Aquacal GBB Installation Manual Download Page 73

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Liquid Blankets

An invisible liquid heat barrier designed to retain heat and
extend the swimming season.

AquaCal

recommends

Lo-Chlor

Aqua Blanket

™

Over Temperature Alarm Kit

This kit is an additional safety device. It disables the heat
pump if

any malfunction occurs that allows the water

temperature to surpass a safe level.

This kit is strongly recommended for all spa applications.

Single Phase Heat Pump - (# STK0221)

Three Phase Heat Pump - (# STK0222)

Plumbing Unions

4 Inch Unions - (# PLP0081)

Temperature Port Kit (# STK0133)

This port can be used to adjust water flow using Delta-T.

The kit comes with port, installation components, and a
temperature probe.

3.7 ICM Digital 3-Phase Monitor

DANGER

Failure to heed the following will result in injury or death.

Deactivate power while routing wiring to control board.

ppe

ndi
x

Summary of Contents for GBB

Page 1: ...ation Manual Important Read this document before operating installing this product For additional product manuals and operation installation procedures please visit www AquaCal com LTM0934 REV 1 04 pr...

Page 2: ......

Page 3: ...g a Call Flex 20 1 6 b Connecting External Controllers to Heat Pump 22 b 1 Connecting Smart Bus Controllers 23 b 2 Connecting Two wire Controllers with internal thermostat 26 1 6 c Connecting Gas Back...

Page 4: ...3 6 Available Accessories 68 3 7 ICM Digital 3 Phase Monitor 69 3 8 Schematics 71 Schematic LTM0949 73 ii...

Page 5: ...an authorized service center l Warranties may be voided if the equipment has been improperly installed maintained or serviced l If service is deemed necessary please contact AquaCal See Contacting Aqu...

Page 6: ...erthermia People having an adverse medical history or pregnant women should consult a physician before using a hot tub or spa Children and the elderly should be supervised by a responsible adult l Pro...

Page 7: ...Pump 10 1 4 d In Line Chlorine Feeders 10 1 4 e Water Flow Rates 11 1 4 f Adjusting Water Flow Using T Delta T 12 1 4 g Maintaining Ability to Winterize 13 1 4 h Adjusting Water Pressure Switch 13 1...

Page 8: ...panel Mounting Pad Requirements l The heat pump s base must be installed on a flat and level surface that completely supports the entire base l Build the heat pump pad out of concrete or other code ap...

Page 9: ...e heat pump l Avoid storing chemical containers near the heat pump The chemicals can cause equipment damage l Avoid placing objects near or on top of the heat pump This includes shrubbery and lawn fur...

Page 10: ...e product warranty l Water flow exceeding maximum flow rates will negatively affect the total pool filtration performance and may damage the heat pump This will not be covered under the equipment warr...

Page 11: ...installations are shown l If the installation does not closely follow any of the supplied plumbing diagrams AquaCal Technical Support is available for installation advice and guidance l Confirm water...

Page 12: ...Page 8 Good Plumbing Examples Great Big Bopper Single Unit Example 1 Great Big Bopper Single Unit Example 2 1 Installation...

Page 13: ...e shown in the following diagrams it is not a requirement Sizing requirements will determine the number of required heat pumps Great Big Bopper Multiple Units Z Flow Plumbing Design Great Big Bopper M...

Page 14: ...age to equipment l Do not use glue on the threaded portion of the equipment s unions A glued in place union will prevent the equipment from being properly winterized Great Big Bopper BB500 A strap wre...

Page 15: ...rformance is reduced and performance will suffer Internal safety devices may deactivate the heat pump with the following errors l HIGH PRESSURE FAULT l HP5 SYSTEM LOCKOUT l LOW PRESSURE FAULT l LP5 SY...

Page 16: ...heat pump to the half open position 5 Adjust the valves controlling water leading away from the heat pump to a fully open position 6 Activate the pool water filtration pump 7 Slowly raise the thermos...

Page 17: ...ng any adjustments confirm the following l The filter is clean l Filter pump is operating l The valves are set to direct the appropriate amount of water through the heat pump See Water Flow Rates on p...

Page 18: ...ow Switch 0040S on page 68 9 If the heat pump continues to operate without water flow contact AquaCal 1 5 Electrical 1 5 a Electrical Requirements DANGER Failure to heed the following will result in i...

Page 19: ...and cooling equipment Table 2 Standards Grounding and Bonding Follow local code requirements for proper grounding and bonding of heat pump equipment l A bonding lug has been provided on the lower lef...

