing advise - https://www.aquacal.com/water-source-questionnaire/
Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
LTM1120 REL A
- (project rel 8.00)

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  • Page 1 NOTE - If planning for a purchage, it is strongly recommended that a questionaire be used for purchasing advise - https://www.aquacal.com/water-source-questionnaire/ Important Read this document before operating / installing this product For additional product manuals and operation / installation procedures, please visit www.AquaCal.com LTM1120 REL A - (project rel 8.00)

  • Page 3: Table Of Contents

    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 Incoming Power Access Holes 1.2.C Access Panels 1.2.D Verifying Transformer Setting (Select Units) 1.2.E Schematic Location 1.3 Plumbing 1.3.A Plumbing Requirements 1.3.B Plumbing Diagrams (Water Source)
  • Page 4 2.4.C Menu Trees 2.5 Supplemental 2.5.A Additional Options 2.5.B Available Accessories 2.5.C Cleaning Equipment After Installation 2.5.D Clearances 2.5.E Irrigation and Storm Run-Off 2.5.F ICM Digital 3-Phase Monitor 2.5.G Initial Cooling Recommendations 2.5.H Initial Heating Recommendations 2.5.I Saving Installer Settings to USB 2.5.J Use Installer Settings from USB 2.5.K Site Configuration Presets (Optional) 2.5.L Standards...

  • 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. SAFETY SIGNALS Throughout this document, safety signals have been placed where particular attention is required.
  • Page 6 In sizing power wiring, be especially aware of up-sizing requirements necessary due to wiring distances. Always satisfy applicable codes and standards. AquaCal AutoPilot, Inc. heat pumps are designed to use copper conductors, only. Do not use aluminum wire. Page - 2...
  • Page 7 If multiple heat pumps are on-site, confirm that the multiple heat pump configuration has been utilized. This will prevent multiple heat pumps attempting to start at the same time, causing an excessive power drop at start-up. Multiple heat pumps installed at the same site may benefit from automatic sequencing controllers (ASC) to avoid excessive power draws at start-up.

  • Page 8: Installation

    1 - Installation Failure to heed the following will result in injury or death. DANGER Deactivate power while routing wiring to control board. Heat Pump equipment must be installed within manufacturer specifications and must follow all National and/or State and Local installation guidelines. Follow all National Electric Codes (NEC) and/or State and Local guidelines.

  • Page 9: Electrical

    The 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. If needed, contact AquaCal ® to obtain anchoring kit information. Please have the heat pump model number and serial number when requesting support.

  • Page 10: A Electrical Requirements

    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 plumbing 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 the heat pump.

  • Page 11: B Incoming Power Access Holes

    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 12: C Access Panels

    Water Source WS03, WS05 SunPower SP05 Water Source WS10 1.2.C Access Panels Failure to heed the following will result in injury or death. DANGER Deactivate power while routing wiring to control board. Heat Pump equipment must be installed within manufacturer specifications and must follow all National and/or State and Local installation guidelines.

  • Page 13: D Verifying Transformer Setting (Select Units)

    Water Source WS03, WS05 SunPower SP05 Water Source WS10 1.2.D 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.

  • Page 14: E Schematic Location

    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.

  • Page 15: Plumbing

    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.
  • Page 16 Multiple Water Source Heat Pump Configuration (Standard Pressures) Single Water Source Heat Pump Configuration (High-Pressure) Page - 12...
  • Page 17 Multiple Water Source Heat Pump Configuration (High-Pressure) Water Source Heat Pump with Support Equipment Page - 13...

  • Page 18: C Plumbing Diagrams (Sunpower)

    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.

  • Page 19: D Maintaining Ability To Winterize

    Heat Pump union sizes are specified on diagrams. Connections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions. High-pressure units use joint compound on threaded copper connections. Plumbing unions are available from AquaCal ® Page - 15...
  • Page 20 Water Source WS10 Water Source WS03, WS05 SunPower SP05 Page - 16...

