Aquacal LTM0266 User Manual
AquaCal AutoPilot
Water Source
Operation and Installation Manual
LTM0266 rev 1
TABLE OF CONTENTS
SECTION 1 - GENERAL INFORMATION
1.1 Contacting AquaCal AutoPilot ............................................................................................... 1
1.2 Safety ................................ ................................................................ ................................... 1
SECTION 2 - OPERATION
2.1 Control Panel ........................................................................................................................ 2
2.1.a Indicator Lights ............................................................................................................... 2
2.1.b Control Buttons (Inactive if unit under external control) ................................................... 2
2.1.c LED Display .................................................................................................................... 2
2.1.d User Level Programs ...................................................................................................... 3
Turning Heat Pump On ................................................................................................. 3
Setting Operating Mode (“HEA”, “COO”, or “ACH”) ....................................................... 3
Turning Heat Pump Off ................................................................................................. 3
Setting Thermostats...................................................................................................... 3
Selecting Celsius or Fahrenheit .................................................................................... 3
Enabling User Lock Option ........................................................................................... 4
Unlocking Heat Pump ................................................................................................... 4
Disabling User Lock Option .......................................................................................... 4
SECTION 3 - MAINTENANCE
3.1 Cleaning Equipment ............................................................................................................. 5
3.2 Monitoring Conditions ........................................................................................................... 6
3.2.a Pool Chemistry ............................................................................................................... 6
3.2.b Maintain Proper Water Flow ............................................................................................ 6
3.2.c Adjusting Water Flow using ∆T (Delta-T) ........................................................................ 6
3.2.d Irrigation and Storm Run-Off ........................................................................................... 7
3.3 Winterizing ............................................................................................................................ 7
3.4 Planned Maintenance ........................................................................................................... 9
SECTION 4 - INSTALLATION
4.1 Equipment Specifications.................................................................................................... 10
4.1.a Weights ......................................................................................................................... 10
4.1.b Dimensions ................................................................................................................... 10
4.1.c Access Panels .............................................................................................................. 11
4.1.d Electrical Cutouts .......................................................................................................... 12
4.2 Placing Heat Pump ............................................................................................................. 12
4.2.a Positioning Clearances ................................................................................................. 12
4.2.b Controlling Irrigation and Rainwater Runoff ................................................................... 13
4.2.c Planning for Condensation ............................................................................................ 13
4.2.d Mounting Pad Requirements ......................................................................................... 13
4.2.e Anchoring Heat Pump to Pad ........................................................................................ 13
4.3 Plumbing ............................................................................................................................ 13
4.3.a Plumbing Diagrams ....................................................................................................... 14
4.3.b In-Line Chlorine Feeders ............................................................................................... 18
4.3.c Water Connections to Heat Pump ................................................................................. 18
4.3.d Maintaining Ability to Winterize ..................................................................................... 18
TABLE OF CONTENTS
4.3.e Operating Pressures and Water Flow Rates .................................................................. 19
Operating Pressure ..................................................................................................... 19
Water Flow Rates ........................................................................................................ 19
4.3.f Water Flow (Pressure) Switch Adjustment ..................................................................... 20
4.3.g Water Hammer Suppression ......................................................................................... 21
4.4 Wiring .................................................................................................................................. 21
4.4.a Standards ...................................................................................................................... 21
4.4.b General Requirements .................................................................................................. 22
4.4.c Grounding and Bonding ................................................................................................. 22
4.4.d Sizing the Electrical Service .......................................................................................... 22
4.4.e Ground-Fault Protection ................................................................................................ 22
4.4.f External Controls / Equipment ....................................................................................... 22
4.4.g Positioning Mode Jumper .............................................................................................. 23
4.5 Programming....................................................................................................................... 23
4.5.a Program Displays .......................................................................................................... 24
4.5.b Service Level Programs ................................................................................................ 24
