Aquacal GBB User manual

AquaCal®
Installation 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- (project rel 7.02)

Table of Contents
Contacting AquaCalAutoPilot, Inc. 1
Safety Instructions 1
1 - Installation 3
1.1 Positioning Equipment 4
1.2 Clearances 5
1.3 Dimensions 5
1.4 Plumbing 6
1.4.a Plumbing Requirements 6
1.4.b Plumbing Diagrams 7
1.4.c Water Connections to Heat Pump 10
1.4.d In-Line Chlorine Feeders 10
1.4.e Water Flow Rates 11
1.4.f Adjusting Water Flow Using ΔT (Delta-T) 12
1.4.g Maintaining Ability to Winterize 13
1.4.h Adjusting Water Pressure Switch 13
1.5 Electrical 14
1.5.a Electrical Requirements 14
1.5.b Access Panels 17
1.5.c Verifying Transformer Setting 17
1.5.d Three-Phase Adjustment 18
1.5.e Schematic Location 19
1.6 External Equipment 20
1.6.a Connecting 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 Backup Heater to Heat Pump 29
1.6.d Connecting Multiple Heat Pumps (Master / Slaved) 34
1.6.e Connecting a Pool/Spa Switching Relay 40
1.7 Program Heat Pump for the Customer 43
1.7.a Setting Date and Time 43
1.7.b Setting Time and Date Format 44
1.7.c Selecting Celsius or Fahrenheit 47
1.7.d Setting Entry Code Option 48
1.7.e Using Entry Code to Access Heat Pump 50
1.7.f Resetting Factory Defaults 50
1.8 Cleaning Equipment After Installation 52
2 - Troubleshooting 54
2.1 Fault Codes 55
2.2 Issues and Resolutions 59
3 - Appendix 65
3.1 Factory Defaults 65
3.2 Identifying Model Specifications 66
3.3 Weights 67
3.4 Heating Recommendations 67
3.5 Cooling Recommendations 68
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3.6 Available Accessories 68
3.7 ICM Digital 3-Phase Monitor 69
3.8 Schematics 71
Schematic LTM0949 73
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Page - 1
Contacting AquaCalAutoPilot, Inc.
For further assistance, please contact the distributor or installer of this product.
If unavailable, please contact AquaCal®for a partner in your area. To better assist you, please have the heat
pump model and serial number available.
lSee "Identifying Model Specifications" on page66.
Product Information:
Website www.AquaCal.com
Phone [phone]
Hours 8-5 pm, Eastern M-F
Service Information:
Website www.AquaCal.com/request-heat-pump-service/
SAFETY INSTRUCTIONS
lFor 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.
lWarranties may be voided if the equipment has been improperly installed, maintained or serviced.
lIf service is deemed necessary, please contact AquaCal. See "Contacting AquaCalAutoPilot, Inc." above.
SAFETY SIGNALS
Throughout this document, safety signals have been placed where particular attention is
required.
DANGER Failure to heed the following will result in injury or death.
WARNING Failure to heed the following may result in injury or death.
NOTICE
Failure to heed the following may result in damage to
equipment.
When installing and using your heat pump basic safety precautions must always be followed, including the
following:
DANGER Failure to heed the following will result in injury or death.
lThe heat pump utilizes high voltage and rotating equipment. Use caution when servicing.
lFollow all National Electric Codes (NEC) and/or State and Local guidelines.

Page - 2
WARNING Failure to heed the following may result in injury or death.
lInstallation and repairs must be performed by a qualified technician.
lThe 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.
lImproper water chemistry can present a serious health hazard. To avoid possible hazards, maintain pool/spa water
per standards as detailed in the product's operation manual.
lProlonged 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. 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.
lProlonged 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. Persons having an adverse medical history, or pregnant women, should consult a physician before
immersing in a cold body of water. Children and the elderly should be supervised by a responsible adult.
NOTICE
Failure to heed the following may result in damage to equipment.
lMaintain proper water chemistry to avoid damage to the pump, filter, pool shell, etc.
lWater flow exceeding the maximum flow rate requires a bypass. Damage due to excessive water flow will void the
warranty.