Page 20: ...If unsure of heat pump equipment rating please see Identifying Model Specifications on page 66 Equipment Rating Minimum Site Voltage Maximum Site Voltage B Voltage 208 to 230 Volts Three Phase 60 her...

Page 21: ...mp damage The following procedure will allow the installer to set the heat pump s transformer for the appropriate site voltage DANGER Failure to heed the following will result in injury or death l Dea...

Page 22: ...to equipment l Setting a voltage other than what is listed on the heat pump s data plate can damage equipment and is not covered under warranty If a three phase unit fails to operate at start up the...

Page 23: ...Page 19 1 5 e Schematic Location Schematics are located on the inside of the electrical panel Some schematics have been provided in the appendix of this manual See Schematics on page 71 1 Installation...

Page 24: ...ng may result in injury or death l This section is only for qualified installers who are familiar with the swimming pool and spa safety standards l The installer must be familiar with service industry...

Page 25: ...Page 21 Configure Call Flex Enter Installer Menus then proceed 1 Installation...

Page 26: ...y or death l This section is only for qualified installers who are familiar with the swimming pool and spa safety standards l The installer must be familiar with service industry techniques NOTICE Fai...

Page 27: ...ower or ground wire Figure 1 4 Connect control wires to the heat pump s Port B of the microprocessor as indicated See Figure 1 and Figure 2 l It is OK to double up wires at the external controller con...

Page 28: ...6 If additional sensors are required on the external controller install them on the external controller now Example Pentair EasyTouch and Pentair IntelliTouch Some controllers require an additional se...

Page 29: ...Page 25 1 Installation...

Page 30: ...tivate power to the controller 8 Reactivate power to the heat pump C If fault continues to occur check with the manufacturer of the external controller for additional advice on using a heat pump with...

Page 31: ...oltage side of the heat pump s electrical enclosure Follow all National Electric Codes NEC unless State or Local guidelines supersede 4 Connect the controller wires to the microprocessor port labeled...

Page 32: ...Page 28 1 Installation...

Page 33: ...ile routing wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines WARNING Failure to heed the following may result in injury or death l This section is onl...

Page 34: ...Gas Heater s Pool and Common Connection Figure 5 Gas Heater s Fireman Switch Figure 6 If the Gas Heater requires a fireman cool down switch it is the installer s responsibility to ensure this require...

Page 35: ...ontinue to maintain the set temperature l Scheduled mode commonly used for residential applications n The circulation pump operates on the circulation pumps regular on off schedule n The gas heater wi...

Page 36: ...Page 32 1 Installation...

Page 37: ...Page 33 Configure for Scheduled Mode Enter Installer Menus then proceed 1 Installation...

Page 38: ...time and causing an excessive power draw on the electric circuit DANGER Failure to heed the following will result in injury or death l Deactivate power while routing wiring to control board l Follow...

Page 39: ...Route 22 gauge 2 conductor low voltage wires to the low voltage sides of the electrical enclosures Follow all National Electric Codes NEC and or State and Local guidelines 5 Connect the first slaved...

Page 40: ...Page 36 Configuring Multiple Heat Pumps Master Primary Heat Pump Confirm the first connected heat pump is designated as the master primary unit Enter Installer Menus then proceed 1 Installation...

Page 41: ...Page 37 1 Installation...

Page 42: ...o to the next connected heat pump and configure it as a slaved unit with a heat pump address of 01 Each additionally connected heat pump will require a unique heat pump address 02 03 etc Enter Install...

Page 43: ...Page 39 1 Installation...

Page 44: ...will result in injury or death l Deactivate power while routing wiring to control board l Follow all National Electric Codes NEC and or State and Local guidelines WARNING Failure to heed the followin...

Page 45: ...ed switch route wires to the low voltage side of the electrical enclosure The third wire is not used Follow all National Electric Codes NEC unless State or Local guidelines supersede 5 Connect the wir...

Page 46: ...Page 42 1 Installation...

Page 47: ...Page 43 1 7 Program Heat Pump for the Customer 1 7 a Setting Date and Time Set the heat pump s time and date using the following steps 1 Installation...

Page 48: ...Time and Date Format The heat pump s time and date format can be customized Customize Time The time can be displayed in 24 hour military time the default display is 12 hour Enter Installer Menus then...

Page 49: ...Page 45 Customize Date The date can be displayed as Day Month Year the default is Month Day Year Enter Installer Menus then proceed 1 Installation...

Page 50: ...Page 46 1 Installation...