Entering Service Menu ................................................................................................ 24
Deactivating Time Delay ............................................................................................. 24
Configuring for External Controller .............................................................................. 24
Configuring for Remote Flow Switch ........................................................................... 25
Calibrating Water Sensor ............................................................................................ 25
Calibrating Defrost Sensor .......................................................................................... 25
Adjusting Dead-Band Differential ................................................................................ 26
Resetting Heat Pump ("Back Door” Entry) ................................................................... 26
4.5.c Default Program Parameters ......................................................................................... 27
4.6 Optional Installation ............................................................................................................. 27
4.6.a Pool and Spa Combination Heating ............................................................................... 27
4.6.b Spa Setback Heating Option ......................................................................................... 27
SECTION 5 - TROUBLESHOOTING
5.1 Symptom / Resolution Charts .............................................................................................. 28
Control Panel Not Working .......................................................................................... 28
Heat Pump Not Running ............................................................................................. 28
Heat Pump Running, Not Heating ................................................................ ............... 29
Heat Pump Tripping Breaker ....................................................................................... 30
Heat Pump Won’t Shut Off .......................................................................................... 30
Heat Pump Running, Not Cooling ............................................................................... 31
Water Coming From Heat Pump ................................................................................. 31
5.2 Fault Code Definitions ......................................................................................................... 32
“dPO” Indicator ............................................................................................................ 32
“PO” Indicator .............................................................................................................. 32
“dPC” Indicator ............................................................................................................ 32
“PC” Indicator .............................................................................................................. 32
“HP” Indicator .............................................................................................................. 32
“HP5” Indicator ............................................................................................................ 32
“LP” Indicator .............................................................................................................. 33
“LP5” Indicator ............................................................................................................ 33
“OtA” Indicator ............................................................................................................. 33
“FLO” Indicator ........................................................................................................... 33
“CSE” Indicator ........................................................................................................... 34
“CEr” Indicator ............................................................................................................ 34
SECTION 6 - APPENDIX
6.1 Available Accessories ................................................................ ......................................... 35
6.2 Schematics ......................................................................................................................... 35
TABLE OF CONTENTS
Page 1
Web
www.AquaCal.com
Phone
(727) 823-5642
8-5 pm, Eastern M-F
Fax
(727) 821-7471
SECTION 1 - GENERAL INFORMATION
1.1 Contacting AquaCal AutoPilot
Please have your model and serial numbers available when contacting AquaCal AutoPilot for questions,
service, or parts.
1.2 Safety
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 your heat pump must be performed by qualified
service personnel. Should you suspect your equipment is not performing properly, refer to the section in
this manual entitled: "Troubleshooting," to determine if a call for service is required. Warranties will be
voided if the equipment has been improperly installed, maintained or serviced. Throughout this manual,
safety signals have been placed where particular attention is required.
Safety Signals:
" WARNING" - signal relates to personal safety.
" CAUTION” - signal promotes avoiding damage to the equipment.
Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. 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.
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. Service must be performed only by qualified
HVAC technicians. Recover refrigerant before opening system.
Improper water chemistry can present a serious health hazard. To avoid possible hazards, maintain
pool / spa water per standards detailed later in this manual.
CAUTION - Failure to heed the following may result in equipment damage.
Maintain proper water chemistry in order to avoid damage to pump, filter, pool shell, etc.
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.
SAVE THESE INSTRUCTIONS
Page 2
The following information outlines the operation for a
standard installation. Control Buttons will operate
differently for custom installations; such as a heat pump
connected to an external controller. Please see
“External Controls / Equipment” on page 22 for more
information.
“Pool”
Heat Pump is referencing the pool thermostat.
“Spa”
Heat Pump is referencing the spa thermostat.
“Cooling”
Indicates unit is cooling. Please note - the compressor must be operating before this light
will illuminate.
“Desired Temp”
Indicates temperature set point is displayed. This is displayed when “UP” or “DOWN” is
selected.
“Water Temp”
Indicates current water temperature is displayed.
“Heating”
Indicates unit is heating. Please note - the compressor must be operating before this light will
illuminate.
“Pool / Spa”
Select either the pool or the spa thermostat.
“Up”
Increase temperature set point.
“Down”
Decrease temperature set point.
“Mode”
Select heat pump operating mode.
“XXX”
Heat Pump is on and displaying current water temperature.
“FLO”
No water flow is detected. Circulation pump is off or heat pump is not receiving correct water
flow.
“OFF”
Heat pump has been turned off via the mode selector button or the temperature set point has
been lowered below 45o F.
“888”
Control program is initializing. Displays only as power is applied to the heat pump. The
program version number will be displayed.
