®
AquaCal
Operation Manual
Important
Read this document before operating / installing this product
For additional product manuals and operation / installation procedures, please visit www.AquaCal.com
LTM0885 REV 2a
Table of Contents
Section 1 - Contacting AquaCal AutoPilot, Inc.
Section 2 - Safety
Section 3 - Operation
3.1 Energizing Heat Pump
3.2 Display Lock
3.3 Display Panel
3.3.a Buttons
3.3.b Indicator Lights
3.3.c Display
3.4 User Level Factory Defaults
3.5 Setting Operating Mode
3.6 Selecting Celsius or Fahrenheit
3.7 Setting Thermostats
3.8 User Lock Option (Enable)
3.9 User Lock Option (Disable)
3.10 User Lock Option (Entering Pass Code)
3.11 Operating Heat Pump (With an External Controller)
Section 4 - Maintenance
4.1 Monitoring Conditions
4.1.a Water Chemistry
4.1.b Water Flow Rates
4.1.c Adjusting Water Flow Using ΔT (Delta-T)
4.1.d Irrigation and Storm Run-Off
4.1.e Clearances
4.2 Cleaning Equipment
4.3 Planned Maintenance
4.4 Winterizing
Section 5 - Troubleshooting
5.1 Fault Codes
5.2 Issues and Resolutions
Section 6 - Appendix
6.1 Identifying Model Specifications
6.2 Initial Heating Recommendations
6.3 Initial Cooling Recommendations
6.4 Available Accessories
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SECTION 1 - CONTACTING AQUACAL AUTOPILOT, INC.
For further assistance, please contact the installing dealer or contact AquaCal AutoPilot, Inc. for a service
partner in your area. To better assist you, please have the heat pump model and serial number available. See
"Identifying Model Specifications" on page 19.
Website
www.AquaCal.com
Request Service Online
www.AquaCal.com/request-heat-pump-service/
Phone
(1) 727-823-5642
Hours
8-5 pm, Eastern M-F
SECTION 2 - SAFETY
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For personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the equipment
and within this manual. 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 the installing dealer. Or contact AquaCal® for a service partner in
your area. See "Contacting AquaCal AutoPilot, Inc." on page 1.
SAFETY SIGNALS
Throughout this document, safety signals have been placed where particular attention is
required.
WARNING - signals relate to personal safety.
CAUTION - signals promote avoiding damage to the equipment.
When installing and using your heat pump basic safety precautions must always be followed, including the
following:
WARNING - Failure to heed the following may result in injury or death.
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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.
The heat pump utilizes high voltage and rotating equipment. Use caution when servicing.
Electrical installation and service should be performed by a Licensed Electrician only.
Improper water chemistry can present a serious health hazard. To avoid possible hazards, maintain pool / spa
water per standards detailed in this document.
Prolonged immersion in water warmer than normal body temperature may cause a condition known as
Hyperthermia. The symptoms of Hyperthermia include unawareness of impending hazard, failure to perceive
heat, failure to recognize the need to exit the spa, and unconsciousness. The use of alcohol, drugs, or medication
can greatly increase the risk of fatal Hyperthermia. In addition, persons having an adverse medical history, or
pregnant women, should consult a physician before using a hot tub or spa. Children and the extreme elderly
should be supervised by a responsible adult.
Prolonged immersion in water colder than normal body temperature may cause a condition known as
Hypothermia. The symptoms of Hypothermia include shivering (although as hypothermia worsens, shivering
stops), clumsiness or lack of coordination, slurred speech or mumbling, confusion and poor decision-making,
drowsiness or low energy, lack of concern about personal welfare, progressive loss of consciousness, weak
pulse and slow or shallow breathing. In addition, persons having an adverse medical history, or pregnant
women, should consult a physician before immersing in a cold body of water. Children and the extreme elderly
should be supervised by a responsible adult.
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CAUTION - Failure to heed the following may result in equipment damage.
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Maintain proper water chemistry in order to avoid damage to pump, filter, pool shell, etc.
Water flow exceeding maximum flow rate requires a bypass. Damage due to excessive water flow will void
warranty.
SAVE THESE INSTRUCTIONS
SECTION 3 - OPERATION
3.1 Energizing Heat Pump
Turn power on at external fuse box or breaker disconnect.
