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Summary of Contents for Aquacal Great Big Bopper
- Page 1 AquaCal AutoPilot Great Big Bopper Operation and Installation Manual LTM0239 rev 1...
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Page 3: 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 ........................3 2.1.a Indicator Lights ....................... 3 2.1.b Control Buttons ....................... 3 2.1.c LED Display ........................3 2.1.d User Level Programs ...................... - Page 5 TABLE OF CONTENTS 4.3.c In-Line Chlorine Feeders ....................18 4.3.d Water Connections to Heat Pump ................. 18 4.3.f Maintaining Ability to Winterize ..................19 4.3.g Water Flow Rates and Operating Pressures ..............19 4.3.h Water Flow (Pressure) Switch Adjustment ..............19 4.3.i Installations with In-floor Cleaning Systems ..............
- Page 7 TABLE OF CONTENTS “LP5” Indicator ......................34 “OtA” Indicator ......................34 “FLO” Indicator ......................34 “FS” Indicator ......................35 “CSE” Indicator ......................35 “CEr” Indicator ......................35 SECTION 6 - APPENDIX 6.1 Available Accessories ......................37 6.2 Schematics ......................... 37 6.3 Connecting External Controllers ..................
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Page 9: Section 1 - General Information
Repairs must be performed by a qualified technician. If service is deemed necessary, contact installing dealer or AquaCal AutoPilot Customer Support for a service center in your area. Heat pump contains refrigerant under pressure. Repairs to the refrigerant circuit must not be attempted by untrained and/or unqualified individuals. -
Page 11: Section 2 - Operation
Page 3 SECTION 2 - OPERATION 2.1 Control Panel The following information outlines how the control panel will operate for a standard installation. Control Buttons will operate differently for custom installations; such as a heat pump connected to an external controller. -
Page 12: User Level Programs
Page 4 2.1.d User Level Programs The heat pump allows for two levels of programming; User-level and Service-level programming. This section describes User-level programming. STEPS EXPLANATION Turning Heat Pump On Controller performs a lamp test. The display reads “888”. Turn power on at external fuse Controller’s software version is briefly displayed. -
Page 13: Enabling Lockout Option
Page 5 STEPS EXPLANATION Enabling Lockout 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 until “CF1”... -
Page 14: Heating Water
Page 6 2.2 Heating Water 1) Heat pump’s mode is set to “HEA”. 2) Thermostat is set to desired water temperature. 3) Water pump’s time clock is overridden to 24-hour operation. This is only necessary for an initial startup. After the water reaches the desired temperature, the time clock can be reset to a normal time frame operation. -
Page 15: Heat Pump's Defrost Operation
Page 7 2.4 Heat Pump’s Defrost Operation WARNING - Failure to heed the following may result in injury or death. ROTATING FAN PROP HAZARD: fan may start during defrost cycle. Keep hands clear of fan blade at all times. Frost can form on the heat pump evaporator coil under certain weather conditions. When enough frost has formed to inhibit heat pump operation, the heat pump starts a defrost cycle. -
Page 17: Section 3 - Maintenance
Page 9 SECTION 3 - MAINTENANCE WARNING - Failure to heed the following may result in injury or death. Possible electric shock hazard - Disconnect power to all electrical devices on pad when washing heat pump. Do not restore electrical power until equipment is completely dry. -
Page 18: Monitoring Conditions
Page 10 3.2 Monitoring Conditions 3.2.a Pool Chemistry CAUTION - Failure to heed the following may result in equipment damage. Stop water flow when refinishing or acid washing pool. Failure to follow these instructions may damage equipment and voids heat pump warranty. CAUTION - Failure to heed the following may result in equipment damage. -
Page 19: Winterizing
An annual inspection and maintenance program is strongly recommended starting one (1) year after installation of heat pump. See Figure 4 for recommended inspection checklist. AquaCal AutoPilot can perform this service in limited areas. Contact Customer Support for more information. -
Page 21: Section 4 - Installation
Page 13 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 22: Access Panels
4.2.a Indoor versus Outdoor Installation Outdoor heat pump installations are recommended. Indoor installations require specialized airflow controls and can be problematic. If no viable alternative exists, contact the AquaCal AutoPilot Engineering department for assistance prior to proceeding with an indoor installation. -
Page 23: Planning For Condensation
Follow all relevant local, state, or national requirements regarding wind load anchoring. When anchoring is required, use AquaCal AutoPilot optional Hurricane Anchoring Kits. AquaCal AutoPilot anchoring kits satisfy the very stringent Florida Building Code Section 301.13: Wind Anchoring Requirements. Contact AquaCal AutoPilot to obtain the correct anchoring kit for the heat pump being installed. -
Page 24: Plumbing Diagrams
Page 16 4.3.b Plumbing Diagrams PLUMBING EXAMPLE 1 (U-FLOW COLLECTION HEADER) POOL Great Big Bopper Bypass Valve Circulation Pump Skimmer Main Drain Filter Bed Figure 7 PLUMBING EXAMPLE 2 (U-FLOW COLLECTION HEADER) POOL Great Big Bopper Bypass Valve Circulation Pump Skimmer Main Drain Filter Bed... - Page 25 Page 17 PLUMBING EXAMPLE 3 (Z-FLOW COLLECTION HEADER) POOL Great Big Bopper Bypass Valve Circulation Pump Skimmer Main Drain Filter Bed Figure 9 PLUMBING EXAMPLE 4 (Z-FLOW COLLECTION HEADER) POOL Great Big Bopper Bypass Valve Circulation Pump Skimmer Main Drain Filter Bed Figure 10...
