Aquacal AutoPilot WS03 Specification sheet

LTM0266 rev 3
AquaCal AutoPilot
Water Source
Operation and Installation Manual

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
3.1.a Pool Chemistry................................................................................................................6
3.1.b Water Flow Rates............................................................................................................6
3.1.c Adjusting Water Flow using ∆T (Delta-T).........................................................................7
3.1.d Irrigation and Storm Run-Off............................................................................................8
3.2 Winterizing............................................................................................................................8
3.3 Planned Maintenance..........................................................................................................10
SECTION 4 - INSTALLATION
4.1 Equipment Specifications....................................................................................................11
4.1.a Weights.........................................................................................................................11
4.1.b Dimensions ...................................................................................................................11
4.1.c Access Panels...............................................................................................................12
4.1.d Electrical Cutouts ..........................................................................................................13
4.2 Placing Heat Pump .............................................................................................................13
4.2.a Positioning Clearances..................................................................................................13
4.2.b Controlling Irrigation and Rainwater Runoff ...................................................................14
4.2.c Planning for Condensation ............................................................................................14
4.2.d Mounting Pad Requirements.........................................................................................14
4.2.e Anchoring Heat Pump to Pad........................................................................................14
4.3 Plumbing.............................................................................................................................14
4.3.a Plumbing Diagrams.......................................................................................................15
4.3.b In-Line Chlorine Feeders...............................................................................................20
4.3.c Water Connections to Heat Pump .................................................................................20
4.3.d Maintaining Ability to Winterize......................................................................................21
4.3.e Water Flow (Pressure) Switch Adjustment.....................................................................21

TABLE OF CONTENTS
4.4 Wiring.................................................................................................................................23
4.4.a Standards..................................................................................................................... 23
4.4.b General Requirements..................................................................................................23
4.4.c Grounding and Bonding................................................................................................23
4.4.d Surge Suppression .......................................................................................................23
4.4.e Sizing the Electrical Service..........................................................................................23
4.4.f Verify Transformer Tap.................................................................................................24
4.4.g Three Phase Monitor Adjustment..................................................................................24
4.4.h External Controls / Equipment.......................................................................................26
4.4.i External Controllers and Cooling Mode.........................................................................26
4.4.j Positioning Mode Jumper..............................................................................................27
4.5 Programming...................................................................................................................... 27
4.5.a Program Displays.......................................................................................................... 28
4.5.b Service Level Programs................................................................................................28
Entering Service Menu ...............................................................................................28
Deactivating Time Delay.............................................................................................28
Configuring for External Controller..............................................................................29
Configuring for Remote Flow Switch...........................................................................29
Calibrating Water Sensor............................................................................................ 29
Calibrating Defrost Sensor.......................................................................................... 30
Adjusting Dead-Band Differential................................................................................ 30
Resetting Heat Pump ("Back Door” Entry) .................................................................. 31
4.5.c Default Program Parameters ........................................................................................31
4.6 Optional Installation............................................................................................................31
4.6.a Pool and Spa Combination Heating ..............................................................................31
4.6.b Spa Setback Heating Option.........................................................................................31
SECTION 5 - TROUBLESHOOTING
5.1 Symptom / Resolution Charts .............................................................................................32
Control Panel Not Working ......................................................................................... 32
Heat Pump Not Running............................................................................................. 32
Heat Pump Running, Not Heating...............................................................................33
Heat Pump Tripping Breaker ......................................................................................34
Heat Pump Won’t Shut Off..........................................................................................34
Heat Pump Running, Not Cooling...............................................................................35
Water Coming From Heat Pump................................................................................. 35
5.2 Fault Code Definitions ........................................................................................................36
“dPO” Indicator ...........................................................................................................36
“PO” Indicator .............................................................................................................36
“dPC” Indicator ...........................................................................................................36
“PC” Indicator .............................................................................................................36
“HP” Indicator .............................................................................................................36
“HP5” Indicator ...........................................................................................................37
“LP” Indicator..............................................................................................................37
“LP5” Indicator............................................................................................................37
“OtA” Indicator ............................................................................................................37
“FLO” Indicator ...........................................................................................................38
“CSE” Indicator...........................................................................................................38

TABLE OF CONTENTS
“CEr” Indicator.............................................................................................................38
SECTION 6 - APPENDIX
6.1 Available Accessories .........................................................................................................39
6.2 Schematics .........................................................................................................................39

Page 1
SECTION 1 - GENERAL INFORMATION
1.1 Contacting AquaCal AutoPilot
Web
www.AquaCal.com
Phone
[phone]
8-5 pm, Eastern M-F
Fax
[phone]
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
SECTION 2 - OPERATION
2.1 Control Panel
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 23 for more
information.
Figure 1
2.1.a Indicator Lights
“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.
Table 1
2.1.b Control Buttons (Inactive if unit under external control)
“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.
Table 2
2.1.c LED Display
“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.
Table 3

Page 3
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.
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.

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
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
the exterior of the heat pump. Do not use chemicals on control 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 exterior cabinet using a soft cloth.
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 control panel.
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
restoring electrical power.
APPROVED CLEANING AGENTS
Fantastic
409
All Power Plain Detergent (3% solution)
Cascade
APPROVED POLISHING AGENTS
Simoniz Wax
Aero Wax
Glo-Coat
Armorall Protectant
Table 5

Page 6
3.1.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.
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
Table 6
3.1.b Water Flow Rates
CAUTION - Failure to heed the following may result in equipment damage.
Water flow exceeding maximum flow rate may damage titanium heat exchanger;
such damage will not be covered under the equipment warranty.
Maintain water flow rates as shown below. Please note, these specifications relate to the heat pump only.
Code-specified whole system turnover rates must be satisfied. Contact AquaCal AutoPilot Technical
Support for guidance regarding testing for water flow rates.
Source-Side Water Flow Rates
MODEL
HEAT EXCHANGER
TYPE
FLOW RATES
MINIMUM
MAXIMUM
WS03
Titanium
20 GPM
70 GPM
Cupro-Nickel
10 GPM
14 GPM
WS05
Titanium
20 GPM
70 GPM
Cupro-Nickel
08 GPM
18 GPM
WS10
Titanium
30 GPM
70 GPM
Cupro-Nickel
30 GPM
54 GPM
SP05
Titanium
20 GPM
70 GPM
Cupro-Nickel
Table 7
Pool-Side Water Flow Rates
MODEL
HEAT EXCHANGER
TYPE
FLOW RATES
MINIMUM
MAXIMUM
RATED
WS03
Titanium
30 GPM
70 GPM
45 –50 GPM
WS05
Titanium
30 GPM
70 GPM
45 –50 GPM
WS10
Titanium
30 GPM
70 GPM
45 –50 GPM
SP05
Titanium
30 GPM
70 GPM
45 –50 GPM
Table 8