SECTION 2 - OPERATION
2.1 Control Panel
2.1.a Indicator Lights
Figure 1
2.1.b Control Buttons (Inactive if unit under external control)
2.1.c LED Display
Table 1
Table 2
Table 3
Page 3
STEPS
EXPLANATION
Turning Heat Pump On
Turn power on at external fuse
box or breaker disconnect.
Controller performs a lamp test. The display reads “888”.
Controller’s software version is briefly displayed.
Controller displays as described in section entitled “LED Display” on page 2.
Setting Operating Mode (“HEA”, “COO”, or “ACH”)
Press “MODE” control button
until “HEA” is selected.
Heat pump heats water to temperature set on thermostat.
Press “MODE” control button
until “COO” is selected.
Heat pump cools water to temperature set on thermostat.
Press “MODE” button until
“ACH” is selected.
Heat pump operates in either heating or cooling mode until reaching the
temperature set on the thermostat. Once reached, the heat pump maintains the
water temperature within three (3) degrees Fahrenheit of the temperature
setting.
Turning Heat Pump Off
Press “MODE” control button
until “OFF” is selected.
Heat pump functions, values, and programming become unavailable. The
current water temperature is still displayed.
An alternate method of inactivating the heat pump is to lower the active
thermostat below 45º F. This turns the thermostat off, leaving the heat pump
itself available for programming.
Setting Thermostats
Set heat pump to an active
operating mode.
See “Setting Operating Mode (“HEA”, “COO”, or “ACH”)” in this chart for more
information.
Press "POOL/SPA" control
button to select thermostat.
The “Pool” or “Spa” indicator light specifies which thermostat is currently being
used.
Press “Up” or “Down” control
button to select desired
temperature.
The “Desired Temp” indicator light illuminates.
The thermostat’s temperature setting raises or lowers 1-degree per button
key press. The thermostat can be adjusted from a minimum of 45º F to a
maximum of 104º F. Please note - Setting the temperature below 45º F turns
the thermostat off.
Wait 15 seconds to allow heat
pump to exit programming
mode.
The “water temp” light turns on and the current water temperature is
displayed.
If the desired water temperature is different than the current water
temperature, the heating or cooling light will illuminate and the heat pump’s
compressor will activate after a four minute time delay.
Selecting Celsius or Fahrenheit
Press and hold “Up” and
“Down” buttons simultaneously.
"CF1" (Celsius / Fahrenheit) code appears.
Press “Up” or “Down” button to
select codes “0” or “1”.
Code “0” = Temperature displays in Celsius.
Code “1” = Temperature displays in Fahrenheit.
Wait 15 seconds to allow heat
pump to exit programming
mode.
2.1.d User Level Programs
The heat pump features two levels of programming; User-level programming designed for the end user
and Service-level programming designed for the product installer. This section describes User-level
programming.
Page 4
STEPS
EXPLANATION
Enabling User Lock Option
Press and hold “Up” and
“Down” buttons simultaneously
until “CF1” is displayed.
If “LOC” is briefly displayed, followed by a “0”, the heat pump is already locked.
A numerical password is required to proceed. See “Unlocking Heat Pump” on
page 4 for more information.
Press “Pool/Spa” button until
“ELC” is displayed.
Any prior password can be viewed from this program.
Press “Up” button once to view
any existing numerical
password.
if desired, press “Up or “Down”
button to change or add a
numerical password
The password can be any number from “00” to “99”. Without knowledge of the
correct password, control adjustments will not be possible.
Press “Pool/Spa” Button to lock
in the password.
Press “Pool/Spa” button until
“ULC” is displayed.
Press “Up” button till “1” is
displayed.
Code “0” = User Lock disabled.
Code “1” = User Lock enabled.
Press “Pool/Spa” Button to save
selection.
Wait 15 seconds to allow heat
pump to exit programming
mode.
The heat pump lock-out feature is now enabled and the heat pump itself is
locked. Any future changes will now require a numerical password.
Unlocking Heat Pump
Press “Up” or “Down” Button.
If the heat pump is locked, “LOC” is briefly displayed followed by a “0”,
prompting the entry of the correct password.
Press “Up” button to enter the
password.
Press “Pool/Spa” Button.
If the correct password has been entered, the heat pump is unlocked. The
current water temperature is displayed and control settings are available.
The heat pump locks after being left idle for 15 seconds or after changing a
program option.
Before changing multiple program options it is recommended the lock-out
option be disabled. The lock-out option can be enabled after all changes are
completed
Disabling User Lock Option
Press and hold “Up” and
“Down” buttons simultaneously
until “CF1” is displayed.