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Controller performs a lamp test.
The display reads 888.
Controller then displays as normal. See "Display" on page 3.
3.2 Display Lock
The heat pump has a display lock to protect against
inadvertent setting changes. To activate display and
controls, slide finger across the controls as shown from
left to right.
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The code UnL will briefly appear, then the set temperature
or mode will display.
This is different than a user-lock which requires a pass
code. See "User Lock Option (Enable)" on page 6.
3.3 Display Panel
The following information outlines the operation for a standard installation.
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Control Buttons will operate differently for custom installations; such as a
heat pump connected to an external controller. See "Operating Heat Pump
(With an External Controller)" on page 8.
Display Panel
3.3.a Buttons
Buttons
Display Lock
Pool / Spa
Up Arrow
Down Arrow
Mode
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Description
Sliding your finger across the buttons from left to right will
temporarily disable the display lock.
Select either the pool or the spa thermostat.
Used to increase temperature set point and navigate
though menu options.
Used to decrease temperature set point and navigate
though menu options.
Select heat pump's operating mode.
3.3.b Indicator Lights
Indicators
Pool
Spa
Heating
Cooling
Water Temp
Desired Temp
Description
The Heat Pump is referencing the pool thermostat.
The Heat Pump is referencing the spa thermostat.
Indicates the unit is heating the water.
Please note - the compressor must be operating before this
light will illuminate.
Indicates the unit is cooling the water.
Please note - the compressor must be operating before this
light will illuminate.
Indicates current water temperature.
Indicates temperature set point is displayed. This is
displayed when "UP" or "DOWN" is selected.
3.3.c Display
Display
75
FLO
OFF
888
CF1
Description
The heat pump is on and displaying the current water
temperature. In this example 75° F is displayed.
No water flow is detected. The filter pump is off or heat
pump is not receiving correct water flow.
The heat pump has been turned off via the mode selector
button or the temperature set point has been lowered
below 45° F.
The control program is initializing. This displays only as
power is applied to the heat pump. The program version
number will then be displayed.
Select water temperature format (in either Celsius or
Fahrenheit).
ULC
Enable heat pump lockout feature.
ELC
Select passcode to lock the keyboard.
LOC
This is a Service Entry Point (not intended for use by the
owner). The LOC code permits service personnel to enter a
factory passcode to access adjustable calibration and site
dependent setup parameters. Service adjustments are
available to authorized installation and service personnel,
only.
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3.4 User Level Factory Defaults
Certain programming options have been preset at the factory. These options can be overwritten for sitespecific conditions.
CAUTION - Failure to heed the following may result in equipment damage.
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Unauthorized adjustments in the Installer Menu (beyond the LOC menu) may void heat pump's warranty.
Table 1 - Factory Defaults
CODE
DESCRIPTION
DEFAULT
VALUE
RANGE
OFF
Heat Pump is
deactivated.
HEA
Set to heat water
to point set on
thermostat.
COO
Set to cool water
to point set on
thermostat.
ACH
Set to maintain a
water temperature
set on the
thermostat.
CF1
Celsius /
Fahrenheit
Selection
1
0 = Celsius
1 = Fahrenheit
ELC
Enter Lock Code
0
0 - 99
ULC
User Lock Code
0
0 = "User Lock Disabled"
1 = "User Lock Enabled"
3.5 Setting Operating Mode
Heat
Mode
Cool
Mode
Heating / Cooling modes only available
on select equipment. Confirm heat pump
features before setting a mode.
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Automatic
Heat / Cool Mode
Deactivate
Heat Pump
3.6 Selecting Celsius or Fahrenheit
Hold "UP" and
"DOWN" until
CF1 displays.
Press "UP or
"DOWN" button
to select.
"0" - Celsius
"1" - Fahrenheit
3.7 Setting Thermostats
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Select "POOL" or
"SPA"
Press "UP" or
"DOWN" to the
desired
temperature.
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The heating
indicator will
illuminate when
heating the
water.
The cooling
indicator will
illuminate when
cooling the
water.
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3.8 User Lock Option (Enable)
The user-lock feature allows the heat pump display panel to be "locked". This can prevent unauthorized
temperature adjustments in commercial applications.
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Do not confuse a user-lock with the display lock. See "Display Lock" on page 2.