  • Page 21: F In-Line Chlorine Feeders

    MINIMUM MAXIMUM ® Titanium ThermoLink 20 GPM (75.7 L/min) 70 GPM (265 L/min) Source-Side Cupronickel 10 GPM (37.9 L/min) 14 GPM (53 L/min) WS03 30 GPM (113.6 ® Pool / Spa* Titanium ThermoLink 70 GPM (265 L/min) L/min) ® Titanium ThermoLink 20 GPM (75.7 L/min) 70 GPM (265 L/min)

  • Page 22: Flow Rates

    SunPower FLOW RATES MODEL SOURCE HEAT EXCHANGER TYPE MINIMUM MAXIMUM ® Source-Side Titanium ThermoLink 20 GPM (91 L/min) 70 GPM (265 L/min) SP05 ® Spa Side* Titanium ThermoLink 30 GPM (113.6 L/min) 70 GPM (265 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.

  • Page 23: H Heat Pump Bypass Requirements

    1.3.H Heat Pump Bypass Requirements The heat pump requires a certain water flow rate in order to operate properly. A bypass can be used to regulate the flow to the Heat Pump. See "Water Flow Rates" on page 17. Bypass Valve Kit (# STK0135) When high flow rates are outside recommended specifications, please use this kit or an alternative bypass valve system.

  • Page 24: Programming

    ENTER TO VIEW ARROWS TO VIEW ARROWS TO VIEW "SOURCE DIFFERENCE" "POOL / SPA DIFFERENCE" "SOURCE PUMP" ARROWS TO VIEW ARROWS TO VIEW ARROWS TO VIEW "SOURCE FLOW" "SOURCE INLET" "SOURCE OUTLET" ARROWS TO VIEW ARROWS TO VIEW MENU TO EXIT, PRESS "POOL / SPA INLET"...

  • Page 25: B Setting Date And Time Format

    USE ARROWS TO MENU PRESS ENTER, ITEM TO USE ARROWS TO "TIME / DATE" CHANGE WILL BLINK CHANGE ENTER TO SAVE MENU TO EXIT, PRESS & HOLD TO STATUS 1.4.B Setting Date and Time Format The heat pump's date and time format can be customized. Customize Time The time can be displayed in 24-hour military time (the default display is 12-hour).

  • Page 26: C Selecting Celsius Or Fahrenheit

    Customize Date The date can be displayed as Day-Month-Year (the default is Month-Day-Year). Enter "System" menus, then proceed PRESS MENU USE ARROWS TO PRESS "ENTER" BUTTON "SYSTEM" USE ARROWS TO MENU ENTER TO EDIT USE ARROWS "DATE FORMAT" TO CHANGE ENTER TO SAVE MENU TO EXIT, PRESS &...

  • Page 27: D Activate Heat Mode, Cool Mode, Auto Mode, Or Deactivate Equipment

    1.4.D Activate HEAT Mode, COOL Mode, AUTO Mode, or Deactivate Equipment Press "Mode / Enter" button until the desired mode is displayed. "HEAT" mode - After the fan and compressor start, the red "Heating" light will activate. "COOL" mode - After the fan and compressor start, the blue "Cooling" light will activate. "AUTO"...

  • Page 28: E Set A Desired Temperature (Setpoint) For The Heat Pump To Activate

    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°...

  • Page 29: F Using Shortcuts

    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 "...
  • Page 30 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...

  • Page 31: Optional Installations

    MENU TO EXIT, PRESS & HOLD TO STATUS 1.5 Optional Installations The heat pump can have features installed as options. This section describes those additional options. PLEASE NOTE Some of these features depend on having an expansion board installed in the system. If the feature is needed, and the expansion board is not installed, it can be purchased and installed separately.

  • Page 32: A Connecting Geothermal Source Side Relays

    Device Connections Figure 1 1.5.B Supplemental Options For more information visit the options manuals at https://www.aquacal.com/hp11-options-manuals/. Connecting an Air Sensor for Freeze Protection As an option, an air sensor can be installed for the freeze protection feature (Expansion Board Required). The air temperature is then used to monitor for freezing conditions instead of the water.

  • Page 33: External Controllers

    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.

  • Page 34: A Freeze Protection

    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. Damage due to improperly configured or operated heat pumps are not covered under warranty.
  • Page 35 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. NOTICE Use extreme care when setting and adjusting freeze protection options.