SAVE THESE INSTRUCTIONS

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1 - Installation
WARNING Failure to heed the following may result in injury or death.
lInstallation of this equipment by anyone other than a qualified installer can result in a safety hazard.
lThe information contained throughout the "Installation" section is intended for use by qualified installation
technicians familiar with the swimming Pool/Spa safety standards.
NOTICE
Failure to heed the following may result in damage to equipment.
lFailure to protect equipment against corrosive conditions will adversely affect the life of the equipment and will
void equipment warranty.
IN THIS SECTION:
1.1 Positioning Equipment 4
1.2 Clearances 5
1.3 Dimensions 5
1.4 Plumbing 6
1.4.a Plumbing Requirements 6
1.4.b Plumbing Diagrams 7
1.4.c Water Connections to Heat Pump 10
1.4.d In-Line Chlorine Feeders 10
1.4.e Water Flow Rates 11
1.4.f Adjusting Water Flow Using ΔT (Delta-T) 12
1.4.g Maintaining Ability to Winterize 13
1.4.h Adjusting Water Pressure Switch 13
1.5 Electrical 14
1.5.a Electrical Requirements 14
1.5.b Access Panels 17
1.5.c Verifying Transformer Setting 17
1.5.d Three-Phase Adjustment 18
1.5.e Schematic Location 19
1.6 External Equipment 20
1.6.a Connecting a Call Flex 20
1.6.b Connecting External Controllers to Heat Pump 22
1.6.c Connecting Gas Backup Heater to Heat Pump 29
1.6.d Connecting Multiple Heat Pumps (Master / Slaved) 34
1.6.e Connecting a Pool/Spa Switching Relay 40
1.7 Program Heat Pump for the Customer 43
1.7.a Setting Date and Time 43
1.7.b Setting Time and Date Format 44
1.7.c Selecting Celsius or Fahrenheit 47
1.7.d Setting Entry Code Option 48
1.7.e Using Entry Code to Access Heat Pump 50
1.7.f Resetting Factory Defaults 50
1.8 Cleaning Equipment After Installation 52
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Page - 4
1.1 Positioning Equipment
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not install equipment inside of a building.
Outdoor Use Only
Do not install equipment inside of a room or building.
lHeat Pumps require unobstructed airflow for proper operation. Heat Pumps should never be installed indoors or in
a location where airflow is restricted.
lSee "Clearances" on the facing page.
Controlling Irrigation and Rainwater Runoff
lIrrigation water may damage heat pump components. Direct irrigation water away from the heat pump.
lThe 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.
Planning for Condensation
The heat pump can produce a large amount of condensation. The amount of water depends on air temperature
and humidity.
lInstall the heat pump with enough height to allow for water drainage.
l1" PVC can be connected to the drainage outlet to redirect water as needed. This connection is under the lower
access panel.
Mounting Pad Requirements
lThe heat pump's base must be installed on a flat and level surface that completely supports the entire base.
lBuild the heat pump pad out of concrete or other code-approved material.
lConfirm the pad can support the weight of the heat pump. See "Weights" on page67.
lElevate the pad enough to allow for drainage.
lMake sure the pad is flat and level.
lHave the pad support the entire heat pump base in all directions.
lDo not install the heat pump on soil or grass.
lDo not allow the heat pump base to touch the building's foundation.
lDo not place the heat pump directly on a concrete floor. This can cause noise to be transmitted to an occupied
space. If necessary install vibration dampers between the heat pump base and floor.
lEquipment pad must meet all requirements of authorities having code-related jurisdiction.
Anchoring to Pad
lFollow all applicable local, state, and national requirements regarding wind load anchoring.
lThe shipping brackets used to secure the heat pump to the pallet are approved mounting (hurricane) brackets.
They should be used to anchor the heat pump to the pad.
lIf needed, contact AquaCal®to obtain anchoring kit information. Please have the heat pump model number and
serial number when requesting support. See "Identifying Model Specifications" on page66.