If LOC is briefly displayed, followed by a "0", the heat pump is already locked.
If the user-lock code has been misplaced, please contact AquaCal® Customer Service for
further assistance.
Hold "UP" and
"DOWN" until
CF1 displays.
Press "POOL /
SPA" button until
ELC is displayed.
Press "POOL /
SPA" button until
ULC is displayed.
Press "Up" button
till "1" is
displayed to
enable.
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Press "UP or
"DOWN" button to
change or add a
numerical password
Press "POOL /
SPA" button to
lock in the
password.
3.9 User Lock Option (Disable)
Use "UP" button
to enter existing
password.
Press "Pool / Spa"
button to unlock.
Hold "UP" and
"DOWN" buttons
until CF1 is
displayed.
Press "POOL /
SPA" button until
ULC is displayed
Press "DOWN"
button until "0" is
displayed.
3.10 User Lock Option (Entering Pass Code)
If LOC is briefly displayed when attempting to change a heat pump's settings followed by a "0", the heat
pump is in a user-lock mode. A numerical passcode is required to proceed.
Press "UP" or
"DOWN" arrow
to enter user lock
code.
Press "POOL /
SPA" button to
unlock.
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After three seconds of inactivity, the heat pump's display lock will activate. See "Display
Lock" on page 2.
If the user-lock code has been misplaced, please contact AquaCal® Customer Service for
further assistance.
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3.11 Operating Heat Pump (With an External Controller)
Controller with an internal thermostat control
Activating Heat Pump
1. Set the desired temperature at the external controller.
2. Use the external controller to select either the "Pool" or "Spa" to heat.
Deactivating Heat Pump
l Set the external controller to "OFF".
Please note - If equipped, the heat pump's cooling function will be disabled when using
this type of controller.
If the cooling function is needed, the heat pump must be temporarily re-programed for
local control. Check with controller installer if heat pump needs to be re-programmed.
Controller with 2 positions - ("Pool" and "Spa" - no internal thermostat control)
Activating Heat Pump
1. Set the desired temperatures on the heat pump thermostats. See "Setting Thermostats" on page 5.
2. Use the external controller to select either the "Pool" or "Spa" to heat.
l Rapid movement between thermostats without a "rest" between each change can cause a missed signal
by the heat pump.
Deactivating Heat Pump
l Go to the heat pump and set the mode to "OFF". See "Setting Operating Mode" on page 4.
Please note - If equipped, the heat pump's cooling function will be disabled when using
this type of controller.
If the cooling function is needed, the heat pump must be temporarily re-programed for
local control. Check with controller installer if heat pump needs to be re-programmed.
Controller with 3 positions - ("High", "Low", and "Off" - no internal thermostat control):
Activating Heat Pump
1. Set the desired temperatures on the heat pump thermostats. See "Setting Thermostats" on page 5.
2. Use the external controller to select either "High" or "Low" to heat.
l When changing between thermostats, select "Off" first. Then select desired thermostat.
l Rapid movement between thermostats without a "rest" between each change can cause a missed signal
by the heat pump.
Deactivating Heat Pump
l Set the external controller to "OFF".
SECTION 4 - MAINTENANCE
4.1 Monitoring Conditions
4.1.a Water Chemistry
Check water chemistry regularly and maintain within recommended levels. Standards for commercial
applications vary in different areas. Follow all local applicable codes.
CAUTION - Failure to heed the following may result in equipment damage.
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Do not allow water to flow through heat pump when refinishing or acid washing a pool. Either use an installed
bypass to route water away from heat pump or deactivate filter pump.
To avoid damage to equipment, monitor and maintain chemistry within recommended levels.
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CHEMISTRY LEVEL CHART
(RESIDENTIAL)
CHEMICAL
POOLS
SPAS
Chlorine
1.0 – 3.0 ppm 3.0 – 5.0 ppm
Bromine
2.0 – 6.0 ppm 2.0 – 6.0 ppm
Cyanuric
Acid
30 - 50 ppm
pH
7.4 – 7.6 ppm 7.4 – 7.6 ppm
Total
Alkalinity
80 – 120 ppm 80 – 120 ppm
Calcium
Hardness
200 – 400
ppm
150 – 250 ppm
Total
Dissolved
Solids•
0 – 1,500 ppm
1,500 ppm above start-up total dissolved solids in
spas
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30 - 50 ppm
Salt from a chlorine generator is not included in Total Dissolved Solids.