  • Page 36: B Setting Entry Code Option

    PRESS "ENTER" ENTER & ARROWS TO ENTER & ARROWS TO "PROTECT ON SETPOINT" "PROTECT OFF SETPOINT" TO EDIT ENTER & ARROWS TO ENTER & ARROWS TO MENU TO EXIT, PRESS "CYCLE TIME" "ACTIVE TIME" & HOLD TO STATUS 1.6.B Setting Entry Code Option The entry code feature can prevent unauthorized access to the heat pump adjustments.

  • Page 37: C Disabling Entry Code Option

    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. Use Entry Code USE ARROWS TO ENTER TO UNLOCK...

  • Page 38: D Schedule And Program Modes

    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.
  • Page 39 Set Schedule Mode to "AUTO" Enter "Shortcuts" menus, then proceed 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"...
  • Page 40 Set Schedule Mode to "OFF" Enter "Shortcuts" menus, then proceed 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"...
  • Page 41 ENTER TO EDIT ARROWS TO ENTER TO SAVE "ON" 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". Enter "Schedules"...
  • Page 42 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". Enter "Schedules" menus, then proceed PRESS MENU USE ARROWS TO PRESS "ENTER"...

  • Page 43: Appendix

    2 - Appendix IN THIS SECTION: 2.1 Service Mode 2.2 Service Help 2.3 Adjustments 2.3.A Adjusting Water Flow Using ΔT (Delta-T) 2.3.B Adjusting Water Pressure Switch (Select Units) 2.3.C Three-Phase Adjustment 2.4 Defaults 2.4.A Equipment Parameters 2.4.B Factory Reset 2.4.C Menu Trees 2.5 Supplemental 2.5.A Additional Options 2.5.B Available Accessories...

  • Page 44: Service Help

    Failure to heed the following may result in minor or moderate injury. CAUTION Servicing of this equipment by anyone other than a qualified technician can result in a safety hazard. Ordering Parts - https://www.aquacal.com/looking-for-a-part/ Sizing Equipment - https://sizing.aquacal.com/ 2.3 Adjustments IN THIS SECTION: 2.3.A Adjusting Water Flow Using ΔT (Delta-T)

  • Page 45: A Adjusting Water Flow Using Δt (Delta-T)

    2.3.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. 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 A.1 Geothermal Menus These menus are used when adjusting Water Flow Using ΔT (Delta-T) on a geothermal heat pumponly.
  • Page 46 12. Mark valves at these positions for future reference. HEAT EXCHANGER MODEL SOURCE-SIDE POOL-SIDE TYPE 1° to 5° F 2° to 4° F WS03 (.5° C to 2.8° C) (1.1° C to 2.2° C) 2° to 8° F 3° to 6° F Titanium pool-side and WS05 source-side exchangers (1.1°...

  • Page 47: B Adjusting Water Pressure Switch (Select Units)

    PLEASE NOTE - Temperature differences are based on pool and source 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. 2.3.B Adjusting Water Pressure Switch (Select Units) Adjust the water pressure switch when heat pump attempts to operate without water flow.
  • Page 48 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. 9. If the heat pump continues to operate without water flow, contact AquaCal ®...

  • Page 49: C Three-Phase Adjustment

    2.3.C Three-Phase Adjustment Failure to heed the following will result in injury or death. DANGER Deactivate power while routing wiring to control board. Heat Pump equipment must be installed within manufacturer specifications and must follow all National and/or State and Local installation guidelines. Follow all National Electric Codes (NEC) and/or State and Local guidelines.
  • Page 50 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 51: Defaults

    2.4 Defaults IN THIS SECTION: 2.4.A Equipment Parameters 2.4.B Factory Reset 2.4.C Menu Trees 2.4.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.

  • Page 52: B Factory Reset

    Relays Parameter Description A set of labels are provided for easy identification of the relay. Name Relay Type Currently there is only one choice for this option. (24 VDC RELAY). This is the connection port where the device is connected to the heat Port expansion board.
  • Page 53 USE ARROWS TO PRESS "ENTER" USE ARROWS TO "ADVANCED" "INSTALLATION" PRESS "ENTER" USE ARROWS TO MENU ENTER TO SELECT "FACTORY DEFAULTS" PRESS BUTTON UNDER "YES" TO CONFIRM The system will restart and operate as if no equipment is connected directly to the heat pump.