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Page - 5
1.2 Clearances
lProper air circulation is required for the heat pump to operate efficiently. The following diagrams show the
minimum clearances required for the proper operation of the heat pump.
lAvoid storing chemical containers near the heat pump. The chemicals can cause equipment damage.
lAvoid placing objects near or on top of the heat pump. This includes shrubbery and lawn furniture. These objects
will reduce performance and efficiency and hinder maintenance access.
Great Big Bopper®(Side View) Great Big Bopper®(Top View)
1.3 Dimensions
(Great Big Bopper®)
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Page - 6
1.4 Plumbing
1.4.a Plumbing Requirements
NOTICE
Failure to heed the following may result in damage to equipment.
lDo 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.
lThe heat pump must receive water flow within the specified minimum ranges under worst-case conditions such as
a fouled water filter.
lFailure to provide clean filtered water to the heat pump can void the product warranty.
lWater 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 warranty. See "Water Flow Rates" on
page11.
lTemperature ports with PVC tees and a test thermometer are also provided in selected models. These ports must
be installed between the unions and the bypass valves. The preferred location of the port is 6" from the heat pump
union. See "Adjusting Water Flow Using ΔT (Delta-T)" on page12.
lA safety-enhancing "Over Temperature Alarm"kit is strongly recommended for all spa applications. See "Over
Temperature Alarm Kit" on page69.
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Page - 7
1.4.b Plumbing Diagrams
Plumbing diagrams are provided in this section as a planning guide to the sequence of equipment, valves, and
fittings.
lThe basic plumbing configurations for typical installations are shown.
lIf the installation does not closely follow any of the supplied plumbing diagrams, AquaCal®Technical Support is
available for installation advice and guidance.
lConfirm water provided to the heat pump is clean and filtered.
The Heat Pump MUST be plumbed so that the water inlet and outlet are on opposite sides.
DO NOT PLUMB UNITS IN SERIES AS SHOWN HERE
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Page - 8
Good Plumbing Examples:
Great Big Bopper®
Single Unit - Example 1
Great Big Bopper®
Single Unit - Example 2
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Page - 9
While multiple Great Big Bopper®heat pumps are 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®Multiple Units - U-Flow Plumbing Design
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Page - 10
1.4.c Water Connections to Heat Pump
lHeat Pump union sizes are specified on diagrams.
lConnections to site plumbing are made via PVC solvent cement to the female slip socket of the plumbing unions.
lUnions are to be tightened on heat pump using a strap wrench. Do not use metal wrench on unions.
lPlumbing unions are available from AquaCal®.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo 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 wrench is used to tighten and loosen
unions
1.4.d In-Line Chlorine Feeders
Place in-line chlorinators downstream from the heat pump and as low in elevation as possible.
lIf an erosion type feeder is used, it is recommended that a Hartford Loop be installed to protect internal heat
pump components.
lA Hartford Loop is not necessary with a Salt Chlorine Generator.
Heat Pump with Hartford Loop
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Page - 11
1.4.e Water Flow Rates
Maintain water flow rates as indicated. Please note, these specifications relate to the heat pump only. Code-
specified whole system turnover rates must be satisfied.
NOTICE
Failure to heed the following may result in damage to equipment.
lWater 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 warranty.
MODEL HEAT EXCHANGER
TYPE
FLOW RATES
MINIMUM MAXIMUM
BB500 50 Hz 380 - 415
VTitanium ThermoLink®120 GPM (454 L/min)
280 GPM (1060
L/min)
BB500 60 Hz 208 - 230
VTitanium ThermoLink®120 GPM (454 L/min)
280 GPM (1060
L/min)
BB500 60 Hz 460 V Titanium ThermoLink®120 GPM (454
L/min)
280 GPM (1060
L/min)
PLEASE NOTE -
If minimum flow rates are not met, heat pump performance is reduced and performance will
suffer. Internal safety devices may deactivate the heat pump with the following errors:
lHIGH PRESSURE FAULT
lHP5 SYSTEM LOCKOUT
lLOW PRESSURE FAULT
lLP5 SYSTEM LOCKOUT
lOperate water filtration devices per manufacturer's specifications. Dirty filters can cause a reduction of water flow
to the heat pump. An increase of 7-10 psi (48 to 69 kPa) higher than the clean filter pressure typically reduces
flow rates. This requires the filter to be cleaned or back-washed.
lKeep baskets free of debris. A large quantity of debris in the pump and skimmer baskets can reduce water flow.
lCheck 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.
lThe maximum static pressure (or operating pressure) is 50 psi (345 kPa). These specifications relate to the heat
pump only.
lCode-specified whole system turnover rates must be satisfied.