4.1.b Water Flow Rates
Maintain water flow rates as indicated. Please note, these specifications relate to the heat pump only. Codespecified whole system turnover rates must be satisfied.
CAUTION - Failure to heed the following may result in equipment damage.
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Water flow exceeding maximum flow rate may damage heat exchanger; such damage will not be covered under
the equipment warranty
MODEL
FLOW RATES
HEAT EXCHANGER
TYPE
MINIMUM MAXIMUM
BB500 50 Hz 380 - 415 V
Titanium ThermoLink®
120 GPM
280 GPM
BB500 60 Hz 208 - 230 V
Titanium ThermoLink®
120 GPM
280 GPM
BB500 60 Hz 460 V
®
Titanium ThermoLink
120 GPM
280 GPM
If water flow through the heat pump is reduced, performance will suffer and internal safety devices may
deactivate the heat pump with error codes HP and HP5, or (if equipped) an LP and LP5.
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Operate water filtration devices per manufacturer's specifications. Dirty filters can cause reduced water flow to the
heat pump. An increase of 7-10 psi higher than the clean filter pressure typically reduces flow rates. This requires
the filter to be cleaned or back-washed
Keep baskets free of debris. Similar to a dirty filter, large volumes of debris in the pump and skimmer baskets can
reduce water flow.
Check for improper valve settings. A partially closed valve after the filter, or a full-open bypass around the heat
pump, will cause insufficient water flow through the heat pump.
The maximum static (or operating pressure) is 50 pounds-per-square-inch (PSI). These specifications relate to the
heat pump only. Code-specified whole system turnover rates must be satisfied.
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4.1.c 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.
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Installed Temperature / Pressure probes and ports are required to perform the following procedures.
This adjustment procedure is to be completed with the unit in HEA mode only; ACH and COO discharge
temperatures are not shown.
PLEASE NOTE Temperature / Pressure ports are required for all Great Big Bopper® installations on both
inlet and outlet piping.
1. Adjust heat pump thermostat to its lowest setting while in
Temperature / Pressure Port
HEA mode.
(Shown with Probe)
2. Deactivate the water filtration pump.
3. Adjust valves to a halfway open position leading to the
heat pump.
4. Adjust valves to a fully open position leading away from
the heat pump.
5. Activate the pool water filtration pump.
6. Slowly turn the thermostat up until the heat pump
activates.
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compressor will start.
7. With the heat pump running, confirm water filtration
pump is operating properly with adequate flow and no
short cycling. If needed, clean filters leading to the heat
pump.
8. Wait for water and refrigerant pressure to stabilize (approximately 5 minutes).
9. Adjust valves in the following order:
A. Adjust valve leading away from the heat pump to correct temperatures measured with a temperature
pressure probe.
B. Allow pressure to stabilize . Then check temperature again. Re-adjust valve leading away from the
heat pump as needed.
10. Mark valves at these positions for future reference.
Temperature differences are based on pool temperatures of 72° (+ or – 3° F). For water
temperatures outside this range, contact AquaCal Technical Support.
®
MODEL
TEMPERATURE
BB500 50 Hz 380 - 415 V
3° to 7° F
BB500 60 Hz 208 - 230 V
4° to 8° F
BB500 60 Hz 460 V
4° to 8° F
Table 2 - Temperature Chart
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4.1.d Irrigation and Storm Run-Off
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Irrigation water may damage heat pump components. Have irrigation water directed 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. Or install the heat pump in
another location.
4.1.e Clearances
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Proper air circulation is required for the heat pump to operate efficiently. Avoid placing objects near or on top of
the heat pump. This includes shrubbery and lawn furniture. These objects will also hinder maintenance access.
Avoid storing chemical containers near the heat pump. The chemicals can cause equipment damage.
Great Big Bopper® (Side View)
Great Big Bopper® (Top View)
4.2 Cleaning Equipment
Cleaning and polishing your heat pump regularly can protect its appearance and longevity. More frequent
servicing may be required for heat pumps located in sandy or coastal areas where sand and salt spray can
become detrimental factors to equipment.
WARNING - Failure to heed the following may result in injury or death.
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Possible electric shock hazard - Deactivate power to all electrical devices on the pad when washing heat pump.