Press “Pool/Spa” button until
“ULC” is displayed
Press “Down” button until “0” is
displayed.
Code “0” = User Lock disabled.
Code “1” = User Lock enabled.
Wait 15 seconds to allow heat
pump to exit programming
mode.
All programmable features are now available.
Table 4
Page 5
APPROVED CLEANING AGENTS
Fantastic
409
All Power Plain Detergent (3% solution)
Cascade
APPROVED POLISHING AGENTS
Simoniz Wax
Aero Wax
Glo-Coat
Armorall Protectant
SECTION 3 - MAINTENANCE
3.1 Cleaning Equipment
Clean and polish heat pump frequently to prevent damage to equipment. More frequent service is 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.
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.
CAUTION - Failure to heed the following may result in equipment damage.
Do not use a pressure cleaner to wash heat pump. Damage to heat pump
components will result. If using a hose-end spray nozzle adjust spray pattern to low
strength only.
CAUTION - Failure to heed the following may result in equipment damage.
Do not spray water directly into interior of heat pump; damage to components is
likely.
Washing
1) Wash outside cabinet using a low-pressure water hose.
2) While the heat pump is still wet, use an approved cleaning agent and pump spray bottle to coat
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 exterior cabinet using a soft cloth.
Polishing
1) Polish the heat pump’s cabinet panels using an approved polishing agent and following the
2) Rinse the heat pump panels with fresh water and 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
the exterior of the heat pump. Do not use chemicals on control panel.
manufacturer’s instructions. Do not use chemicals on control panel.
restoring electrical power.
Table 5
Page 6
CHEMICAL
POOLS
SPAS
Chlorine
1.0 – 3.0 ppm
1.5 – 3.0 ppm
Bromine
2.0 – 4.0 ppm
3.0 – 5.0 ppm
pH
7.4 – 7.6 ppm
7.2 – 7.8 ppm
Total Alkalinity
80 – 140 ppm
80 – 120 ppm
Calcium Hardness
200 – 400 ppm
200 – 400 ppm
Total Dissolved Solids
1,000 – 2,000 ppm
1,500 ppm above start-up TDS in
spas
3.2 Monitoring Conditions
3.2.a Pool Chemistry
Check water chemistry regularly and maintain within recommended levels as shown in Table 6. Standards
for commercial applications vary in different areas. Follow all local applicable codes.
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.
To avoid damage to equipment, monitor and maintain chemistry within
recommended levels.
Table 6
3.2.b Maintain Proper Water Flow
Water flow through the heat pump may be reduced to a point where internal safety devices will shut off the
heat pump (i.e.: “HP”, “HP5”, “LP” or “LP5”). Maintain equipment as outlined below to prevent water flow
issues:
Operate water filtration devices per manufacturer's specifications. Dirty filters can cause reduced
water flow to the heat pump. The higher the pressure on the filter gauge, the lower the flow rate.
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 heat pump.
3.2.c Adjusting Water Flow using ∆T (Delta-T)
CAUTION - Failure to heed the following may result in equipment damage.
Do not exceed 5°F ∆T on a titanium condener.
The ∆t is the difference in water temperatures going in and out of the heat pump. The equipment can be
fine-tuned for maximum performance by balancing water flow rates to maintain an ideal ∆T for both the
source-side and pool-side water. See Table 7 for correct temperatures. If you are unsure what condenser
type your heat pump uses, take front panels off the equipment and compare to figures starting on page 8.
Please note that source-side and pool-side equipment may have different condenser types.
1) Turn heat pump thermostat to its lowest setting while in “HEA” mode.
2) Turn off water pump.
3) Turn valves leading to heater to half-way open positions.
4) Turn valves leading away from heater to wide-open positions.
5) Turn on pool water pump.
6) Slowly turn up heat pump thermostat until heat pump turns on.