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Page - 12
1.4.f Adjusting Water Flow Using ΔT (Delta-T)
The Delta-T is the temperature difference between the water temperatures entering and leaving the heat pump.
The equipment can be fine-tuned for maximum performance by balancing water flow rates to maintain an
ideal ∆T.
The adjustment procedure must be completed with the unit in heating mode.
lInstalled temperature ports are required to perform the following procedures.
lThese ports are typically located on the pool in and pool out water lines approximately six inches away from the
heat pump.
PLEASE NOTE -
lThe installation of temperature ports is required for all Great Big Bopper®installations on
both inlet and outlet piping.
nSee "Temperature Port Kit (# STK0133) " on page69.
Temperature Port
(Shown with Probe)
1. Adjust the thermostat to its lowest setting with the unit in
heating mode.
2. Deactivate the water filtration pump.
3. Confirm that the filters leading to the heat pump are clean.
4. Adjust the valves controlling water headed towards the 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 thermostat temperature until the heat pump
activates.
lAfter a four-minute delay, the heat pump's compressor will start.
8. With the heat pump running, confirm the filtration pump is operating properly with adequate flow and no short
cycling.
9. Wait for water temperatures to stabilize (approximately 5 minutes).
12. Adjust valves in the following order using the temperature chart provided.
a. Adjust the valve that controls water exiting the heat pump until the correct temperature differential is
achieved. Match the temperature measured with a temperature probe to the chart.
b. Wait for water temperatures to stabilize. Then check the temperature again. Re-adjust the valve as needed.
13. Mark valves at these positions for future reference.
HEAT EXCHANGER
TYPE MODEL TEMPERATURE
Titanium ThermoLink®
BB500 50 Hz 380 - 415 V 3° to 7° F
(1.7° C to 3.9° C)
Titanium ThermoLink®
BB500 60 Hz 208 - 230 V 4° to 8° F
(2.2° C to 4.4° C)
Titanium ThermoLink®
BB500 60 Hz 460 V 4° to 8° F
(2.2° C to 4.4° C)
Table 1 - Temperature Chart
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Page - 13
PLEASE NOTE -
lTemperature differences are based on pool water temperatures of 69° to 75° F. (20.5° to
23.8° C)
lFor water temperatures outside this range, contact AquaCal®.See "Contacting
AquaCalAutoPilot, Inc." on page1.
1.4.g Maintaining Ability to Winterize
Do not glue the threaded portion of the unions. The unions are used to decouple the heat pump from the
plumbing system during hard freeze conditions.
NOTICE
Failure to heed the following may result in damage to equipment.
lDo not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will prevent the heat
pump from being properly winterized.
1.4.h Adjusting Water Pressure Switch
Adjust the water pressure switch when heat pump attempts to operate without water flow.
Before attempting any adjustments confirm the following :
lThe filter is clean.
lFilter pump is operating.
lThe valves are set to direct the appropriate amount of water through the
heat pump. See "Water Flow Rates" on page11.
l"NO POOL/SPA WATER FLOW" is displayed (or displays
intermittently).
DANGER Failure to heed the following will result in injury or death.
lDeactivate power while routing wiring to control board.
lFollow all National Electric Codes (NEC) and/or State and Local guidelines.
WARNING Failure to heed the following may result in injury or death.
lWater Pressure Switch adjustment procedure to be performed by experienced service personnel only; procedure
must not be attempted by individuals lacking adequate electrical and mechanical experience.
NOTICE
Failure to heed the following may result in damage to equipment.
lIf the heat pump continues to operate after a water pressure switch adjustment, deactivate equipment and perform
additional troubleshooting.
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Page - 14
1. Remove heat pump access panel.
2. Locate the water pressure switch. It will be outside and along
the bottom edge of the electrical enclosure. The exact location
varies by model.