Do not restore electrical power until equipment is completely dry.
CAUTION - Failure to heed the following may result in equipment damage.
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Do not use a pressure cleaner to wash heat pump. Damage to heat pump components may result. If using a hoseend spray nozzle adjust spray pattern to low strength only.
Do not spray water directly into the interior of the heat pump; damage to components may result.
Do not use chemicals on the display panel.
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Cleaning
1. Wash outside cabinet using a low-pressure water hose. A high-pressure water stream will cause damage to the
aluminum fins of the heat pump. This damage is not covered under product warranty.
2. While the heat pump is still wet, use an approved cleaning agent to clean the exterior of the heat pump. Do not
use chemicals on the display panel.
3. Use a detergent-dampened cloth to wipe the heat pump's exterior cabinet.
4. Flush all exterior with fresh water using a low-pressure water hose.
5. Dry the exterior cabinet using a soft cloth being careful not to damage evaporator fins.
APPROVED CLEANING AGENTS•
Fantastic®
Formula 409®
Cascade®
All Power Plain Detergent (3% Solution)
Table 3 - Cleaning Agents
Polishing
1. Polish the heat pump’s cabinet panels using an approved polishing agent and following the manufacturer’s
instructions. Do not use chemicals on the display panel.
2. Rinse the heat pump panels with fresh water, wipe, and buff panels using a dry soft cloth.
3. Allow heat pump interior and surrounding equipment to "air-dry" for several hours prior to restoring electrical
power.
APPROVED POLISHING AGENTS•
Simoniz® Wax
Glo-Coat®
Armor All® Protectant
Table 4 - Polishing Agents
•
The trademarks used in approved cleaning and polishing agents are property of their owners and are not
related to AquaCal .
4.3 Planned Maintenance
An annual inspection and maintenance program is strongly recommended starting no longer than one year
after installation of the heat pump. In coastal areas a bi-annual inspection is recommended. See
recommended inspection checklist.
AquaCal can perform this service in limited areas. Contact Customer Support for more information.
WARNING - Failure to heed the following may result in injury or death.
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Annual inspection and service must be performed by a qualified heat pump specialist in order to prevent
physical injury or damage to equipment.
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RECOMMENDED INSPECTION CHECKLIST:
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Check Air Temperature Change through Evaporator
Check and Clean Condensate Drains
Check Capacitor Value
Check Compressor Amperage Draw
Check Electrical Connections
Check Flow / Pressure Switch
Check Operating Controls and Temperature Sensors
Check Water Chemistry
Check Proper Voltage to Unit
Check Refrigerant Levels
Check Relay Contacts
Check Water Flow
Check filter pump Amperage Draw
Check Water Temperature Change through Heat Exchanger
Clean Evaporator's Coil
Clean Heat Pump's Cabinet
4.4 Winterizing
WARNING - Failure to heed the following may result in injury or death.
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Deactivate all electrical power to heat pump before performing hard freeze procedures.
CAUTION - Failure to heed the following may result in equipment damage.
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Failure to winterize heat pump may result in serious equipment damage. Freeze damage is not covered under the
heat pump warranty.
While the plumbing connections are in the winterized condition (not fully tightened), it is imperative the pool
and spa water not be circulated through the heat pump. Loss of water through loose plumbing connections may
result in damage to circulation pump, pool and spa structures, and other equipment.
Light Freeze Conditions
There are two freeze conditions requiring heat pump attention. A light freeze is when the ambient air
temperature falls below 32 degrees Fahrenheit for less than 8 hours. Typically during light freeze conditions
circulating (moving) water will not freeze. Override time clocks and allow filtration system to run
continuously during light freeze conditions.
Hard Freeze Conditions
A hard freeze is when the ambient air temperature falls below 32 degrees Fahrenheit for more than 8 hours.
In areas where this condition is prevalent and sustained, the heat pump MUST be winterized for hard freeze
conditions. Follow the correct procedure depending on the type of heat exchanger found in the heat pump.
Identify Exchanger:
1.
2.
3.
4.
Deactivate all electrical power to heat pump.
Deactivate filter pump.
Remove front access panel.
Identify heat pump exchanger from illustrations in this section. Then follow procedure for that heat pump's
exchanger.