Page 7
MODEL
SOURCE-SIDE
MODEL
POOL/SPA –SIDE
(“HEA” Mode Only)
CONDENSER
TEMPERATURE
CONDENSER
TEMPERATURE
WS03
Cupro-Nickel
6° to 8°F
WS03
Titanium
3° to 4°F
Cupro-Nickel
6° to 8°F
WS05
Cupro-Nickel
8° to 10°F
WS05
Titanium
4° to 5°F
Cupro-Nickel
8° to 10°F
WS10
Cupro-Nickel
8° to 10°F
WS10
Titanium
4° to 5°F
Cupro-Nickel
8° to 10°F
SP05
Cupro-Nickel
8° to 10°F
SP05
Titanium
4° to 5°F
Cupro-Nickel
8° to 10°F
The source water pump will cycle on first.
After a four minute delay, the heat pump compressor will start.
7) With the heater running, confirm the source-side water pump is operating properly with
adequate flow and no short cycling. If needed, clean filters leading to heat pump.
8) Wait for water and refrigerant flows to stabilize (approximately 5 minutes).
9) Adjust both source-side and pool-side valves leading away from heater to correct
temperatures. Please note - Temperatures shown when unit is in “HEA” mode only; “ACH” and
“COO” discharge temperatures not shown.
10) Mark valves at this position for future reference.
Table 7
3.2.d Irrigation and Storm Run-Off
Irrigation water spray can damage heat pump components. Regardless of water quality, it is important that
irrigation be directed away from the heat pump. Prevent rainwater runoff from pouring directly into the heat
pump. The heat pump is designed to withstand normal rainfall, but solid streams of water from roof driplines may eventually damage heat pump components. If the heat pump resides beneath a roof edge, a
rain leader (gutter) or rain shield is required.
3.3 Winterizing
There are two freeze conditions requiring heat pump attention. A light-freeze is when ambient air
temperature falls below 32 degrees Fahrenheit for fewer than 8 hours. A hard-freeze is when ambient air
temperature falls below 32 degrees Fahrenheit for 8 or more hours.
CAUTION - Failure to heed the following may result in equipment damage.
Failure to properly 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
pool/spa water not be circulated through the heat pump. Loss of water through loose plumbing
connections may result in damage to circulating pump, pool/spa structure, and/or other equipment.
Light-Freeze Conditions
Override time clocks and allow filtration system to run continuously during light-freeze conditions. Typically
during light-freeze conditions, circulating (moving) water will not freeze.
Page 8
a) Remove external drain plug. (see Figure 2)
b) A large volume of water will drain out of the
exchanger at first. The remaining water will trickle
out slowly. Allow sufficient time for all water to
completely drain from exchanger.
c) After heat pump is fully drained, re-connect
external drain plug.
d) Partially reconnect plumbing connection unions.
Heat Pump
(with External Drain Plug)
Figure 2
a) Remove internal drain plug. (see
b) Figure 3)
c) A large volume of water will drain out of the exchanger
at first. The remaining water will trickle out slowly. Allow
sufficient time for all water to completely drain from
exchanger.
d) After heat pump is fully drained, re-connect internal
drain plug and re-install front access panel.
e) Partially reconnect plumbing connection unions.
Titanium Exchanger
(with Internal Drain)
Figure 3
a) Re-install front access panel. Water will drain out of
connection unions.
b) A large volume of water will drain out of the exchanger
at first. The remaining water will trickle out slowly. Allow
sufficient time for all water to completely drain from
exchanger.
c) After heat pump is fully drained, re-install front access
panel.
d) Partially reconnect plumbing connection unions.
Titanium Exchanger
(no drain plug)
Figure 4
Hard-Freeze Conditions
In areas where freezing conditions are prevalent and sustained, the heat pump MUST be winterized for
hard freeze conditions. Please be aware that a water source unit will have multiple heat exchangers, one
or more on the pool-side and one or more on the source-side. All exchangers must be properly winterized.
Also note - different exchangers may require different methods of winterizing. In addition if using an
external plate exchanger, you will need to follow the manufacturer’s directions for winterizing that
equipment as well.
1) Disconnect all electrical power to heat pump; turn “OFF” water circulation pump.
2) Disconnect the plumbing to the heat pump at connection unions, (removal is counterclockwise).
3) If heat pump does not have an external winterizing plug, remove front access panel. Compare
heat exchanger with Figures 4 through 7. Follow appropriate winterizing instructions for heat
exchanger type.
4) When ready to use heat pump again, hand-tighten connection unions. Re-connect electrical
power, and set operating mode on heat pump. Turn “ON” circulation pump.
Heat Pump with External Drain Plug
Titanium Exchanger with Internal Drain
Titanium Exchanger with no Drain
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