3. Activate the filter pump.
4. Apply power to heat pump.
5. Slowly rotate the adjustment wheel on the switch. Keep
turning the wheel until the heat pump indicates it is receiving
water. The display will no longer indicate "NO POOL/SPA
WATER FLOW".
6. Deactivate filter pump. If correctly adjusted, theheat pump will deactivate and the display will show "NO
POOL/SPA WATER FLOW".
7. Re-install heat pump access panel.
8. If the heat pump continues to operate without water flow, the installation of a grid flow switch may be required.
lThis can become necessary if the heat pump is installed below the elevation of the body of water to be heated
or cooled. The standing pressure from the water can cause the water pressure switch to activate when the
circulation pump is off. Therefore a water flow switch must be used in place of a water pressure switch to
determine if incoming water is being sent to the heat pump. See "Grid Flow 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 injury or death.
lDeactivate power while routing wiring to control board.
lFollow all National Electric Codes (NEC) and/or State and Local guidelines.
WARNING Failure to heed the following may result in injury or death.
lThe information contained in this section is intended for use by qualified electricians familiar with electrical
service-industry safety standards and methods.
lLocate the equipment disconnect as near to the heat pump as possible. Always satisfy applicable codes and
standards.
lNever mount power-disconnects directly to the heat pump.
lIn sizing power wiring, be especially aware of up-sizing requirements necessary due to wiring distances. Always
satisfy applicable codes and standards.
lAquaCal®heat pumps are designed to use copper conductors, only. Do not use aluminum wire.
lIf multiple heat pumps are on-site, confirm that the multiple heat pump configuration has been utilized. See
"Connecting Multiple Heat Pumps (Master / Slaved)" on page34. This will prevent multiple heat pumps
attempting to start at the same time, causing an excessive power drop at start-up.
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Page - 15
Electrical Standards
Standards Title
NFPA 70, Nat'l Elec.
Code 2017
The electrical installation must conform to the current
version of the National Electric Code (NEC), and all
applicable local and state codes
IEC 60335-1 Household and similar electrical appliances - Safety -
General Requirements
IEC 60335-2 Household and similar electrical appliances - Safety –
Particular requirements for electrical heat pumps, air-
conditioners, and dehumidifiers
UL 1995 & CSA C22.2
No. 236-15 Standard for Safety - Heating and cooling equipment
Table 2 - Standards
Grounding and Bonding
Follow local code requirements for proper grounding and bonding of heat pump equipment.
lA bonding lug has been provided on the lower left hand corner of the electrical access panel.
Surge Suppression
The use of approved commercial surge protectors is strongly recommended.
Sizing the Electrical Service
Refer to equipment data plate for specific information required to size electrical service and over-current
protection of the heat pump. Sizing is based on data plate information, wire size, wiring devices, and over-
current protection per applicable local codes and standards. See "Identifying Model Specifications" on
page66.
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Minimum and Maximum Operating Voltage
The heat pump must operate within specified voltages.
NOTICE
Failure to heed the following may result in damage to equipment.
lOperating equipment under higher or lower voltage conditions may result in damage to your compressor, motors
or other electrical components. This damage will not be covered by the product warranty.
1. Measure site voltage. The site voltage MUST be measured under “FULL LOAD” conditions. Activate all
equipment using the same electrical panel as the heat pump.
2. If measured site voltage is outside listed ranges, immediately deactivate equipment until site conditions have been
corrected. 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 hertz
200 Volts 253 Volts
D Voltage
(380 to 420 Volts)
Three Phase 50 hertz
361 Volts 441 Volts
G Voltage
(460 Volts)
Three Phase 60 hertz
437 Volts 483 Volts
PLEASE NOTE
ICM Digital
Three-Phase
Monitor
The Great Big Bopper®heat pump comes with an ICM phase-rotation
monitor located inside the electrical panel.
The device protects the heat pump by preventing operation during
abnormal voltage conditions.
lIf the unit fails to operate, a qualified technician should check the
phase rotation monitor for faults preventing operation. Complete
instructions for the ICM phase monitor are in the appendix. See "ICM
Digital 3-Phase Monitor" on page69.
1 - Installation