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Titanium ThermoLink® Exchanger (with Internal Drain)
1. Disconnect the plumbing to the heat pump at connection unions (removal is counterclockwise).
2. Remove internal drain plug.
3. Allow water to drain completely from the heat pump. Expect to see a lot of water drain out
at first, and then a small amount to continue to drain out over a long period.
4. After heat pump is fully drained, re-connect internal drain plug and reinstall front access
panel.
5. Partially reconnect plumbing connection unions.
6. Winterizing is complete.
7. When ready to use heat pump again, hand-tighten connection unions. Reconnect electrical
power, and set the operating mode on the heat pump. Activate filter pump.
Internal
Drain
Titanium ThermoLink® Exchanger (with no Drain)
1. Reinstall front access panel.
2. Disconnect the plumbing to the heat pump at connection unions (removal is counterclockwise).
3. Allow water to drain completely from the heat pump. Expect to see a lot of water drain out
at first, and then a small amount to continue to drain out over a long period.
4. After heat pump is fully drained, reinstall front access panel.
5. Partially reconnect plumbing connection unions.
6. Winterizing is complete.
7. When ready to use heat pump again, hand-tighten connection unions. Reconnect electrical
power, and set the operating mode on the heat pump. Activate filter pump.
No Drain
SECTION 5 - TROUBLESHOOTING
5.1 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 the installing dealer. Or contact AquaCal for a service
partner in your area. See "Contacting AquaCal AutoPilot, Inc." on page 1.
®
WARNING - Failure to heed the following may result in injury or death.
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Repairs must not be attempted by untrained or unqualified individuals.
The heat pump contains refrigerant under high pressure. Repairs to the refrigerant circuit must not be attempted
by untrained or unqualified individuals. Service must be performed only by qualified HVAC technicians.
Recover refrigerant before opening the system.
CAUTION - Failure to heed the following may result in equipment damage.
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Service by unauthorized personnel will void the heat pump warranty.
Page - 14
FLO Indicator
ISSUE
Low or no water detected.
RESOLUTION
1. Confirm the filter pump is on.
2. If a multiple-speed filter pump is being used, run at a higher speed to determine if the error persists. Do not
exceed maximum flow rate for your model.
3. Confirm water is not being diverted away from the heat pump.
l See "Water Flow Rates" on page 9.
l See "Adjusting Water Flow Using ΔT (Delta-T)" on page 10.
CEr Indicator
ISSUE
This can indicate a loose or damaged communication cable.
RESOLUTION
A qualified technician should check the cable from control board to display assembly for a loose connection
or visible damage.
CSE Indicator
ISSUE
This is a control system error.
RESOLUTION
Deactivate then reactivate power to reset controls.
dpC or dPO Indicator
ISSUE
Shorted or open defrost sensor.
RESOLUTION
A qualified technician should replace the defrost sensor.
pC or pO Indicator
ISSUE
Shorted or open water sensor.
RESOLUTION
A qualified technician should replace the water sensor.
HP Indicator
ISSUE
The refrigerant system’s high-pressure switch is showing as open.
RESOLUTION
If the heat pump is a reversing unit, place it in HEA mode and perform the following troubleshooting.
Determine if an insufficient amount of water is being supplied to the equipment.
1. Confirm the filter pump is on.
2. If a multiple-speed filter pump is being used, run filter pump at a higher speed. Do not exceed maximum flow
rate for the model.
3. Confirm water is not being diverted away from the heat pump.
l See "Water Flow Rates" on page 9.
l See "Adjusting Water Flow Using ΔT (Delta-T)" on page 10.
Page - 15
HP5 Indicator
ISSUE
The heat pump has locked due to five HP (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 " HP Indicator" on page 15.
LP Indicator
ISSUE
The refrigerant system’s low-pressure switch is showing as open.
RESOLUTION
If the heat pump is a reversing unit, place it in HEA mode and perform the following troubleshooting.
1.
2.
3.
4.
Check for proper fan operation. If fan is not operating, contact AquaCal® Technical Support.
Check for obstructed air flow around the heat pump. See "Clearances" on page 11.
Check for dirty or blocked evaporator coil. See "Cleaning Equipment" on page 11.
Check for signs of ice buildup on the coil.
LP5 Indicator
ISSUE
The heat pump has locked due to five LP (low-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 low-pressure issue causing the error. See "LP Indicator" on page 16.