Page 51: ...Page 47 1 7 c Selecting Celsius or Fahrenheit Set the water temperature to show in either Fahrenheit default or Celsius Enter Installer Menus then proceed 1 Installation...

Page 52: ...e heat pump goes into the sleep mode for the first time NOTICE Failure to heed the following may result in damage to equipment l Before enabling the entry code feature be sure to record the code If lo...

Page 53: ...Page 49 1 Installation...

Page 54: ...splaced the heat pump will need to be reset to factory defaults l After three minutes of inactivity the heat pump s sleep mode will activate 1 7 f Resetting Factory Defaults If needed the installer ca...

Page 55: ...Page 51 1 Installation...

Page 56: ...the heat pump damage to components may result l Do not use chemicals on the display panel Cleaning 1 Wash cabinet using a low pressure water hose A high pressure water stream will cause damage to the...

Page 57: ...nels 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 POLISHI...

Page 58: ...FAULT 58 WATER TEMP SENSOR SHORT or WATER TEMP SENSOR OPEN 58 Issues and resolutions A Front Panel Warning Indicator is Red Select Units 59 Blank Display 59 Display Panel Not Responding 59 Displays D...

Page 59: ...or unqualified individuals Service must be performed only by qualified HVAC technicians Recover refrigerant before opening the system NOTICE Failure to heed the following may result in damage to equip...

Page 60: ...w rate for the model 3 Confirm water is not being diverted away from the heat pump l See Water Flow Rates on page 11 l See Adjusting Water Flow Using T Delta T on page 12 4 The water pressure switch m...

Page 61: ...es on page 5 3 Check for a dirty or blocked evaporator coil l See Cleaning Equipment After Installation on page 52 4 Check for signs of heavy ice buildup on the coil LP5 SYSTEM LOCKOUT ISSUE The heat...

Page 62: ...rnal controller is being used l If not set external controller mode to none instead of SMART o See Configure for Smart Bus Controller on page 24 2 Confirm connection points from the external controlle...

Page 63: ...lot Inc on page 1 A Front Panel Warning Indicator is Red Select Units ISSUE The Heat Pump is experiencing an incoming power fluctuation RESOLUTION An electrician should check for improper electrical s...

Page 64: ...n the circulation pump is deactivated 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...

Page 65: ...e is selected 3 Confirm thermostat is set correctly l When heating the water is desired the thermostat should be set above the current water temperature l When cooling the water is desired the thermos...

Page 66: ...ode is set to heat 3 Confirm thermostat is set to the desired water temperature 4 Confirm valves are positioned to heat the correct body of water either the pool or the spa If heating a spa that overf...

Page 67: ...mp is moving heat out of the water 7 Confirm that the filter pump has a sufficient run time The heat pump will not run or cool the water without water flow Ice Forming on the Heat Pump Ice Forming on...

Page 68: ...refrigeration process The heat pump can produce up to 30 gallons 114 liters of condensation per hour depending on the humidity of the ambient air Determine if the water is condensation or a possible...

Page 69: ...e overwritten for site specific conditions NOTICE Failure to heed the following may result in damage to equipment l Unauthorized adjustments in Service Menus not shown may void the heat pump s warrant...

Page 70: ...USER ENTRY CODE 01 SET CALL FLEX INSTALLED NO YES NO SET CALL FLEX MODE OFF OFF CALL FLEX 3 2 Identifying Model Specifications 1 Find Data Plate The data plate is usually posted on the side of the equ...

Page 71: ...ility review equipment data plate See Identifying Model Specifications on the previous page 1 Confirm heat pump mode has been set to heating mode 2 Set the desired temperature set point for the water...

Page 72: ...rature reset the filter pump to normal operating time frames 3 6 Available Accessories Accessories may be purchased through an authorized dealer of AquaCal products Call Flex Accessory 0030 LEDS l Thi...

Page 73: ...surpass a safe level l This kit is strongly recommended for all spa applications n Single Phase Heat Pump STK0221 n Three Phase Heat Pump STK0222 Plumbing Unions l 4 Inch Unions PLP0081 Temperature Po...

Page 74: ...Page 70 l Follow all National Electric Codes NEC and or State and Local guidelines 3 Appendix...

Page 75: ...Page 71 3 8 Schematics Some schematics have been provided in the appendix of this manual 3 Appendix...

Page 76: ...le by calling AquaCal Customer Support See Contacting AquaCal AutoPilot Inc on page 1 l Please have the complete model and serial number available l See Identifying Model Specifications on page 66 Sch...

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