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Page 26: In-Line Chlorine Feeders
Page 18 DO NOT PLUMB AS SHOWN HERE Figure 11 4.3.c In-Line Chlorine Feeders Always place in-line chlorinators as low, and as far downstream from the heat pump as possible. If an erosion type feeder is used, always install a Hartford Loop to protect internal heat pump components. 4.3.d Water Connections to Heat Pump The Great Big Bopper is supplied with 4"... -
Page 27: Maintaining Ability To Winterize
Water flow exceeding 280-GPM may damage titanium condenser; such damage will NOT be covered under the equipment warranty. Install a bypass valve whenever water flow rate may exceed 280-GPM. Contact AquaCal AutoPilot Technical Support for guidance regarding testing for water flow rate. The maximum static (or operating pressure) is 50 pounds-per-square-inch (PSI). - Page 28 Page 20 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. “Len Gordon” Switch: 1) Locate black rectangular plastic tab, located on forward-facing side of the switch. See Figure 13.
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Page 29: Installations With In-Floor Cleaning Systems
Page 21 4.3.i Installations with In-floor Cleaning Systems Where a cycling cleaning system is installed, AquaCal AutoPilot strongly recommends a water hammer suppression standpipe assembly within the plumbing circuit. For additional information, please contact AquaCal AutoPilot Customer Support. 4.4 Wiring WARNING - Failure to heed the following may result in injury or death. -
Page 30: Ground-Fault Protection
Page 22 Data Plate Example Figure 15 4.4.e Ground-Fault Protection Local codes and regulations may require the use of a ground fault interruption device (GFI Circuit Breaker). Nuisance tripping of these devices is common and not covered under the terms of the Manufacturer’s warranty. -
Page 31: Positioning Mode Jumper
Page 23 Great Big Bopper Microprocessor Board “Y” and “Z” “FS-2” connection connection points points Figure 16 4.4.g Positioning Mode Jumper WARNING - Failure to heed the following may result in injury or death. Risk of Electrical Shock- Ensure all electrical power to the heat pump has been disconnected prior to removing the heat pump front access panel. -
Page 32: Programming
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 33: Program Displays
Page 25 4.5.a Program Displays MESSAGE DESCRIPTION “CFI” Select water temperature format; in either Celsius or Fahrenheit. “ULC” Enable heat pump lock out feature. “ELC” Select password to lock out heat pump access. Access to site-dependent setup parameters. Factory code required. (Not intended for “LOC”... -
Page 34: Configuring For Remote Flow Switch
Page 26 STEPS EXPLANATION Configuring for Remote Flow Switch It is assumed that a remote flow See “Connecting External Controllers” on page 37 for more information. switch has been connected to the heat pump. If needed, see “Entering Service Menu” in this chart. Enter Service Menu Press the “Pool/Spa”... -
Page 35: Adjusting Dead Band Differential
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. Unless instructed by AquaCal AutoPilot Technical Support Group, the installer should not adjust sensor calibration or dead-band values. The steps below outline the procedure. -
Page 36: Default Program Parameters
Page 28 4.5.d Default Program Parameters The following options have been pre-programmed into the microprocessor. CODE DESCRIPTION DEFAULT VALUE RANGE “CFI” Celsius/Fahrenheit Selection. 0 = Celsius / 1 = Fahrenheit “CFO” Call Flex Options This option is not used. “dBP” Pool Dead Band Differential 1°... -
Page 37: 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 38: 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: Measure temperature of discharge air coming out of the Heat pump not top of the heat pump. -
Page 39: Heat Pump Tripping Breaker
Incorrect mode “Setting Operating Mode” on page 4 for more setting information. STEP 3: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. Heat Pump Running, Not Cooling STEP 1: Measure the temperature of the discharge air coming Heat pump not out of the top of the heat pump. -
Page 40: Water Coming From Heat Pump
See “Heating time Water on page 6 for more information. 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 41: Fault Code Definitions
Page 33 5.2 Fault Code Definitions FAULT CODE RULE OUT RESOLUTION “dPO” Indicator Defrost sensor is open Cut or loose Defrost sensor requires replacement. sensor wiring. “PO” Indicator Water temperature sensor is open Cut or loose Water temperature sensor requires replacement. sensor wiring. -
Page 42: Lp" Indicator
Please note – improperly charging the system can void manufacturer’s warranty. STEP 3: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. “LP5” Indicator Heat Pump has locked out due to... -
Page 43: Fs" Indicator
Page 35 FAULT CODE RULE OUT RESOLUTION STEP 3: Call heat pump installer or AquaCal AutoPilot Customer Support for further assistance. “FS” Indicator Heat pump in defrost mode. This is a normal operation of heat pump. See “Heat Pump” on page 7 for more information. -
Page 45: Available Accessories
Page 37 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 0040S When using two-speed circulation pumps (and low-speed water pressure will not properly activate heat pump water pressure switch) ASC-2...
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