OtA Indicator
ISSUE
Incoming water temperature exceeded 110° F and the unit is locked with an OtA over temperature alarm.
The heat pump will not operate until incoming water temperature drops to 100° F or lower.
RESOLUTION
1. Determine if another heat source (gas heater, solar heater, etc.) is heating water being sent directly to the heat
pump with the OtA indicator. This situation will need to be corrected before continuing.
2. Rule out an incorrect reading from the water temperature sensor. Verify existing water temperature with an
accurate thermometer. If heat pump’s sensor is inaccurate, the water temperature sensor may require
replacement.
5.2 Issues and Resolutions
WARNING - Failure to heed the following may result in injury or death.
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Repairs must not be attempted by untrained or unqualified individuals.
The heat pump contains refrigerant under pressure. Repairs to the refrigerant circuit must not be attempted by
untrained or unqualified individuals. Service must be performed only by qualified HVAC technicians. Recover
refrigerant before opening the system.
CAUTION - Failure to heed the following may result in equipment damage.
l
Service by unauthorized personnel will void the factory warranty.
Please perform the following troubleshooting.
For further assistance, please contact the installing dealer. Or contact AquaCal for a
service partner in your area. See "Contacting AquaCal AutoPilot, Inc." on page 1.
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Display Panel Not Responding
1. If the heat pump is controlled be an external controller, confirm the external controller settings. See
"Operating Heat Pump (With an External Controller)" on page 8.
2. If the issue is still occurring, contact the installer or manufacturer of the external control device.
Heat Pumps Not Running
1. Confirm equipment is receiving power. Is the heat pump display illuminated?
l If not, confirm the main breaker (located at the power supply panel) and the disconnect switch (located
near the heat pump) are both turned on.
l If the display still does not illuminate, it is recommended that the heat pump installer or electrician
confirms heat pump is receiving power.
2. Confirm correct mode is selected. See "Setting Operating Mode" on page 4.
3. Confirm thermostat is set correctly. See "Setting Thermostats" on page 5.
l If heating the water, the thermostat should be set above the current water temperature.
l If cooling the water, the thermostat should be set below the current water temperature.
4. If an error code is displayed, diagnose and correct the cause of the code. See "Fault Codes" on page 14.
5. If the heat pump is using an external controller, the heat pump may not be set correctly to accept the
controller’s signal.
l See "Operating Heat Pump (With an External Controller)" on page 8.
Heat Pumps Tripping Breaker
1. Have an electrician confirm breakers are in good condition and properly sized for the heat pump.
2. Multiple heat pumps installed at the same site may benefit from special automatic sequencing controllers to
avoid excessive power drops at start-up. See "Automatic Sequencing Controller" on page 20.
3. If a fault occurs immediately when the compressor starts, a qualified technician should evaluate the system.
Heat Pump Won’t Shut Off
PLEASE NOTE
When heat pump is set to " OFF ", the display will show either the water temperature or FLO .
1. Confirm the heat pump has reached the desired temperature set on the thermostat. The heat pump will continue
to run until the set temperature is reached.
2. If the heat pump is using an external controller, it may not be set correctly.
l See "Operating Heat Pump (With an External Controller)" on page 8.
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Heat Pump Is Running, Not Heating
1. If the heat pump is using an external controller, confirm it is set correctly.
l See "Operating Heat Pump (With an External Controller)" on page 8.
l If the heat pump is still not running correctly with this device, contact the installer of the external
controller device or the device’s manufacturer for further assistance.
2. Confirm heat pump mode is set to HEA operating mode.
3. Confirm thermostat is set to the desired water temperature.
4. Confirm valves are correctly positioned to heat the correct body of water (either the pool or the spa). If heating
a spa that overflows into a pool, confirm the spa is isolated when being heated (not flowing into the pool).
5. Confirm heat pump is transferring heat into the water.
l Measure the temperature of air discharge coming out of heat pump fan. If discharge air is between 8° to
10° colder than the outside ambient air (entering air), then the heat pump is moving heat into the water.
6. If an error code is displayed, diagnose and correct cause of code. See "Fault Codes" on page 14.
7. Confirm that filter pump has a sufficient run-time. The heat pump will not run (or heat the water) without
water flow. Great Big Bopper® equipment will generally be set to run 24 hours a day in commercial
applications.See "Initial Heating Recommendations" on page 20.