  • Page 54: C Menu Trees

    2.4.C Menu Trees Page - 50...
  • Page 55 Page - 51...

  • Page 56: Supplemental

    Using External Controllers, Installing expansion boards, Connecting relays and actuators, using installation presets, and setting up groups and schedules. 2.5.B Available Accessories Accessories may be purchased through an authorized dealer of AquaCal ® products. Bypass Valve Kit (# STK0135) When high flow rates are outside recommended specifications, please use this kit or an alternative bypass valve system.
  • Page 57 This kit contains an upgrade board that will give the heat pump direct control of actuators, circulation pumps, and relay- controlled devices. Liquid Blankets An invisible liquid heat barrier designed to retain heat and extend the swimming season. AquaCal ® recommends Lo-Chlor ® Aqua Blanket ™...

  • Page 58: C 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 - 54...

  • Page 59: D Clearances

    Table 4 - Polishing Agents • The trademarks used in approved polishing agents are the property of their owners and are not related to AquaCal ® 2.5.D Clearances Locate the heat pump at least 24 inches (61 cm) away from the wall. And provide a minimum 24 inches (61 cm) between heat pumps.

  • Page 60: E Irrigation And Storm Run-Off

    2.5.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.
  • Page 61 Page - 57...
  • Page 62 Page - 58...

  • Page 63: G Initial Cooling Recommendations

    2.5.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 71. 1. Confirm the valves are turned to the correct body of water. 2.

  • Page 64: J Use Installer Settings From Usb

    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.
  • Page 65 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.

  • Page 66: K Site Configuration Presets (Optional)

    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. 2.5.K Site Configuration Presets (Optional) A list of site configurations (presets) can be used to easily configure equipment directly connected to the heat pump.
  • Page 67 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 Valves, No Pump Pool / Spa, No Valves, Single Speed Pool / Spa, Valves, Single Speed Pool Only.
  • Page 68 Pool / Spa, No Valves, Single Speed This preset configures the heat pump as follows: No valve actuators are configured. A single speed circulation pump is configured to use the relay "A" connection point on the expansion board. A pool schedule is configured (Everyday from 8:00 am to 6:00 pm) When pressed, the "Pool/Spa"...

  • Page 69: L Standards

    Pool Only, No Valves, Single Speed This preset configures the heat pump as follows: No valve actuators are configured. A single speed circulation pump is configured to use the relay "A" connection point on the expansion board. A pool schedule is configured (Everyday from 8:00 am to 6:00 pm) When pressed, the "Pool/Spa"...

  • Page 70: M Schematics

    2.5.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.
  • Page 71 Hard Freeze Conditions A hard freeze is when the ambient air temperature falls below 32 degrees Fahrenheit (0° C) for more than 8 hours. In areas where this condition is prevalent and sustained, the heat pump MUST be winterized for hard freeze conditions.
  • Page 72 Cupronickel Tube in Tube Exchanger 1. Disconnect the plumbing to the heat pump at connection unions (removal is counter- Cupronickel clockwise). (Orientation 2. Place a garden hose into the inlet side of the heat pump; wrap a clean rag around the hose to depends form a temporary seal.

  • Page 73: System Information

    2.6 System Information IN THIS SECTION: 2.6.A Dimensions 2.6.B Identifying Model Specifications 2.6.C Viewing System Information 2.6.D Weights Page - 69...

  • Page 74: A Dimensions

    2.6.A Dimensions Water Source WS10 Water Source WS03, WS05 SunPower SP05 Page - 70...

  • Page 75: B Identifying Model Specifications

    2.6.B 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. 2. Find the model number on the data plate. The first letters and numbers indicate the model type.