8. If heating a spa, deactivate air blower or venturi (if equipped) to allow for quicker heating times. For pools,
deactivate water features, such as slides, waterfalls, or fountains to allow water to retain heat. Use of a liquid
pool blanket product, such as an Aqua Blanket™, can also compensate for excessive heat loss. See "Liquid
Blankets" on page 20.
Heat Pump Is Running, Not Cooling (Reversing Models)
1. If the heat pump is using an external controller, confirm the heat pump is programmed properly to allow for
cooling.
l See "Operating Heat Pump (With an External Controller)" on page 8.
2. Confirm the heat pump mode is set to COO operating mode.
3. Confirm the thermostat is set below the current water temperature.
4. Confirm valves are correctly positioned to cool the correct body of water (either the pool or the spa). If
cooling a spa that overflows into a pool, confirm the spa is isolated when being cooled (not flowing into the
pool).
5. If an error code is displayed, determine and correct the condition causing the code. See "Fault Codes" on page
14.
6. Confirm heat pump is transferring heat out of the water.
l Measure the temperature of air discharge coming out of heat pump fan. If discharge air is between 8° to
10° warmer than outside ambient air (not coming out of heat pump), then the heat pump is moving heat
out of the water.
7. Confirm that filter pump has a sufficient run-time. The heat pump will not run (or cool the water) without
water flow. Great Big Bopper® equipment will generally be set to run 24 hours a day in commercial
applications.See "Initial Cooling Recommendations" on page 20.
Water Coming From Heat Pump
The water may be normal condensation produced as a by-product of the heat pump's refrigeration process.
The heat pump can produce 8 to 10 gallons of condensation per day depending on the humidity of the
ambient air. Determine if the water is condensation or a possible leak.
1. If using chlorine or bromine as a pool / spa sanitizer, use a test strip in the water at heat pump to determine if
sanitizer is present. If sanitizer is present, a leak may exist.
2. Deactivate heat pump, leaving the filter pump on. After several hours, determine if water is still coming from
the heat pump.
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SECTION 6 - APPENDIX
6.1 Identifying Model Specifications
1. Find Data Plate - The data plate is usually posted on the
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.
3. The complete model number identifies the equipment's
specifications.
Data Plate Example
Model Number Example
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6.2 Initial 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. See "Identifying Model Specifications" on
page 19.
1. Confirm heat pump mode has been set to HEA.
2. Set thermostat to desired water temperature.
3. Temporarily override the filter pump's time-clock for continuous operation.
l This will allow the Heat Pump the time required to heat the water at start-up.
l After the water has reached the desired temperature, the time-clock can be reset to normal operating
time-frames.
6.3 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 19.
1. Confirm heat pump mode has been set to COO.
2. Set thermostat to desired water temperature.
3. Temporarily override the filter pump's time-clock for continuous operation.
l This will allow the Heat Pump the time required to cool the water at start-up.
l After the water has reached the desired temperature, the time-clock can be reset to normal operating
time-frames.
6.4 Available Accessories
Automatic Sequencing Controller
l An Automatic Sequencing Controller (ASC) provides easy control of all units from one lead unit and prevents the
simultaneous start-up of multiple heat pumps.
l Site voltage drop is minimized and utilities are not subjected to large in-rush demands of electrical current.
®
l Part number is based on number of heat pump's to be controlled. Call AquaCal Customer Support for assistance
with correct configuration.
External Flow Relay (Grid Flow) Switch Kit (0040s)
l Used when the pool / spa elevation is higher than the heat pump.
l Used when a variable two-speed filter pump set on low-speed mode does not provide enough water pressure to
activate a heat pump’s water pressure switch.
l Also used for automatic pool / spa thermostat switching.
PLEASE NOTE The 0040s is not to be used on applications exceeding 50 PSI.
Liquid Blankets
l An invisible liquid heat barrier designed to retain heat and extend the swimming season.
®
l AquaCal recommends the Aqua Blanket™.
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Plumbing Unions:
SIZE
PART NUMBER
4 INCH PLP0081
Remote Control Kit (STK0070)
l A remote (wired) control kit allows for full control of the heat pump from up to 100 feet from the equipment.
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