  • Page 76: D Weights

    & HOLD TO STATUS 2.6.D Weights NOTE: Specifications subject to change. Model Type Model Number Install Weight 290 Pounds WS03 (source side Titanium) Water Source (131.5 kg) 300 Pounds Water Source WS03 (source side Cupronickel) (136.1 kg) 300 Pounds Water Source WS05 (source side Titanium) (136.1 kg)

  • Page 77: Troubleshooting

    3 - Troubleshooting Failure to heed the following will result in injury or death. DANGER Deactivate power while routing wiring to control board. Heat Pump equipment must be installed within manufacturer specifications and must follow all National and/or State and Local installation guidelines. Follow all National Electric Codes (NEC) and/or State and Local guidelines.
  • Page 78 IN THIS SECTION: Fault Codes AQUASTAR VS PUMP FAULT ERROR AT PRIMARY UNIT FREEZE PROT SENSOR OPEN or FREEZE PROT SENSOR SHORT HAYWARD VS PUMP FAULT HIGH PRESSURE FAULT HIGH WATER TEMP HP5 SYSTEM LOCKOUT HPC TEMP SYSTEM LOCKOUT JANDY VS PUMP FAULT LOW PRESSURE FAULT LP5 SYSTEM LOCKOUT MULTIPLE PRIMARY FAULT...

  • Page 79: 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. AQUASTAR VS PUMP FAULT ISSUE The heat pump has either lost communication with a connected Aquastar circulation pump.

  • Page 80: High Pressure Fault

    See "Adjusting Water Flow Using ΔT (Delta-T)" on page 41. 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.

  • Page 81: Hp5 System Lockout

    HP5 SYSTEM LOCKOUT ISSUE The heat pump has locked due to five high-pressure faults during one call for heating or cooling. RESOLUTION 1. Deactivate then reactivate power to the heat pump to clear error. 2. Troubleshoot the high-pressure issue causing the error. See "HIGH PRESSURE FAULT"...

  • Page 82: Low Pressure Fault

    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.

  • Page 83: Lp5 System Lockout

    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. Page - 79...

  • Page 84: Internal Expansion

    Confirm the model number in the system matches the heat pump's data plate. See "Viewing System Information" on page 71. If the model number is incorrect, contact AquaCal Customer Support for assistance.

  • Page 85: Source Flow Fault

    SOURCE FLOW FAULT ISSUE If source water flow goes on and off 5 or more times during one call for heating or cooling, the Heat Pump will deactivate. RESOLUTION Confirm source water pump is operating correctly. SOURCE-IN SENSOR SHORT SOURCE-IN SENSOR OPEN ISSUE Shorted or open water sensor.

  • Page 86: Sta-Rite Vs Pump Fault

    STA-RITE VS PUMP FAULT ISSUE The heat pump has either lost communication with a connected Sta-Rite water pump. Or the Sta-Rite pump needs attention. RESOLUTION Check wiring between pump and unit for breaks or damage. Reset the heat pump and circulation pump power breakers to potentially clear any internal pump faults.

  • Page 87: Issues And Resolutions

    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.

  • Page 88: Displays "Freeze Protection Active

    Displays Defrosting "FREEZE PROTECTION ACTIVE" Displays ISSUE The heat pump has sensed the air temperature has dropped below 37° F (3° C). This is the default setpoint before the heat pump begins to circulate water to groups marked as needing freeze protection.

  • Page 89: Displays "No Source Water Flow

    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. Page - 85...

  • Page 90: Heat Pump Not Running

    The heat pump breaker(s) keeps tripping. RESOLUTION ® 1. If AquaCal heat pumps have been connected using a multiple heat pump configuration, the configuration may be incorrect. Please confirm settings or contact installer of equipment. 2. Have an electrician confirm breakers are correct type, in good condition, and properly sized for the heat pump.

  • Page 91: Heat Pump Is Running, Not Heating

    Heat Pump Is Running, Not Heating ISSUE The heat pump is running. But the water is not heating. RESOLUTION 1. If the heat pump is using an external controller, confirm it is set correctly. Contact the installer of the device or the device’s manufacturer for further assistance. 2.

  • Page 92: Light Not Working

    Light Not Working ISSUE A light connected to the heat pump isn't working RESOLUTION 1. Confirm the light is included in any group that requires it. See "Edit a Group". 2. Confirm the group containing the light has an appropriate schedule. See "Edit a Schedule".

  • Page 93: Schedule Not Working

    Schedule Not Working ISSUE A device isn't operating as scheduled. RESOLUTION Confirm the device is part of the scheduled group. Confirm the group has an appropriate schedule program. See options manuals for help on creating schedules. Confirm the schedule mode is set to "AUTO" and the scheduled program mode is set to "ON". See "Schedule and Program Modes"...

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